Coal panels and face lengths are increasing – the average seam height is not. Maximizing productivity levels as the seam height diminishes requires a robust and compact cutting machine design with optimal coal-loading performance –
backed by advanced automation capabilities for visualization and control.
The fully modular haulage system features a separate gearbox and motor and is suitable for a parking brake attachment and absolute encoder for shearer position.
Features include:
The unique mainframe of the HBT shearer is one of its key features. The fabricated structure of the mainframe with cast ranging-arm hinge points results in an extremely robust design not only to meet the toughest mining conditions and ensure reliability and long service life, but also to handle even higher cutting and haulage forces in the future. The mainframe is designed to allow retrofit of ranging arms and haulage units. A split mainframe is available in case of transportation limitations.
Trapping shoes protect the haulage sprockets and form an area of interaction with the haulage rack system attached to the armored face conveyor, allowing the shearer to be hauled up and down the face. A new type of trapping shoe developed by HBT offers numerous advantages over the original design:
The patent-pending trapping shoe Inserts show a separation of structural and wear parts to allow quick and easy replacement of surfaces/items subject to wear.
The new design simplifies replacement by reducing the weight from more than 400kg (880lbs) to less than 50kg (110lbs) per insert and cuts the time required for exchange. Due to the lighter weight being handled, changeout can take place anywhere along the face. Previously, this work had to be completed at the gate ends, where heavy lifting equipment was available.
Based on proven design concepts, the new ranging arm delivers maximum cutting power in an application-focused profile. Enhancements generated over years of experience in operation include an independent epicyclic oil compartment for optimizing lubrication and cooling with a second layer of protection from debris ingress.
Ranging arm features:
The PMC-S control system represents a state-of-the-art distributed automation system for the control, monitoring, and protection of the shearer. Its modular design allows system configuration to meet the customer’s specific control needs, from basic monitoring and protection to advanced automation and data transmission. State-of-the-art Ethernet communication and backup functionality allows remote control and diagnosis of all components.
HBT offers different shearer automation packages. The Standard Machine Control offers zone-based automation, in which parameters are defined in zones along the face. Basic Automation features state-based automation and allows the shearer to operate precisely to the operator’s defined production process, including directions, speeds, arm height, and ranging arm control modes. Advanced Automation offers improved face alignment and horizon control with additional cowl automation.
HBT MineStar Health for Longwall is a cost-effective and user-friendly data visualization and reporting tool. It enables to efficiently view, manage and use machine data of a shearer — so that informed maintenance decisions can be made that will help maximize the equipment availability. The VSoftware package VShearer provides complete machine data visualization and parameter management for predictive maintenance planning and production optimization.
The innovative downdrive design of HBT shearers results in extended bearing life, increased gear rating and greater modularity for simplified maintenance.
Height adjustment of the shearer is relatively easy and is achieved with replacement of the downdrive (and skid shoe post) to allow adaption to changing seam conditions.
All shearer model mainframes are designed to fit the full range of downdrive arrangements suited to specific extraction ranges in various seam thicknesses.
The direct downdrive is designed to maximize tunnel clearance when the shearer is operating on a narrow AFC profile. Due to the geometrical design requirements, the direct drive profile does not allow the fitting of the trapping shoes with replaceable inserts.
The indirect downdrive has the sprocket driven by a gear arrangement which promotes improved sprocket life. Indirect downdrives are also designed to accept insert trapping shoe technology. The inserts are the wear component and weigh less than 45kg each, rather than replacing the complete trapping shoe.
HBT longwall shearers operate more predictably, more consistently and with greater component life and availability when supported by the latest HBT longwall automation tools.
Downtime is inconvenient and has the potential to become an enormous expensive for operators. With an understanding of customer expectations each shearer design is subjected to rigorous in-house testing to maximize availability and reduce the required service time.
Ranging arms and haulage units are subjected to an intense test regime to establish the optimum oil-level requirements to suit all mining conditions.
This test applies loads far in excess of those encountered during normal mining operations, ensuring that the shearer can operate reliably at the installed power ratings. The endurance block load test imposes loads from 100 to 175% to ensure that the ranging arm design meets the requirements of the most demanding applications.
This test for ranging arms and haulage units gradually increases the load up to full load. All temperatures and vibration points are monitored during the test, and oil samples are again collected for analysis.
The HBT PMC-S control system delivers efficient control of the shearer. The modular design allows individual configuration – from basic monitoring and protection to advanced automation and data transmission.
High-powered ranging arms and haulage units ensure worldclass production in the toughest mining conditions.
The mainframe not only offers maximum protection of major units – its fully modular construction means versatility in application as well as the option for targeted overhauls to manage your total costs of ownership (TCO).
You need further product information or like to request a quote? Just contact us.
HBT GmbH
Industriestrasse 1
44534 Luenen
Germany
Phone: +49 2306 747-1100
Email: info@hbt-group.com
