SURFACE LOADING
Komatsu Mining’s nextgen giant, the P&H 4800 XPC
Paul Moore spoke to Patrick Singleton, Product Director
– Shovels, Komatsu
Q Has this shovel yet been built, whether an ordered machine or
prototype? Where will be be tested?
The P&H 4800XPC is completing detailed design shortly and
manufacturing has begun. It is scheduled for production digging starting in
December 2019 in North America.
Q Unlike the hybrid shovel, this is a larger machine than the 4100XPC but
is it more than just a scaled up version? What are the important differences
between the two in design and technology?
Yes, this is more than simply an upscaled 4100XPC AC. As technology and
engineering analysis tools have advanced, we have been able to more
confidently attack design margins and design our machines more
efficiently. To the novice the changes to the machine might be difficult to
spot but the primary items that change are on the attachment (boom,
handle, and dipper). Design principles dictated a wider boom and handle
for the 4800 to maintain dig stability. Also new to the boom is direct drive
crowd system. Crowd loading has increased to the point that a new path
forward was required. This new path has already experienced a trial of
sorts as an integral part of the P&H Hybrid Shovel design. The dipper has
undergone several design upgrades that have transformed the
performance of the unit. Whether targeting latch reliability, rope life, or
simply dipper wear through frictional resistance with the bank, the dipper
has been improved considerably. Another key to the 4800XPC, especially
as the above noted design margins have been approached, is technology.
This machine’s technology is there to both improve the productive
potential of the machine without sacrificing machine life, and to help all
operators perform to the best of their abilities.
Q In modelling of the machine in use does it provide higher productivity
and cost performance versus the 4100XPC or even two smaller shovels?
The modelling is purely theoretical at this point but based on inputs from
existing 4100XPC AC applications. Given similar truck presentation to a
4100XPC AC and looking at the design criteria to meet or exceed the
4100XPC AC from a cycle time perspective, we feel the 4800XPC can
achieve up to a 20% increase in productivity with a corresponding
decrease in cost per tonne. Of course, those two criteria are linked and the
production must be available (in the form of trucks to the machine) for the
cost benefit to be achieved.
Q Is this machine intended as an ideal match for the new Komatsu 980E?
Q What are the challenges in upscaling a rope shovel to this size? Size of
castings and components mainly?
The main challenge with upscaling a rope shovel is the multiplicative effect
of a single change. Despite its size and strength, a mining shovel is meant
to operate in a controlled balance. This balance is reflected in the
structural survivability of the machine as it experiences digging and
propelling forces throughout the years. Balance in the design means
understanding the effects of design changes and the many ripples that
changes could affect regarding the performance of the machine over time.
Fortunately, we have extremely experienced engineering, manufacturing,
and field product support teams to help optimise designs.
Q To what extent has the delay on the machine been driven by the
downturn and parked truck fleets; new technology that needed to be
added to what was an older design; and awaiting a firm order?
We were ready for our first machine at MINExpo 2012. The downturn not
only dried up what was an extremely profitable electric mining shovel
segment in the industry, but it also diminished risk appetites at mines and
corporate levels despite this being what we see as an extremely low risk
product. Since enthusiasm in the product has been renewed with the first
sale we have absolutely looked at the design with fresh eyes to see if any
of the lessons learned in the intervening years would be applicable to th