SURFACE LOADING
Nardo , Project Manager , New Machine Deliveries , Liebherr-Australia Pty Ltd in a recent article posted by the company . “ Once this R 9400 had been removed from its operations in Western Australia , the base machine was returned to our branch in Perth , where the conversion could begin .”
Among the changes necessary for the R 9400 to become an R 9400 E , the diesel powerpack and fuel tank needed to be removed and replaced with their electric counterparts – in this case , an electric-drive powerpack and a high voltage electric cabinet respectively . Components needed in the diesel-drive R 9400 – like the water-cooling radiators , fans , exhaust , and air intake systems – were made redundant with the introduction of the electric-drive powerpack . However , the rotary connection was a unique case : in order to accommodate the high voltage interface between the upper- and undercarriage of the R 9400 E , an entirely new rotary connection needed to be installed .
In order to simplify major machine maintenance for customers , Liebherr recommends that repowers occur when a machine is due for a major service or component exchange . So while the R 9400 was being transitioned from diesel to electric power , major components that had achieved service life were also exchanged . Performing major maintenance in this way also has the benefit of making the process more cost-effective for customers . Once the new electric-drive modules were installed , connections completed , and systems checked , the repowered R 9400 E was then ‘ powered up ’ to energise the excavator ’ s operational systems . The R 9400 E requires 6,600 volts at 50 hertz for its power up process and then the electric motor and hydraulics can be ‘ started and run up .’
To minimise the inrush current needed to start the electric motor , Liebherr developed a specialised system that consists of high voltage transformers . This system of transformers reduces the current required from the customer ’ s power grid to avoid excessive network disturbance .
Although the repower process is not overly complicated , specific expertise from Liebherr ’ s excavator factory in Colmar , France , was required to support the Liebherr team in Australia with its first diesel to electric repower project . “ Repowering the R 9400 was an exciting challenge for our team , but one that they quickly overcame ,” says Di-Nardo . “ Most of the people working on this project had only worked with diesel powered machines previously . However , thanks to the combined efforts of more experienced team members here in Australia and the engineering assistance from our excavator factory , the team was able to complete the project tasks safely and on time .”
Weir ESCO and next gen GET
ESCO , a division of Weir Group , engineers and manufactures mission-critical wear & replacement products for mining , construction & industrial applications . IM caught up with the world leader in ground engaging tools for some insight into its pioneering innovations , including a preview of its new Nexsys™ Mining System for rope shovels .
Q Are most or all your GET solutions customised packages for individual mines - is this one of the things that makes ESCO stand out in the market ? A As the world ’ s leading independent provider of mining GET , Weir ESCO offers a wide selection of options with maximum flexibility to best suit each mining application . Selecting the proper lip system and GET combination can influence the site ’ s productivity , ability to achieve key performance indicators ( KPI ) and operating efficiency . Weir ESCO works closely with mine personnel to provide product training and the best maintenance practices to maximise GET performance . ESCO ’ s fieldproven Nemisys ® lip system for mining class wheel loaders is a perfect example . Depending on site preferences and machine use , there are both weld-on and mechanically attached options . The weld-on system provides better penetration and lower product weight , allowing for a higher bucket payload . The mechanically attached system has a slightly higher profile but allows for easier component replacement in the pit without any hot work , reducing overall machine downtime . A broad selection of teeth , wear caps and shrouds are available to suit the site ’ s needs . Weir ESCO ’ s GET experts partner with the mine to select the best option for the machine class and application .
Q How do you actively benchmark the TCO of ESCO GET solutions versus competitors in the market ? A When considering total cost of ownership ( TCO ), multiple factors come into play : component cost , time required for installation and replacement , productivity , wear life and unplanned downtime are the most common . All hold a different level of importance to each mine site . As a leading supplier of GET , Weir ESCO delivers values outside of just product pricing . We collaborate with the site to evaluate their current system , whether it is a competitor ’ s system or a previous Weir ESCO system . Through selection of the optimal GET combination , the customer will benefit with increased efficiency and achieving critical KPIs .
As an example of the options available to customers , for an EX5600 hydraulic excavator operating in extreme applications , the Nemisys ® N5 nose size would be an excellent choice . It offers a range of options to deliver optimal performance . The XHD intermediate adapters and shrouds combined with a heavyduty point will deliver the best system reliability , wear life and minimise lip maintenance . This GET option also features extended bottom wear shoes to provide additional protection for the structural components on the underside of the cast lip to further reduce maintenance and extend lip life . For the same machine in less demanding conditions , the Nemisys ® N5 V2 lip is available . It allows for smaller , lighter Nemisys N3 points and shrouds which can be used without sacrificing nose strength on the cast lip . This option saves more than 1,590 kg ( 3,500 lbs ) over the XHD configuration , potentially increasing the bucket payload or freeing up weight that could be reallocated to additional wear protection in high wear areas of the bucket .
Q Are customers relying more on high quality GET to maximise cost per tonne in today ' s mining world ? A Mine digging performance expectations continue to become increasingly challenging . Customers want to maximise equipment use by extending GET system service life to better match planned maintenance schedules . One way Weir ESCO is able to provide optimal performance is through reliable GET retention and with proprietary alloys that provide an unsurpassed metallurgical advantage over OEM and competitor systems . Although all suppliers provide alloy steels , our alloys provide the best balance of superior material toughness and through-hardness . With this , Weir ESCO components deliver the best infield performance for wear life and reduced chance of cracking or catastrophic failure . The result is improved productivity , increased GET service life and less downtime , all of which lower a mine ’ s cost-per-ton . In addition , all Nemisys GET components come equipped with sealed locks to minimise the effects of impacted fines for easier and faster GET replacement .
Q Is the GET market very distinct from the attachments market , ie buckets , or is it common for both to be sold in combination and does this bring the best overall results ? A Attachments serve as a primary structural component that are expected to have a long
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30 International Mining | MARCH 2024