SURFACE LOADING
prevention measures the force on the crowd rope and automatically adjusts motor output to avoid shock loading . Rope crowd overspeed prevention eliminates unnecessary wear on the crowd brake by providing more braking power to avert overspeed situations .
By providing the foundation for support technology expansion and integration , the Integrated Technology Package helps to provide more robust and reliable reporting . New Cycle Segmentation establishes operating key performance indicators ( KPIs ) and identifies dwell time when idle . It divides cycle time data into digging , swinging to the truck , dumping and swinging to the bank segments . This allows miners to track machine performance across different shifts and operators .
With this introduction , legacy reporting technologies change to new Machine Health , Vibration Monitoring , Payload Management and Bearing Temperature Monitor technologies . Machine Health delivers improved reporting capabilities and provides remote real-time machine monitoring . Using sensors to capture data from the crowd , hoist , swing motors and gearboxes , Vibration Monitoring examines vibration signals for changes , allowing for proactive maintenance to reduce unplanned outage downtime . Payload Management provides real-time feedback on material moved to avoid truck over / underloading . Bearing Temperature Monitor keeps track of hoist , swing and crowd bearing temperatures and alerts the operator if figures rise beyond established thresholds .
The optional Integrated Technology Package will be available in standard and premium subscription levels . Standard subscriptions include all package technologies and push notifications for software updates . Premium subscriptions include all standard features plus vibration data analysis , monthly report generation from a Caterpillar engineer and inperson consultation to review the report ’ s findings and conclusions .
New Cat 7495 and 7495 HF shovel purchases can be optionally equipped with the Integrated Technology Package and Operator Assist Technology Package as of 2023 . Availability of these technology packages as field retrofit kits is scheduled for mid-2023 .
Komatsu ’ s Track Shield 2
Repeated dipper-to-track strikes on electric rope shovels can reduce crawler shoe life and cause structural cracking and dipper damage , resulting in unplanned downtime and increased repair costs . Track Shield 2 is a new suite of control functions from Komatsu Mining that helps the operator decrease the number or severity of impacts between the dipper and the tracks or other parts of the shovel .
This solution calculates the position of the dipper and modifies controls to mitigate collisions . Komatsu says that Track Shield 2 is ideal for a variety of mining operations and applications including but not limited to oil sands with wide path tracks ; TRC dippers ; wider dippers ( 76 cubic yards or greater ); plus configurations where it is difficult to see potential strikes .
Komatsu states : “ Track Shield 2 has been engineered to substantially reduce the number or severity of costly collisions with the dipper on your valuable shovel asset . It ’ s a sophisticated technology upgrade that can help reduce maintenance costs and increase machine longevity from fewer incidents of damage or fatigue to the shoes , front idler , dipper components , cable reel and other components .”
It adds : “ We ’ ve worked with our valued customers to design a solution that minimises the impact on operator motions during tuck to maintain shovel productivity . Field tests have shown statistically no reduction in productivity while Track Shield 2 is in operation when properly tuned . It can also assist operators by guiding them to where they need to be with respect to the shovel ’ s structure and digging face while reinforcing best digging practices .”
Tuning is an initial process that configures Track Shield 2 based on operational priorities and objectives . “ We ’ ll work with you to pinpoint your optimal approach that aligns with your unique operation . For instance , Track Shield 2 can be custom tuned to focus on mitigating risk – avoid almost all collisions . Or it can be performance-configured – optimise productivity while reducing damage . It ’ s your choice . Komatsu service personnel provide one-time tuning in close collaboration with your mining operations and fleet maintenance teams .”
Large wheel loaders – here comes the Cat 995
Caterpillar ’ s 994 wheel loader has been a leader in its size class since it was first introduced in 1990 . Now the company is set to enhance its offering with a step up to the all new Cat ® 995 Wheel Loader which it says will deliver more payload , more power and more performance while using less fuel . First shipments are expected in Q4 2023 with an official launch in the coming months .
The 995 builds
Komatsu ' s Track Shield 2 is a suite of control functions that helps the operator reduce the number or severity of impacts between the dipper and the tracks or other parts of the shovel
on the success of the 994K model with the goal of achieving even higher efficiency and production . Compared to the 994K , Cat says the new 995 is up to 19 % more efficient and up to 19 % more productive , thanks to a higher rated payload , increase in hydraulic force and up to 20 % reduction in hourly fuel consumption in Enhanced Eco Mode . Standard rated payload is 45.3 t for moderate to high digging resistance and 54.4 t for low to moderate . It also has 6 % more hydraulic force than the 994K .
Using less fuel reduces engine emissions and carbon footprint ; it ’ s 3516E Tier 4 Final engine reduces NOx and particulate matter . It also has Engine Idle Shutdown , which saves fuel by making it possible to avoid unnecessary idling .
Efficiency focussed technology includes Tire Slip Prevention , which reduces rimpull when there is less downforce on the tyre and increases rimpull when there is more downforce on the tyre — providing maximum rimpull when you can use it . Lift Stall Prevention automatically applies the impeller clutch when necessary to prevent hydraulic stall when lifting up through the face — keeping the lift motion continuous , without excessive use of the impeller clutch .
It also offers an improved operator environment . Designed for visibility , it has a taller windshield that provides a 25 % increase in glass surface area for a better view to the bucket , standard rear-view camera , optional Detect 270-degree cameras , standard
Caterpillar ’ s new 995 large wheel loader
32 International Mining | MARCH 2023