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COBRA01Multichannelbrake
forwinders
Highestavailabilityandsafetyforminewinders

MiningTechnologies

Thenextstepinevolutionofmine
winderbrakes
Yourchallenge:

Theperformanceofundergroundminesiscriticallydependantonthecapabilityoftheshaft
hoistingsystems.Availabilityisthekeyfactorandavailabilityisinfluencedmost
heavilybythesafefunctionofthewinderbrakeanditshydraulicandelectriccontrol
system.

Springappliedandhydraulicallyreleaseddiskbrakeswithtwomainfunctionsarestateof
theart:

__Holdingtheconveyancesduringnormaloperationwithagivenfactorofsafetyatthe
stoppingpositions(servicebrake)

__Bringingthewindertoacontrolledstopincaseofafaultinthedrivesystem(safety
brake)

Modernsafetybrakesystemssupportconstantretardation.Comparedwiththeconventional
constantpressurebraking,thiscontrolmodeguaranteesthesamedecelerationunderall
loadconditions(fullemptyupdown).

Undernormalconditionsthesesystemsworkquitewell,buttherearetwobig
disadvantages:

__Incaseofafaultinthebrakesystem,thebrakestepsbacktoconstantpressuremode,
soallbrakecalculationsmustbedoneforthismode.Thisincreasesthepriceofthe
mechanicalsystem.
__Therearestillsomescenarioswherethewindercangooutofcontrol.E.g.,abroken
hydraulicpipecanresultinanimmediatechangetomaximumbrakeforce.Thiswillcause
toohighdecelerationtheropetoslipincaseoffrictionwinders.

Oursolution:

Toavoidtheserisks,themultichannelconstantretardationbrakewasintroduced15years
ago.Itfeaturesanumberofindependenthydraulicchannelswiththeirowncontrolsystems
andbrakeelements.Ifonechanneltrips,theothersremainasbackups:Thisishowthe
multichannelconstantretardationbrakepreventslossofcontrol.However,theconceptdid
notfindwideacceptancefortworeasons:Thehydraulicunitisquitelargeanddifficultto
maintain,andtheoverallsystemwastooexpensiveformostcustomers.

Becausepriceandsizewerethemainobstacles,wekepttheconceptbutshiftedmostofthe
functionalintelligencetotheelectroniccontrolsystem.Byusingmodernandpowerful
stateoftheartelectroniccontrols,wearenowinapositiontodramaticallyreducethe
sizeofthehydraulicstation.UsingtheSIMATICS7automationsystem,wecombineda
brakewithasmallandeasytomaintainhydraulicthathasapowerfulandsimpletohandle
electricsystem.

AdvantagesofCOBRA01:
__Maximumsafetythroughmultipleclosedcontrolloops

__Maximumavailabilitythankstoasimpledesignusingalownumberofstandardized
componentsandoneextraloopasreserve,maintenancetimeissignificantlyreduced

__Reducedcoststhankstosmaller,morecompactdesignofthewinderitself

Weputthebrakesonyourcosts

TheprimarytaskforaKoepeorfrictionwinderis:Neverlosethefrictionbetweenthe
drumandtheheadrope.Asinglechannelconstantretardationbrakealwayscarriestherisk
oflosingspeedcontrol(electricalorhydraulicmalfunction)andsteppingbacktoconstant
pressuremode.Tomaintainfrictionunderthesecircumstances,theconveyanceweight
mustbeincreasedbyadditionaldeadweight,resultinginthickerropesandabiggerwinder
diameterand,consequently,aslowerandmoreexpensivemotor.Ontheotherhand,a
multichannelsystemensuresbrakingwithconstantretardation.Thewinderdimensioning
needstobedoneonlyforthismode,andsocostsremainlow.

Designvalues Singlechannel Multichannel

Depthofshaft370m Skip+attachments50tons Skip+attachments27tons

Payload25tons Ropediameter50mm Ropediameter40mm

Hoistingspeed10m/s Weightofheadrope8.4kg/m Weightofheadrope6.4kg/m

Ropebreakingload1.5kN Ropebreakingload1.0kN

Ropesafetyfactor7 Ropesafetyfactor7

Winderdiameter4.0m Winderdiameter3.2m

Oneforallandallforonethe
electrohydraulicbrakesystem
TheCOBRAhydraulicstationstandsoutduetoitscompactness.

