Series on Bulk Materials Handling Vol.1 (1975) No.2 The Bucket Wheel Excavator Development - Design Application by Dr.-Ing. Dr.-Ing. E. h. Ludwig Rasper First Edition 1975 Trans Tech Publications‘See on Bat Nate Mang ‘al 10995. Inthe USA tnd Cana by ‘TRANS TECH PUBLICATIONS "11 Lang Beach Py. ‘ay Vip, Oo #00 tia snd wold by ‘hss Germy Tranter he evs Oem eto Pbnmhing Eon see Geoman eition pais by ‘ron Toh Penton 193 ‘ntratinal Sasa Back Number ISBN Ouse. Lay of Congest Cuno Card Number ee N98 “This ook or tee may aa be eprodied in ay fom without he ‘wen perma othe pase Allright ened‘PUBLISHER'S FOREWORD “The present volume i the fit deaied acount on the development design ‘and application of ucket wheel excavators (BWE) ofa zs, twas special honor fr ust Dr. Rasper, probably one of the best own exper inthis field in Germany, agreed to write the manuscript. Only someone who had Spent many yeu designing and applying wheel excavators abd who had intimate knowlege in thi eld could posbly qualify for his dfclt tsk. ‘Wie believe that hs book wil belp many engineers worldwide to evaluate this {ype equipment It wll ost certainly have an impact on the international Iniing scene stat ming engineers wil arto evaluate this excavating {ool at many new projec We foresce an increase interest inthis mos ef ‘Sent mining mchne ia the light ofan ever ineresing demand for eas mo- {evs buried under larger mates of overburden, ad or bigger earhmoving Schemes for cl engineering projet Uke cant! or dam bling snd tnd rechimaton ‘Stating ot wi text ia German language and trying come up with more ‘orlese perfect book in the Enlh ingeage presents a number of unforeseen problems Overthe deration af on yar there were several "geneitons” of Itanstions allo which were continously improved upon. A major difiuly tra that the Exgla shoud at only be grammatical correct, but also the ‘pest terms inmechanicalclectrical and mining engineering had tobe ght “Thisiwe could only guarantec by ening thebelpof good Hendin the US.A, who bot had considerable expereac wih this type equipment ‘Ms. Jim Kat, LE, Industria Appctins Eaginer withthe General Etre ‘Compaoy in Ckveland, Ohio ead the tansation and concentrated especial fon the coretese ofthe trms referring to eects eaglncrig. We sn ‘erely appreciate his elp and his many Suggestions. ‘Our most since thanks are dae to Mr- George E Aiken, Manager, Mining Engineering of river Eaginers, Oakland, Calforna for thoroughly reading the manuscript and advising on all mechanical and ining expressions. Mr ‘Alken suggestad many changes and casifictios within the text and has eal contritated to this book But not enough, Mr. Aiken has alo writen the Introduction tothe book nd has etal stated the opinion of may Intucatil mining engineers ia the US.A. on the fare of the BWE in North Americ ‘We ar also extemely thank! othe equipment manufacturing, consling snd pablshing companies which have placed dispy advertisement athe ee ‘ott Book, They have heed sto finance the remendouly inereased cox ‘or paper, typeseting, printing and promotion. Those companies ar also the ‘most ely to bs asocated wit the new mining and bulk materials handing, ‘stems lloverthe world and we reste thatthe planing engsec wil Wel ‘ome this almost complete coletion of important companies. The Author ‘nd the Publishes epard the Adhertsing Section asa valuable supplement to the tex. We are ako expecily appreciative ofthe coatiouous support we received from Dring, ©. Erwin Gattaer, Member ofthe Board of Diesors of‘Renische Brankohlenwerke AG, Cologne, who wrote the Intodution to the German Eaton aad rom Dr- Ing H Heuser, Member ofthe Board of Director of Orenstein e Koppel AG, Doctmund “This book conoestrates on the term excavator of bucket whest machines and ‘hough many components and design features are more or les dential othe bucket whee eclamers, ome readers may be dsippsnted in not geting thor information on the wheel eclimer Since these machines ar elng used to an ever incresing degre in al large tckpe banlng acties in mines, ports power generating statins ante plans tsexmed appropriate treat {his ubjest na separate volume Sofa, we mere unable to find an author who would be wing to write & ‘mancit onal aspect ofthis subject. Therefore, mo have decide to com ple esymposiam of papers on bucket whee sackerreclaimers, which should Contin many diferent popes on thei espn, apptcation and actual per ‘on, Tew