Energy saving analysis of the hydrostatic drives used in the rotary head system of the blast hole drill rig

Abstract

Blast hole drill rigs are used for drilling the soft and the medium-hard rocks in open-pit mines. In such rigs, the drill bit is rotated by a hydrostatic drive. In this respect, two different type hydrostatic drives have been considered. In the first drive, the rotation of the drill bit takes place by a variable displacement pump and two low-torque high-speed hydro-motors along with a step-down gear unit (i.e. LTHS drive), whereas in the second drive an identical pump and a high-torque low-speed hydro-motor (i.e. HTLS drive) rotate the drill bit. In this study, the energy saving analysis of the above mentioned hydrostatic drives has been performed with respect to the load profile of the blast hole drilling. In this respect, the modelling, simulation and the experimentation of the drives have been carried out. Simulations have been performed in MATLAB–Simulink environment and it has been verified through experiments. The proportional-integral-derivative control algorithm has been used to control the drives speed in various loading stages. Results show that the high-torque low-speed drive save more energy compares to the low-torque high-speed drive for the usual operating range of the blast hole drilling.

Keywords

Blast hole drill rig open-pit mine hydrostatic drive MATLAB–Simulink environment proportional-integral-derivative control

Get full access to this article

View all access options for this article.

References

Manring

Luecke

. Modeling and designing a hydrostatic transmission with a fixed-displacement motor. J Dyn Syst Meas Control 1998; 120: 45–49.

Murrenhoff

. Systematic approach to the control of hydrostatic drives. Proc IMechE, Part I: J Systems and Control Engineering 1999; 213: 333–347.

Hui S, Ji-Hai J and Xin W. Factors influencing the system efficiency of hydrostatic transmission hybrid vehicles. In: IEEE vehicle power and propulsion conference 2008: VPPC'08, Harbin, China, 3 September-5 September 2008, pp.1–6. Piscataway, NJ: IEEE.

Mandal

Dasgupta

Pan

, et al. Theoretical and experimental studies on the steady-state performance of low-speed high-torque hydrostatic drives. Part 1: modelling. Proc IMechE, Part C: J Mechanical Engineering Science 2009; 223: 2663–2674.

Mandal

Dasgupta

Pan

, et al. Theoretical and experimental studies on the steady-state performance of low-speed high-torque hydrostatic drives. Part 2: experimental investigation. Proc IMechE, Part C: J Mechanical Engineering Science 2009; 223: 2675–2685.

Dasgupta

Mandal

Pan

. Dynamic analysis of a low speed high torque hydrostatic drive using steady-state characteristics. Mech Mach Theory 2012; 52: 1–17.

Manring

. Mapping the efficiency for a hydrostatic transmission. J Dyn Syst Meas Control 2016; 138: 031004.

Shi

Yang

Gong

, et al. Energy saving of cutterhead hydraulic drive system of shield tunneling machine. Automat Constr 2014; 37: 11–21.

Kumar

Dasgupta

Ghoshal

. Dynamic analysis of a closed-circuit hydrostatic summation drive using bent axis motors. Proc IMechE, Part I: J Systems and Control Engineering 2015; 229: 761–777.

10.

Hasan

Dasgupta

Ghoshal

. Comparison of the efficiency of the high speed low torque hydrostatic drives using bent axis motor: an experimental study. Proc IMechE, Part E: J Process Mechanical Engineering 2017; 231: 650–666.

11.

Vardhan

Dasgupta

Kumar

. Comparison of the steady-state performance of hydrostatic drives used in the rotary head of the drill machine. J Braz Soc Mech Sci Eng 2017; 39: 4403–4419.

12.

Jimeno

Jimino

Carcedo

. Drilling and blasting of rocks, Boca Raton, FL: CRC Press, 1995.

13.

Gokhale

. Rotary drilling and blasting in large surface mines, Boca Raton, FL: CRC Press, 2010.

14.

Chatterjee R, Paul S and Mourya VK. Prediction of uniaxial compressive strength from well log data in Jharia Coalfield. In: 10th Biennial international conference and exposition on petroleum geophysics (SPG 2013), Kochi, India, 23 November-25 November 2013, pp.1–5.

15.

Product catalogue of standard gear unit modular system CSB140. Faridabad, India: New Allenberry Works, www.allenberrygears.com (accessed 25 September 2018).

16.

Product catalogue of the Proportional pressure relief valve, pilot operated RE 29361. Ahmedabad, India: Bosch Rexroth India Ltd, www.tecnicalimpianti.com/pdf/re29361_2013-07.pdf (accessed 25 September 2018).

17.

Hydac electronic GMBH: Operating manual part no.669855. Portable Data Recorder HMG 3010, Edition 2012-06-28-V04 R01, www.hydac.com/uploads/tx_userhysoftware/Handbuch_HMG_3010_V04R0_E_2012-06-28.pdf (accessed 25 September 2018).