Mostpartsofthebrakestandsareeasilyaccessible.

TheCOBRAbrakefeaturesamultiredundantcontrollayout.

TheCobra01safetyconcept

Whenahydraulicpipebreaks,thepressureinthehydraulicsystemdrops.Simultaneously,
thefaultychannelwillincreasethebrakeforce.Atfirst,thiswilldeceleratethewinding
wheel,butthespeeddeviationwillbeimmediatelydetectedbytheremainingtwochannels.
Thesechannelswillthenincreasetheirbrakepressuretoreducethebrakeforce.Withina
splitsecond,thetotalbrakeforcereachesthenominalvalueagain.

n+1channeldesign

Thehydrauliccontrolconsistsofnclosedcontrolloops,whichprovideaconstant,
permanentlysetdecelerationintheeventofsafetybraking.Ifonecontrolloopfails,the
multiplechanneldesignwillensurethatthepreviouslydefinedconstantdecelerationofthe
otherloopswillstayconstantandbelowtheropesliplimit.Thebrakewillregulatethe
brakingforceindependentlyoftheunbalancedload,thedirectionofrotation,andthewear
ofthebrakeliningsandwillcompensatetheusualcoefficientoffrictionfluctuationsof
thebrakelinings.Anadditionalcontrolloopcanbeactivatedatanytimeasasubstitutefor
achannelbeingfaultyorundergoingmaintenance.
Sonormally,theavailabilityisincreasedwithoutthenecessityofacompletesparesystem.

Pressurecontrol

Thehydraulicunitcontrolstheoilpressureofthebrakeasanintegratedserviceandsafety
brakeinnfunctionallyandfullyseparatebrakecircuits,towhichadefinednumberof
brakingforcegeneratorpairsiseachassigned.Onecontrolloopis

utilizedasareserve.Thepressurizedoilforthepressureaccumulatorsandthebraking
forcepairsisgeneratedbytwomotorpumpsets(oneasareserve).Atoperatingpressure,
thebrakeelementsspringassembliesarecompletelyreleasedsothataminimumairgap
appearsbetweenthebrakeshoeandthebrakedisk.

Thebrakingforcerequiredforservicebrakingisachievedthroughcontroloftheoil
pressure.Inmanualoperation,thepressuresetpointisgivenbythebrakeleveronthe
hoistmansconsole.Inautomaticfixedsetpointsareusedforreleaseandapplyofthe
brakes.

Safetyprocedures

Whenthesafetycircuittripsthebrake,circuitsarecontrolledindividually.Fordirectforce
freeapplicationofthebrakeelements,thepressureinallcircuitsisreducedtotherequired
value.Thedirectionalcontrolvalvesarethenactivatedsothatthebrakeforcecanbe
modifiedthroughcontrolledpressureandconstantdecelerationofthehoistisensured.

Atexcessivelyhighdecelerationvalues,thepressureintheindividualbrakecircuitsis
increasedviathebubble

accumulators.Thisachievesastipulateddecelerationvaluethatisindependentofthe
directionoftravelandoverload,andpreventsropesliponKoepewindersinallcases.In
theeventthatonebrakecircuitfailscompletely,thisclosedloopcontrolwilloccurinthe
remainingbrakecircuits.

Electronicmonitoring
[m/s]20

15

10

Velocity

brakepressure1

brakepressure2

brakepressure3
[bar]brakepressure4200

175150125100755025

Theelectronicsystemwillalsomonitorthesynchronizationofthecontrolvalvestothe
safetybrake,hydraulicpressure,openingandclosingofthebrake,springbreakageand
liningwearontheindividualbrakeelements,fillingofthebubbleaccumulator,impactfree
runningofthebrakedisk,andtheoiltemperature,oillevel,andfiltersoilstatusofthe
Brakeforce1
hydrau licunit.Thesinglepointindicationsand0overviewsaredisplayedinthe
controlPressurechannel110 cabinet.ThesafetycircuitwillbeactivatFault

eddependingonthenatureofthefault indication.20
Pressurechannel2

Brakeforce2

Pressurechannel3Brakeforce3Correctionoffaultychannel

ConsoleBrakecontrol

Brakelever

Hydraulicsn+1

Tractionsheave

HydrauliclinesControllinesPROFIBUSDP(twochannel)