papers shoal be authored by design an appbeation engineers of Inanufactaring compres, by consling engineering fms and by enpnees ‘operating such equlpmen in various bulk handling systems. But in ender ‘tieve this we need your belp and cooperation, ase talk this project over ‘ith your fends and suoines an sendin Your comments. suggestions and Conulbutons to Dr. RH. Woblbie, Trans Tech Pbiations,D-3392 Claus- thal-Zelleield, Germany, who had seven year of spetience with his type ‘auipment and woud be in charge of editing aod compiling the manuscript Defining «problem orate of lterest, and ring 8 paper about i 2 manageable projet If hit exer i epentoa by 20-40 comthators, we sil beable fila gap. This should bee wrtheik project and we do hope for your operation Ctaustha- Zeer, Hinasar Wom Jesuary 1975 Ronoian> H. WowsINTRODUCTION “Prior tothe pubiation of Dr. Raspe's book, the absence of bucket whee xcvator GWE information and traditional American falas with other ‘rctation methods have not encouraged the use of wheels as mining 00 ‘Yerwecan ind itat work under many vred conditions throughout the word ‘AS sated in 1966, mut be given consdratin if the low grade orebodies ‘Sovered by hick overburden ae to be sccessfilly worked, A as one io ‘Sebody wih which Lam failing, having an average arade of 2 perce is ‘Sing consdered viable propostion. Mach of thi and ater low grade ‘teil could be bundled Cheaply withthe whee While exotng the merits of the BWE, Dr, Raspe' bok makes it very lest that it ct a unversal answer to every exenvaton project. Too many of he sumed vnfavorable apace atrbutble to the BYE can be ced 0 mis sppiation. Evenywhere today the minerat industry beset by powerful public foros seeking to reshape and nflaence the course of resources development. Fue ‘mineral pects must tony be viable costs but compatblewith environ ‘ment standards Intons are that these dual goals canbe achive through (moderation and understanding BWE technology, where aprropiat, i fechniqu for mesting base envronmental requirements and excavating ‘Sts acegtble othe mineral ndasty signet portion of new mining projets are concerned with he removal ‘tndormicing of very large tonnage. Some ofthese great meri volumes trl ave te be retred to mined out areas. These mas mater movements {ein the domain of te BWE and is accepted transport methods. With he Fight condsions the BWE sail perform exceptionally wel. AS Dr. Reser points out be BWE works best where digging conditions re constnt he ateral stale, anda minim of moving is requied. Hopever, stile BWE performance hs proved in European the machines ‘oi hacer material han before, America shoves ad drags also elt improved wchnoloy. Longer casting dintance and more pres controls may rake dragines a formidebe contender for work also sutabl: fr & wheel ‘The implations of BWE performance with espet to coal ming are very encourage, but ite suitability in each cas must be individually asestod. For ample he penertion of Boe in coal mining is normally undesirable, yt the ming action of BWE tends to eeate more fins. Coal produces are inying this problem and may decide the BWE canbe beter usd for over burden removal and land ssamation echaigues Related to the forts to rapidly develop slterste coerzy resources, the ‘Westen US. coals are prime target We have read of te improved perfom= ance of BHEs in Europe to dig hander mater. Experenc, as noted by De. Rasperin his book, with ight blasting abe of wheel work a introduced 1 bettie “not recommended” procedure as very sce adjnet to WE signing The development ofthe Wester Coals probably the least fovly meio andthe soret route o providing assured shrrange suppis ft eocrgy. Beyond thin U.S. reserves of coal are projected at 0-70 yar. ‘Over 90 perce of known U.S. energy eserves ae in cal andi ale. Notal ofthese coals wl be reoveral with BWE stems, but cere is aendy & Considerable amouat of interes in BWE applications to Wester Coals. (Continued interest in BWES for mining ol ands resent with the ose ‘pplication by GCOS of thie BWES. Log expedeace with the more con ‘entional power shovel and draline fr ll kins excavations has favored ‘hem nrotent new ost projects Dat on these maciaes are wel document ‘and avaiable the iterate I ony mater hat conservative mining Spproach woud favor equipment having the most teasive amount of wal ble technical and experince dat. Although unfortunate, but certainly Juste by the