Using the features found in modular construction techniques, the company has engineered a solid and flexible feeder breaker that essentially breaks long-held design rules but retains the inherent strength required of underground mining equipment.
The feeder breaker represents a big step forward in mining machinery design, according to Kopex Waratah engineering and operations director and project team leader David Edwards.
“The premise behind the project was to look at the design and engineering of feeder breakers from a different perspective,” he said.
“Feedback from our customers had given us some pointers as to where we could improve the productivity of feeder breakers and we had our own ideas of where we could advance equipment design and operation.”
Edwards said the final product of the design approach had been site-tested and delivered on its promise to introduce another paradigm in underground mining equipment design.
As part of the design process, Kopex went to the market to gather feedback about the design and operation of feeder breakers. One of the regular comments was to do with machine weight.
With an operating weight of a little more than 32 tonnes, this machine is among the lightest of the current batch of feeder breakers, achieved through modular design and a simplified construction method.
Without any sacrifice to machine strength, the modular design gives the feeder breaker flexibility and manoeuvrability – two other areas highlighted by the industry feedback, according to Kopex.
Other aspects of the design also warrant comment.
One of the upsides of the modular design is the machine’s three-way access hopper assembly which, Kopex engineers say, can be adapted to whatever arrangement – dictated by the type and quality of material being mined – is required.
Additionally, any reconfiguration of the hopper can be completed underground, virtually eliminating any break in production while the machine is transported to a site workshop for alteration.
It is worth noting the company has applied for a provisional patent for the hopper assembly.
Similarly, the modular design has brought about significant improvements in tail shaft design and accessibility. If required, the tail shaft can be removed through the back of the machine. The need to remove the side plates to access the tail shaft is eliminated – a feature that delivers tangible benefits in terms of production and maintenance.
In keeping with the machine’s “alternative” design philosophy, a different track configuration has been developed. Height adjustable via hydraulic cylinders, the tracks provide improved alignment and stability.
Build quality and machine longevity are said to be hallmarks of this feeder breaker.
Designed and engineered with an eye to the global underground mining sector, maximum operational output, in continuous operation, is 216 cubic metres per hour.
The economic life of the machine is 5.18 million tonnes (with four major overhauls) and the economic life between major overhauls is 1.03Mt. Hopper capacity is less than 16,000kg and machine capacity is rated at 20,000kg.
Installed components maintain the quality theme and include Brevini gearboxes, Kennametal wear components and Rexroth hydraulics.
“This feeder breaker is unique. It not only represents a design breakthrough – which has delivered benefits such as modular construction and underground reconfiguration – but it heralds a new ‘design and build’ era for the company in Australia,” Edwards said.
“We are working to position Kopex as a first choice underground equipment supplier. This new feeder breaker is a step along that track.”
This article first appeared in the September issue of Australian Longwall magazine.
