Published in March 2007 Australian Longwall Magazine

The cordless mining caplamp was invented in China just three years ago in response to intense demand with Chinese mines consuming some 6 million mining caplamps each year – nearly a thousand times more than Australia.

Thanks to the development of cellular phones, mobile computers and other mobile devices, compact rechargeable batteries have significantly advanced in the past decade. Lithium-ion rechargeable batteries stand out owing to their high energy density and other advanced features and LED has become increasingly more efficient.

Kinyun has used these advances, integrating the lithium-ion battery cells with white LEDs loaded into an IP67 caplamp case, making the traditional belt-worn battery pack and electric cord redundant, according to Kinyun Australia’s Dr Henry Gong.

“This brings huge benefits, significantly improved safety – no electric cord to snag or tangle, no heavy battery pack to carry, no acid or toxin to spill, no heat on lens surface, no burning parts to catch fire, and high IP rated enclosure to withstand the harshest mining environments.

“Maintenance could not be easier – very easy to clean, no cable, bulb and headpiece to check or change, no repair, no dedicated staff to look after charging. It also features a fully adjustable angle bracket to direct the beam as required.”

Kinyun has also created compact charging banks for the caplamps, which it claims are as easy to charge as a mobile phone.

After two years of market testing, Kinyun decided to introduce its cordless caplamps to the world market and successfully applied for ATEX and SABS intrinsically safe certificates. Early last year, Kinyun Australia was set up in Sydney to look after the regions in IEC jurisdiction for product redevelopment, certificate application and product distribution; then it applied for an intrinsically safe certificate for its most popular model, the KL2.4ML(A). After significant modifications for IEC standard and Australian mines, this product was granted IECEx and ANZEx certificates.

The KL2.4LM(A) was selected as a try-on for Kinyun to understand the Australian market, IECEx/ANZEx standards and the certification process. This 9-LED caplamp is the flagship product in China and was trialled in Australian hardrock mines.

“Kinyun soon realised that many Australian mines want something different. In China, illumination glare is a big issue because of very different underground working environment whereas our tunnels are big and we do not have many people working closely all the time,” Gong said.

“For most underground tasks, Australian miners need a focused high beam light to enable long distance light projection and spotting.”

Now Kinyun has decided to release its new product, the KL3LM(A), onto the Australian market, applying for the IECEx/ANZEx certificate, along with some other models.

Kinyun has developed a new product range which significantly increases light intensity, reduces the weight and increases the reliability of the caplamps which are undergoing certification at TestSafe at time of print.

The KL3LM(A) uses a reflected high-powered LED as the main source, plus higher battery capacity and improved circuit, so that high beam and long projection can be achieved. This will be the flagship product for mining industry, replacing currently certified KL2.4LM(A) in Australia.

The KL2LM(A) is a new version of KL2.4LM(A), with 10 LEDs and a higher light intensity for well distributed peripheral illumination.

The KL2LM(A)ST is a red colour version of KL2LM(A). The Chinese miners clip it on a vehicle as a warning indicator; however Gong said Australian miners have found various other applications. “For example, they clip it on the back of the helmet or wear it on the back on the belt, so vehicle drivers can see them more easily.”

The KL2LM(B) is a lightweight version of the KL3LM(A), weighing 110g – the world’s lightest mining caplamp, according to Gong. He said many above-ground workers will choose it in the transportation, utilities and processing plants. It is also good for weight-sensitive applications such as with longwall miners who have already heavy loads on the helmet.

Kinyun Australia exclusively disclosed to Australian Longwall Magazine the special caplamps under development behind company doors.

“The two functions of illumination and flash signalling will be put together as one lamp.

“Mine rescue operations sometimes need extremely concentrated high beam light for long projection and heavy smoke penetration. An ultra-high beam lamp is currently under development.

“Kinyun’s tracking caplamps are designed for use in Chinese mines. Kinyun Australia will modify the lamps and integrate them into Australian tracking systems.

“Our gas detection caplamp has been used for two years in China but will be modified for use in Australia.

“The caplamps under development also include a 24-hour mega model, radio communication model and some secret models.”

While Kinyun is mainly concerned with the mining industry, it has also found applications for its product beyond this sector. The company has gained certifications for Group II gas environments, far beyond those of mining to ensure the product is suitable for other industries – such as the petroleum market. It has also developed a low cost version for farmers.