operator» minum of relable an fundamental data on ol Sand mining with BWEs has been fled. Probly moch good BWES ‘experince data exists, but Beste ofthe ime and cost or ts agus itis ed tobe proprietary: ‘Mineral developments in the Thid World counts are being agarestvely ‘Pushed. More higly developed nations wll contin to be asked co make ‘wana investments of ther Knowledge and resources. At the same tine, ‘verging nations must be wiligto participate wih eters havingsomething to olf, ona fuirsbare basis Some of thee new ations wl be sckng 0 ‘velop resources which are amenable to BWE applications. In other eases ‘where materi is unitele for whol the ivesters need wo beavis and [vided tothe slection of he correct machines, Feerck W, Taylor, Bethlehem Stel Company, 13, was one ofthe fist fo ‘spl engoering method to prevent waste and promote efceny in indy. “The Taylor Syrem,athoush better adapted to facory work, was introduced int sme early mining operations Paraphrasing Tio, with regard to BWE ‘pertions “preity the sme mecinisn wl sane case produce disastrovs rere and in another the mst Deefiien™, Its hoped that De. Rasp’ wide Knowledge of whel, which thi book compat, will come the Worl wide stand for the design and selection of BE for years to come Englnering and selstion of BWTEs bed on the extensive data eval in Dr Rarper® book shoeld ensure “most bent” results tis hoped tha ‘he ontats ofthis Dok canbe brought upto dat as Whee! technology and experince are advanced. Furthermore, Dr. Raspes book will provide a Comprehensive source of BWE theoretical and pacial experience, wich will, [poalong way to dispeling the myc formery assign tthe wheel excavator. (Oakland, Calitornia amor. Ace September 1974 Manager, Mining Eaglacring: Kater Engineers.INTRODUCTION TO THE GERMAN EDITION The echnical development of he bucket whee excavator (BWE) bas been on lssway during period of about 170 years I ound it preliiearycaiminating int in 1955 wth the completion ofthe fis argemachinein the ope pit nine Fortuna-Gardoc. Today, this machine still performs a peak production “Meanie the bucket whee! excavator Became one of the most importa production devices opencas mining thoughout the world unis npact on {rowa coal mining had special sipniicance. In spit of he fot that the principle of he continuous dgsns and baling whel was known already snc the be- toning of he ninctenth century in many ive and patents, the application {nthe period before 1930 aver exceeded textwork inthe domains of sei oF unl ass as ot before the thirties, when Hgnte mining companiss in Cen ‘Germany decided ows the BWE asa main device for efiiet bulk handing ‘thatthe fst development ofthis machine for todays purposes Bega. “The decisions over introducing BWES in Central German brow coal aes see met in spt of cfc gelogcl conditions - moraines with embsiet big tones when ope ofthe st protolypes was put to work i the Gop Mine of the Sachrenborg Field. Beste of thee geological ifote the ‘bucket wheal waa quipped witha atone garper which wa able to dpm af Lwoublsome erate boulders during te digging proces This developmest, to enthuriasaly started, was slowed down consierebly by the Second ‘World War, -Avthe beginning ofthe ities an impetuous development of he BWE Bega It Started inthe Rhesh brown coal distri, where the development of opeces rining techniques and the development ofthe BWE depended a great deal {poe each ther and where they oily le to grat succes “Tre machines rein sien fw years rom a otpat capacity of 30, 000cubic smctes ove 6,000 cubic meters to 100,00 cubic meters of natural unconsoli ied sediment perdu. At the sme Ute the development led fo omaration features which arsed aan optimum a fa a ais and operational practice se concerned. These desig eter Faris the elements forthe BWEs with futpts of 200000 cab meters per day and seve weighs in the onder of 13,00 mesic ons, presenti under consrton ‘The development stage of these machine allows the consi that with ‘capacities of 20.000 to 250,000 cubic meters dal production a extn Bal ont hasbeen reached. A further growth of production capac ell for ew concept ofthe sytem component ad ofthe mining methods, without losing the properties ofthe bucket wel exzarator. Such a development wl also he tated onthe elements of development, constriction and operation of [BWES detaed by De Rasperin this book ‘De Rarer hasbeen devoting his time toa considerable ext og arth ‘moving