SpeedTotalbrakeforce

302010

Plotoflastsafetybraking

Sicherheitsbremseaufgelegt

Wheelbrakefixed

00

02468101214161820

Registeredspeedandpressureofthe3channelsduringsafetybraking

302010

01020

30
0.0ropeslipwithballast

30
0.0
1.0Decelerationinm/s2

controlleddecelation_min.requireddeceleration

2.0

3.0

4.0

5.0

1.02.03.04.05.0Decelerationinm/s2

Decelerationundervariousloadconditions

ropeslip

min.brakedecelerationmax.brakedecelaration

rotaryencoder

Payloadint,+=upwards,=downwards

Visualization

VISU

Mastercontrol

ChannelA

ChannelB

I/O

I/O

BrakeChannelControl

Controller1(Spare)

Controller2

Controller3

Controller4
I/O

I/O

I/O

I/O

DifferenttypesofbrakeenginescanbeusedwithCOBRA01.

BrakeLever

PreChargeApplyRelease

RampGenerator

SpeedController

SpringCaracteristic

SimaticS7300

pressurecontroller

DimensionsWxDxHWeightTankvolumePressure

VoltagePumppowerCirculatingpumppowerOilcoolerpowerOilheaterpower

2,000x1,000x1,700mm1,200kg160ltrs200bar

500/400/380V3AC50Hz2x4kW3kW0,37kW

1,7kW

Electriccontroloverview

Technicaldatahydraulicsystem

Overviewofonecontrolchannel

DimensionsWxDxHWeightPowerconsumptionVoltage

ControlvoltageProtection

1,800x600x2,000mmca.500kg2x960W500/400/380V3AC50Hz24VDC

IP43
Technicaldataelectricsystem

Intelligentcontrolautomation
withSIMATICS7
Electricalbrakecontrolcubicle.Theadvancedvisualizationsystemhelpstomonitoreveryaspectof
thebrake.

Thehydraulicunitismerelytheactuatingelementthatprovidesthenecessarypower,
pressure,andforce.Comprehensivebrakecontrolandmonitoringisaccomplished
electronicallybytheworldsleadingautomationsolution:SIMATICS7.

Clever,compact,costefficient

Bymovingallthelogicandsafetyfunctionsfromthehydraulictotheelectronicsystem,
wecreatedacompactbrakethatisnotonlymaximallysafeandavailable,butalsoeasyto
understand.ThankstotheuniquestandardizationofSIMATICS7,componentscanbe
easilyremoved.Becausethesameboardsareusedforthebrake,theautomation,the
visualization,andshaftsignalling,spareparthandlingandcostsarereducedtoaminimum.
Andlastbutnotleast,yourservicepersonnelcanbetrainedonjustoneplatform.

Seeingwhatshappening

Byreducingthesizeandnumberofhydraulicandmechanicalcomponents,wemadethe
brakesystemsmaller.Everymechanicalelementismonitoredanddisplayedinour
advancedvisualizationsystem.

Principle

Theelectronicsystemalsoconsistsofn+1completelyindependentcontrolchannels:nfor
theactivehydraulicchannelsandoneforthesparechannel.Eachofthesechannelsis
equippedwithitsownI/OsandUPSwithbufferbattery.

Themastercontrolperformscommonfunctionslikecommunicationwithwinder
automation,messaging,andmonitoring(ofoil,brakeelements,brakediscs,andmore).

Examplesforvisualizationscreens

Siemens

www.siemens.com/mining

Forfurtherinformationcontact:

SiemensAGIndustryDivisionIISMTMI

Schuhstrasse6091052Erlangen,Germany

Phone:+4991317Email:

Theinformationprovidedinthisbrochurecontainsonlygeneraldescriptionsor
characteristicsofperformancethatinactualcaseofusemaynotalwaysapplyasdescribed,
orthatmaychangeasaresultoffurtherdevelopmentoftheproducts.Anobligationto
providetherespectivecharacteristicsshallonlyexistifexpresslyagreedinthetermsof
contract.

OrderNo.:PrintedinGermanyDispoNo.:KNo.GB100131

Subjecttochangewithoutpriornotice