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s
M should be scrapped and there is always a questions
νo = (2)
Mo rising if the assumed durability has been already spent.
Many years of operation in various conditions make this
where decision very difficult to be made. On the other hand,
Ms – the minimum stabilising moment calculated with old machines must ensure proper safety of operation to
respect of tipping axis prevent accidents causing human and money loss. The
Mo – the maximum overturning moment calculated with main problem in this case is the superstructure of the
respect of the same tipping axis machine, which is in principle not subject to
The above ratio shall be calculated for the most refurbishment, on the contrary to mechanical
unfavourable load combinations and shall not be less than components of the machine.
safety factors assigned to load combinations groups. Recent years brought many research works in this
However, there are certain differences in the results of area [1], [20] and [21]. Authors of this paper have
stability calculations obtained from the mentioned developed a comprehensive guide and recommendations
standards. In the DIN 22261 standard there is additional for technical condition assessment, condition
requirement to multiply by 1.05 factor all permanent monitoring methods development and methods for
loads reducing the same stability of the machine. This is operational live extension of such specialised mining
due to the fact that dead weights cannot be fully and material handling equipment [8]. The main focus in
confirmed at the designing stage. Another difference, the proposed solutions lies in the following activities:
which is related to machines with slew bearings (with or • numerical identification of the stress effort by
without catching hooks), is the way of tipping axis using three-dimensional computational models
diameter consideration, which should be calculated as based on FEM, which then are used in the
95% of the bearing radius. As per AS standard, there is calculation of fatigue,
requirement to install catching hooks in slew bearings
• identification of operational loads, which is
always, so the proof of their strength assure safety of
carried out primarily with the use of
machine from the stability point of view.
experimental tests on investigated machines,
As mentioned in the chapter 2.1 of this paper, there
• residual life prediction based on the identified
are also significant differences in load combinations and
stress effort and the load acting on the analysed
elementary loads calculations in the DIN, ISO and AS
objects,
standards. The most restrictive AS standard imposes on
designers many limitations regarding stability • implementation of proper condition monitoring
requirements. For example load combination III/6 approach to identify or predict failures of the
(blocked chute and excessive material on conveyor) is structure at the earliest possible stage that
usually decisive one in machines with long conveying enables corrective actions implementations,
booms equipped with chutes located at boom’s tips. • design and implementation of local or global
Similarly, requirement of boom grounding modernisations of equipment with consideration
consideration for reclaiming or transfer machines (DIN of the above information on the technical
does not requires this load for spreaders stacking condition of tested machine.
booms) also makes stability requirements more difficult These studies complement the knowledge of the
to fulfil. extent of degradation of the structure, assess its residual
Since stability of opencast mining and material life and in most cases enables operational life extension
handling machines has a great importance for safety of with reasonable costs and expected safety level.
their operation it is not allowed to accept stability The second issue is that the standards and literature,
calculations with safety factors not fulfilling require– when compared to the operational experience, points out
ments unlike to strength calculations where 5% over– a big discrepancy in the dynamic effects factors.
stress can be accepted. This imposes demands on the Observations proved that the real values of dynamic
designer to pay attention at the preliminary design stage factors do not cover the values assumed at the design
of machines, where supporting systems, tipping axes stage [20]. This problem was marked and “solved”
dimensions and locations are set. (increased values of dynamic effects factors, what leads
to the the structure weight increase) in AS standard.
3. A STEP AHEAD of THE STANDARDS Moreover, there is no recommendation for the
validation of the assumed, on the design stage, values of
As all the mentioned standards deal with the design of the factor.
new machines, a big and common issue which is left Recently conducted research [22] and [23] and
unstandardized is technical condition assessment and developed method (Fig. 4) [9] fills the gap between the
residual life of the large structures after decades of scientific calculation methods that are currently being
operation. The service life of the new opencast or developed in relation to dynamics of large-scale
machines and the commonly known and used methods.
FME Transactions VOL. 46, No 3, 2018 ▪ 295
Because it is based on the dynamic effects factor for Furthermore, existing opencast mining and material
dynamic calculations, which, in accordance with handling equipment needs to be properly assessed to
standard recommendations is the basis for these obtain information on the technical condition and rema–
calculations. The proposed method is compatible with inning time of safe operation. There are no standards
all current requirements for designers of large-scale that may help operators of such equipment to make
machines. It covers calculations, experimental decision about the moment when machines worth
validation and assessment. As a consequence the millions should be scrapped, or when, how and what to
detailed control over dynamic behaviour is taken. The do to extend their operational life with an acceptable
method was already validated and proved its safety [27]. As a result of such situation there are many
effectiveness [20]. Additionally, the method, covers failures of opencast mining and material handling equ–
influences of the superstructure dynamics to the ipment occurring in the operation that sometimes create
undercarriage structure [24]. Up to now, that correlation fatal consequences in human resources (injures, death
was neglected in most of the recommendations. cases) and quite often generate huge costs as well. Exa–
mples of such failures are presented in figures 5 and 6.
4. CONCLUSION