and mineral mining problems. Feom the very bepinning be mat co- perting wth extraordinary sucess in 4 proineatpouton ia the soliton fof the multade of sats, constuctinal nd operational problems ofthis evelopment, Thereby may specif solutions of far reaching portance for[BWEs can be trace back to the immliate activity of Dr. Rasper. AS an ‘rame the iting joints may be stenoned which became of imperative imporance forthe satis af large backet whe! excavators. {eis therefore very much welcomed that Dr Raspes i ths book summarizes ba great Knowledge tnd expense inthe Bel of development, consrution tn application of bucket whes! excavators Tis boo wl ea valuable Rep {othe engines of equipment omsraction a: well us tothe engineers of cument operation when dealing with tee manifold problems. Colne, Exwn Giza September 1973 ‘Member ofthe Board Rhine Bravnkoblenwerke AG‘PREFACE, “This volume represents the Engh Eaton of the book “Der Sehauelrad ‘ager as Gevianangagert” which war poblshed in December 1973 by “Trans Tech Pubiotons. “nthe proses oftranlation,the German Eton hasbeea completely revised, ‘he presentation inproved, and th text adaped oa workwde readership. “The burden ofthe cmt translation has kindly been borne by O&K Orenstein {Koppel AG, Dotmund, The asthor would ike to expres hisseca thanks to Mise Margarete Rohrdnt from the Translation Departnet arto ME. Tan “Thomson B Se (Hens) fom the Design Departnent of O&K Libeck Works forthe dtc tat of tanlton, ‘The bucket wheel excavator (BWE) isa favorable synthesis of strata imethanca cletrial and electronic technology. Is present aanced stage ‘of developments tse on the eoperatio of the best engines in ech of these ele ofeniecrng. Its present form, however, ot permanent sine Inteciology theres nothing more permaneet than change dues cominuoos In counties with competive economies the development of the BWE has ‘kena diferent cue than in those countries which are sste-contzlled. Inthe former thiscan be een inthe various dens and design concepts wich ste aconsequenc the presueofindestria ompestion Thi however, has tho led to's notcabe ack of harmony and standardization between the products of various manufacturers. In sae-contoled economies only stand $aed machines are beng uit slog as internal demand hast Be sts fed and rests of government financed research and developaent work a this particule eld avaible and ie being wed to advantage, ‘This volume describes the development of the BWE: and the various design form presety walbe. Ls ao concentrtes on the experierce obtained when digging hare and ificlt sols Results of investigations ae given Concerning the determination ofthe digging resistances for varcos materials lind the problem of curve negotiation of te raver group. The variation of ‘round bearing prssare under giant craviers and the dmeasinin of ball ‘ace slewing vgs under slewable superstructure are dscased ip deta, ‘Sample clelations drawn from atl experience and details o!dieasion- ingand material ection for different mechanical components provide basis for deeper undersunding ofthe problems oearng inthe design ofa whee, xetator. Of spec interes tothe mining snd earth-noviagexiner should "bo be the any case store of mines and civil engineering projets in which ‘hel excavators are Being osed Bucket whoo elmer and stcker/reciaimers ha a tremendous impact on ‘he methods and efiency of handing blk sais ding the st 10 vo 20 year The desig nd onstruction of many of heir compancasare ential for af least very sina to those ted in wheel excavator. Tha, he Balk ‘materials handling engineer wil weleome this weatse la evaluating bucket ‘whee! equipment ‘or bendiog and reaming stockpiles of ea, ton ore, bute phosphate etc, al long as no other deta account om wheel recliners agniblVarious speci BWE design, however, mest remain unmentioned inthis book, for example the bucket chain redger of Kunz & Co, Music, working, in tia Here, in ation tthe normally submerged bucked chain, a bucket ‘nea is used to remove material lasted above water evel. Al, BWEs fx tunreling or appbeaton in underground mining could not be mentioned In his volume the "Tecnical Metric System” (wth the bas alto a) foe force) wed A number of English speaking countries have converted oth Met System or are in the proces f doing ots therefore sumed tha the Metre Sytem will not present any dices to the majority ofthe cadets. Service weights of machines, however are give a muses according to the "International System” (SI and expressed in either Kg or neti ons, Furtheron, quite «few damensios are la being sated inthe Brith Sytem Jnparenteses,andconvesion tables tte ead othe book should prove abe Delta | would keto thank the many people who have asd mein the preparation ofthis book. The encouragement o compile this volume came from Profesor ‘emerta Dr.