Abstract

Kuzbass opencast coal mines use foreign produced excavators as basic equipment. Capital repair of these excavators involves complete replacement of all tooth wheel gearing in reduction gear boxes after 2~3 years of work (depending on operating time). The cost of this replacement is practically equal to the cost of new gear boxes. To minimize repair costs and extend service life of gear-tooth systems in gear boxes a methodology for monitoring technical state of gear boxes in imported mining equipment was developed. It allows to obtain reliable information about the level and significance of in-service defects in their elements. The research showed that the most reliable methods of control are visual and dimensional test (67%) and fluorescent-magnetic inspection (32%), and used together these two methods allow to detect up to 100% of significant defects. The most significant among service defects in typical elements of gearing systems are single and multiple cracks.

Highlights

  • More than 70% of coal in Russian Federation is mined by the open pit

  • Kuznetsk Coal Basin is one of the largest in Russia and in the world [1,2,3,4,5].The main machines working at Kuzbass open cast coal mines are excavators, both produced in Russia (ESh, EKG), and imported (Komatsu, P&H, Katerpillar)

  • New Kuzbass open cast coal mines use dozens of times more imported excavators than those produced in Russia

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Summary

Introduction

More than 70% of coal in Russian Federation is mined by the open pit. The reason is that open cast coal mining is obviously more advantageous than underground. New Kuzbass open cast coal mines use dozens of times more imported excavators than those produced in Russia. As a result in 5 years of operation all units are replaced and even more than once This is explained by severe working conditions of the machines due to climatic and power factors [6]. Reducing gear boxes are the most important units in excavators. Using planetary gearing and closed rack-type differentials makes the situation slightly better This allows to divide the power transferred into several flows by number of planetary gears and reduce the load on the gear pair and significantly downsize the mass-dimensional characteristics of the gear box [7]

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