-Ing. hai. Herbert Woe, former Dtetor of the Depart. ment of Mining Engineering athe Teshnal University Casta Germany His son, Dr Reinhard H. Wobbier, has provided most valuable and festive ssitance inthe realisation of thi project and has sophie information and Photographs of machines operating in the US.A. My thanks are also due to Profesor Dip-lag. Jo. Babrof the Mining Acs w on jee ons #us 3 oor + ca ose oriwoot sus | ¢ g og z az oc/ee 002s SUS a ose € oe be/ovoln Sus 5 ose € a oclean sus § ose 9 a osiusoes sus |? 3 0g gt ob Ogt/ $i oly SHS Z fi o ex/ovy #95 ose z a 0691 oe/m on sus a so “a ort ~ 089 osolwoce sus a 50 6 oor ~ 078 oso leon sus oF £0 9 Ore - O08 oro/9s9 sus [my] (ay fas} LYfey adh, ang jeu | 39 aoeg | 479 4bu | andsno jasyesoous ame Lee 2ORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR, 8“THE BUCKET WHFFI. FXCAVATOKORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR 1s ‘A character design fear, wie inthe Geran Demacratic Republi, the suspension ofthe bucket ‘wheel boom by tes on a traveling rab mounted Within the superstar. By this means ts said to ‘be poole to ashlve a substantial redacsion in the scvice weight (up 0 45%0) a6 aginst the wel-erows, Suspension system with ables and ply on gay Fred onto the supersrctre Fig 115 shows the typeof constraction used fr the excavators fea bund $oachiee large diging Frights The dara shows that tis are attache! toa ter running long tack beans onthe lower chord ofthe ballast tus, which moves in unison with the ouster traveling 2. {A deze design fastens the test th end of the ‘halt trase an the traveling counterweight is moved in uison with the cromd-ype bucket wheel boom, “The bench lope is thus determined by the machine iensions “The opinion eld that n this even bucket whee ‘oom crow mechani increases the service wiht By fonly about 10%, compared with that of = rowdless machine Research and development at the Berpakademie (Academy of Mining) at FreiberSasony, at the ‘Tesh Univers in Dresden and Magicbors, and atthe nwt fr P&rdetechk (Insitute fr ‘Conveying Teehaology in Leipig help to establish ‘he theoretical bases forthe development an improve sent of the BWE. Applications of small BWEs in ly ining have bee. ‘sported, but sone in earthmoving wrk for ci fainering prokeis. The German Democratic Re ‘pblcexports BWEr manly to COMECON countries. .4. The Construction of Wheel Exca- vators in COMECON Countries 1.4.1. In Czechoslovakia ‘The BWE is usd for mining lignite inthe north-west, Bohemia inte districts of Most and Sookov. In 1938 only small potion of the lige dug at Most was obitaed by open pit methods. The fst con- Yinvour-sorking slant chins were tr introduced ‘hy Sadeteliadiche Bergbau AG in Brix, Kubee (1967 expect that in 1980 underground mining will, ‘only amoust to 510.7% ofthe total ouput raza (1967) reported 00 «construction program for open pt mining complete. They east of BWES, face conveyor tet yates, or tains and slacker, the later moving exorively on walking mechanisms ter “Theorsiloutput Qu~1.500 mj 1,960 ex yo) Spectocuting presse f= 90 ke Nicx Bocket whee! excavator Type KU 20; ‘igh ouput unit wth Qy.~2,500 m/f (8268 cay and BWE Type K 800 {500 mh (5,82 cu ya) Specie cating preaure f.=120 kg (him WE Type KU 800 (already employed in mining operations); ‘hefaceconveyor yes hve bel ids of 600mm: stacker Type ZP 5000 103 2 y=10,00 mh (13,07 yh] _BWE Type KU 2000, (at present til athe design stage) “The North Bohemian Lignite openast mines with ificalt, heavy, overburden and some with bard Tgnte seams demand machines with powerflbacket wheel des undiow spec pound bearing pressure ‘Afertheend ofthe war BWES were nial imported fom the German Democratic Republic, but thes ‘were not ently stiactory under the sere mining ‘ondtons in the CSSR, Sebsnquent, the Vitovice Tron Works ia Ostrava and the Univ Mechanical Engineering Works developed «remarkable indepen- ent industry for producing open gt machinery ie ‘olaboration with mining engineers, ‘A major technical achievement i the BWE KU 800, the largest excavator bl inthe CSSR, Tis machine has a specie bucket wheel die peer of =0.24 ‘Whim? a cing height of 32m xowd distance of 16m, a dicharge bridge with minimum length ‘of 7) m ad moves upon walking mechanism (ee Fig. 116 and Fig. 33), Deazan (196) execs frther popes through automation and programming of ‘orking procedures.IME BUCKET WHEEL EXCAVATORORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR ” 1.42. In the USSR Report on the design an operation of BWES can be oundintheoxtenvelieatueendin pperspreseted by lading Russin Scentists and engineers at con- ‘reser on mechanization of earth oes operations. According 0 Kha (196, 10.000 erevatr ants per {rar ve been bul i the USSR in shovel spaces anging fom 2 to 15 m some moving on ere, ‘thereon walking mechanisms DDombrowki (1967) reported onan excavator wih & shovel capacity of 100. The cutting of frozen soi {temperatures Gowa to =30°C) mut be given pia ‘onsdeation. The extent of erthmoving options in the USSR, in 1986, amounted to approximately 500 milion mand is suposed to inreate to 10,500 millon m? by 1975. For thi rasa, the large-scale employment of eoatauousworking excavators espe ‘Sly BWEs, planned. Whereas in 1985 the share of continuous working machines was not more tha 1 of the fot) thi percentage — according to Kah (G960) is expected ore 10167, by 1978 ‘The importance ofthe rapid development of BWE technology to Soviet engncers i underscored bythe large orders pce with West German manicures in 1963 and 196 for complete openeas mining plans ‘Tress consist of BWEs, face conveyer syste, be vungone and stacker; to be ued forthe removal of the top ovebusden in mies ofthe Kumk Magetc ‘Anomaly (Sbeespogest) and near Ordshomkse (Nikopo oe ld) (K- Girne, 1966; Mant 1967) ‘A dtaled description is ven in chapters 14d and 145. For the Inter opencast mie a sina mining plant ab ordered from manufacturers inthe GDR {or the removal ofthe lower part of the overburden aye. Large excavators are designed and manufactured in the engineering works at Novo Kramatorsk inthe Don basin Soviet Rossian sisi ad engine are staying 'BWE-sacker technology end problems concerning thecotting of hear and frozen soi andthe yaamic stresses o steland other metal parts Standardization is an important clement in Resian developmest planing Research makes use ofthe most moders methods of ‘work studies, model tals and problem aaalyss in Iaboratores. Swain gnuges and load transducers wih oscilograpic recording of wp 12 simultaneous ‘measurement sere forthe onsite data eallcon Complicated mathematical programs for computers fare being wed to formlatephysealpenspen and provide sluieas. According to Dombrowsts (1967, 10 mechanical engineering instates are coordinating ‘heir rereare in earhsmoving machinery. ‘The USSR is silat the stage of signing prototypes forthe feture consreton of a line of are BWEs. ‘This program obviously waiting forthe results of research and ooerationl experience Grushka (1968) describes @ umber of clemy andardized BWEs which, as is shown by other Seures, are aleady in operation Tees are: 1 RVE: Gy 600m! Digeiog eight 180m Bit by theCato ark ly mines for their own use (how by Kaha 1960, with photo the machine stwor 2. ERG £917: 4 1.000.090 Spec eating pressure, ~$0 ks em Digging heh 17m Ground bering pressure 2 ka( em” [84 psi) Serve weit 00 me (Ming ours 1957,showsaphotoofthemachine In operat). ERG 35060: Oy 2.00 "fa Digeing bei 20m 4 ERG 1600-88-31 4.500 (Ghown by Dombrowski, 1967, wih photo ofthe ‘machine at aor). ERG 2600: 7,00 "fh [ERG 2600-7: Qy 1,000 Digging heh Som 1. According to Dombrowski (1967 the constuction ‘ofa BWE wth Qy.=1,000 mh was sated. Jn Table 2, Dombrowski shows 1 series of small WE, btwithotentoning where they wb se. “able shows he ecial data fra sere of BWEs fore by contactors Tabled shows sere of open at mining machines including the above-mentioned BWEs‘THE BUCKET WHEEL EXCAVATOR wovqwog) 10 Put day sais Hang sd pus pon eLe oF “6% “ee we on 0 BYL| SEL AZ f#u] a2loy Buying ay | zor | coe | ceo | see | one | 90e--ose|voe-oee| femal) poods Bumiro [oom ve | ore | ox | we | ee | ar |oer--e2|oos—cx| forspey pode Busry joo su | ta | oa | ou | vw | co | sx | v9 17 sripoy Burysoy, om Ou oe Oo ou on Ou 06 | (ug wong aduoyasig $o4jOu87 = =| = | ol = [a | mw | os | cany sree sojoupsag L6L 90 geL Lee 96 08 08 oF [M4] Ramey P2y]DJSU/ JO}, ce 008 OF s ae On ee or [my] eaug jum oc | ox | coc | aw | se | cee | on | su | lyjuy rrcino moyasooy wo | 0 | o | ce | em | on |ves~o9| one upla s0d BLES ogee |eeyes| ere eons eons tases sues aay [ay apuIEIg POU Ze es Z 6 9 Z 9 zi sje107g Jo sequin on | a | ox | ow | o eee 1a] Mowing jewne ever | esc: | vom | over | coo | ever | zoe | soos wang zeuaig aunj204 NOH ¥, Hows eek, 3meORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR » = g a ee £/ 8] R18 Selec) ti] |e g . = ewe rye | 8 | P| |S i Alaa oe ee 8 2 s 3 ’ eee g : $ s|¢ sre ey el el als eo-assje | 2 | 2 | 2 | 20 | o | 25 | oa cms) ee-sosia | 90 | 6 | 3 | 40 | wo | 350 | 205 & EP-1007/3,5 | 100 7 BS | 625 160 780 | 110 BD ee-10.6/6 | 00 | @ | & | te | 250 | 100] 130 i) po ‘6 5 The 1.60 er-200 1/8 | 200 | 10 co | 400 | tm00 | £28, et eesate eg oan ae eae Fg. 1-17 Oe ERG 1600 —t. "Wasi ret 1.9. wha i {uy Nove Krams USSR, OOM sce wot 3.00 Oy 600 ms (019 cyl.20 ‘THE BUCKET WHEEL EXCAVATOR ERG BWE Type oe Theoretical Outeut (ark mfr] Bucket Capacity [4] 250 Murrbor of Buckets a Wheel Diametertuting cick) im) | 47 | 615 | 64s | 15 wreel rom an | a7 | 4x | 3-5 Caleloted sec Deginghone | cil) | chin) | Can |e 649) High Gat Len? zs | 7 | 7 | Deep Gut lm? as | 20 a | @ Weel Boon Crowd Distance [7m] - - a 37 Wheel Boom Length Lr} n27_ | 20% | 210 Discharge Boom Length mn] ws | 20 | 222 Travel Sosed tm|hd 1372/8 | 336/67 | 370 Travel Mechanism Number of Cowlers 2 2 2 wheel orive hw 10 | 320 | 280 voliage Lav] 6 6 6 Wear Boece Tay || 0 Power heguirement _Cewim) _|(asow) | (a4ga) | (ova) Service Weight [mt] 186.6 480 565 Specie round —TigitTom™y | 15 a 7 Bearing Pressure (psi) (%.93)_| (14.22) | (M22) Tipe ERG 1600 hs tm oor cond length ther BWEs cow os es m-opn pi anon st USS (Bogrotow, TOES). Al meres daw! ROunDa spl Waape ORM.ORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR a ‘ogomoliov (1965) meticned that the ist BWE, Type ERG 350/100, designs and but inthe USSR, was nade wt Wore 1S. LKSMU. Ine largest Russian BBWE for opecast mining operations 1s probaly ERG 1600-48-31, tn 1971 thie typeof machin wae reported tobe wed at three sew ses (ee Fy 1-17, among which was the devopment of « aor mangsnese ore opencast, imine neat Nikopol. The ecaieal data ate given in “ble & Ina promectes ased by Maschino Export Moscow, the dupa ven at 3,00, themumber ‘of buckets as 10, andthe Bucket capacity a 1.6 1.5. The Development of the Wheel Excavator in the US.A. Tn the US.A. the develpment ofthe BWE was not recognized by the ming experts al after the con firvcton of the "Kolbe wheel” for snip mining ‘operations (Huey, 1980. ‘Duet the increasing owsbarden depths and vious competion, tbe buns open pit mines in ins (Coabe", “Backhear, and "Fidelity ich were thom thei opening ia 192 mined by ether the shove pullbsk or tandem method), were from 14S onwards Teorgaized on a mare ellsent bass. Ths deision ‘was made by Frank Kolbe, Peseat of tbe Umted Elsie Col Companies n Chicago (Kolb, 1953). “The upper, softer lier of overburden ad until hen teen removed by err mouate dragline with are dumping reaches. Te formations immediately above ‘he coal sam, conating of late and rock were removed by late ripping shovel, afte’ basing, ‘and the mitral war on overeat to the dump. The big peor of rock were ether dumped ot natal} scoured atthe as ofthe poi ple, ths, Forming {good foundation for the upper, efter Kas of so ‘The exposed rip of nal witha with af 3 10 307m, vas slice for digging and leading the 15 t0 25 {hick ard col seme with thovels.Tspor of coal as by spec sel iver tractor rile tucks [1944 ater udirbly persistent developnent work, ‘the first sep mining bcket wheal weat on eperation] ‘uals i the Cuba opeacast mine. IU achived an ‘ffs outpat of 36 bank mh (N15). For the three machines which faloned (he second was put into service i the Bucket ming) as Potable to crease the efetive output la ages up {0 2,670 bank mh (ee Fg. 1-18), Fe. 1-18: Spring BWE nonin pun pt ne (by Beye)‘THE BUCKET WHEE. EXCAVATOR oe Sr ae ee | C7 ra ones aa asi one osey Lys] sybtem 321As8s 9 o9 zo "os 9-9 05 | votawep Sheuatio 2oods aes ore oe ees | a 31 pune w0cg oun sein ce | en | oo |_sem a oz oot ta) axv0961 pedals (Cow = = Fe 6 GOL | (usp soucisi0 PMD O6F £07 xia OLE gle Sin OE Lady pGuay 41009 17 Fore'gie | oF- 102 |oe- ‘002 | OF 'Or | Care S0te| Lee GOe| Ler Geer Te BE One One e O9bL ~ ee 2LE- 96L Ca C7 [m4] D240 [74m ore onal | PRBP A] ove [once | ort Tee, Heady one wat coT | amt aoik | cain-osoe | oo | woe | Bl rpoifSoae we BE HI wire | wee | ore | ofe Bh ges | a $L-#t 79-07 | as _[wmuon | ae as foot 79 ao = $e 0 | 06-67 2 | eyed oad sabgo00 | jae Barapa 07 fear 3gal a @ | sre p80 ei a #1 wo | ae | 0 | eee Apoeen 99 6 wu z 2 29 Za} 6 Pen 7 weer [eae | eo | ae Biers PD Cee encaang| eexroywoner oywza | draw Coes ipa spa weunjoajnuny | ui aU au settee uly ON 1380M Auepiy | stusow rouse | oni \EuM at | ui 2979 oe fe ae |‘ORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR, a “The countereighs necessary forthe shovels and -agines were replaced by a dicarge boom, aranged Sn the longitudinal axis ofthe slable superstructure. “This permite dumping distances fom the center ‘of the bucket whee tothe dstarge boom pulley of scoring tote loading eondions pete by the “Talal drain crawler chs svbetractrs (ax ium service weight of the tol machine with sob -Srocture 2100 at), had dintarge ply dumping eights of up 10 40 m above the top of the cou Unuing the 26 m crowed movement of the Bucket ‘whee! Boom, these machines cold exavate Books Tete 18 tm and a maximum of 320.m above the harder ayer on op ofthe cos Below them, in follow-up operation, the remaing layer of overburden i excavod by gant Buea: Ee (Iype 980 B) shovels Whereas the frst bucket ‘whee ated at ony aya =3. pm the ast rotated BU sui=® ep. The third Ae, which realized ‘oncepis already proposed by Morton (1883) (ee Fig 13) and Glogner (1908, Gee Fig. 1-4, (Le _arunging © high sped wheel anda conveyor belt oa ‘ore axi and, reversing the ietion of wheal rotation) ‘as apparel as unstisfictoy asa simi attempt “mde by Schwermaschnenbus Lauehhanner (GDR), Insp ofthe acceptably high ouput ee Seton 1) ‘Compara with European corditons, Kolbe had a tore dificult overburden to excavate and had to ‘onside fot condos with penetration depths of ‘up to 1.0 m. In developing ‘he BWE, the devon -enainer ofthe United Flee Cosl Cos, used com ‘ponent rely ataale in the US.A. Only the ‘Bucket wheel war specially manufserred for the ‘purpose The fst bucket wel, which weat into ‘Speration inthe Cuba Mine in 1944, a east sel “packets and craters simian o ATO machine. “The ubvequent excavators wee predecessors ofthe cello wheel wing various transfer methods for ‘hel dicharge ono the boom onvejor: to rotting gathering ams ora roll fede transverse tthe eon: ‘Sor bel, using driven room. In frosty wether, ‘bucket wheel and buckets were bested by fame Freehanping chain mats under openings cot in the back of the buckets were wed vo prevent spol fom, sticking inthe buckets and cllchute. Bet speeds Were increased 0 60 mer, whch ear in exes of Ube erin! speed at which the yo tends free f0 the rubber belt All thes, including an improved sand stronger catenary idler dain, are milestones la the development ofthe srp mining BW indies the inventive gents of American engineers. Inthe year 1984 stip mining BWE developed by ‘Bueyrus-Ere in Miwaukee, Wiscoasia, under enes ‘servic inthe Fatt Mie ofthe Truk Ter Coal Co, (SL 1955, 1985; Roman, 1968) Tis machine, wi {service weight of 1.250 si reported fo bave an svalabiity 075% The basic tech data a: Backet wheel dimer =68 m; 9 buckets each with capacity of 0.6 m?; maximum numberof dicarges Sma; ‘maximum whe! rotation peed 5.75 rp ‘Asin the case of stp mining machines, the bucket ‘wheel sped is replated stapes trough DC motors Sof adjustable armature” voltage control (Ward: Leonard or static contro a frosty weather, and in sorme, when excavating sticky material the buckets seated by a fame thower ta dstaoe of 18m ‘xy from the wher. Additonal eaters are installed tthe backend of exch bucket, ‘The next hucket wheel machine bil by Boeyrus- Erie was the excavator with Qa =206)~4,150 taken ino sericea the River King opnaast mite of the Peabody Coal Co. et Table 9) ‘West German manufacturers, however, ao delivered strip mining equipment tothe U.S.A. In 1963, the machine Shits 12305 designed by Fred. Krupp ‘as put ita servic inthe Norther Tinos opencast tincof the Peabody CoalCo. (Fg 1-19), Thismachine probly has oct the hard shale ver encountered ‘ya BWE (Krumrey, 1965; Pty, 962 ee Fig 1-20 [A eomiderable problem i bucket toot Ue, The crawler substructure, designed and bik inthe USA. by Maron Power Shovel Co, has pir of eawles ith bya levelling jacks which ia standardized design of American hetvy equipment. This arrange ‘ment permis the superstroctre to be leveled upon ‘surfaces with inition of up oa 10 (Fig 87). a 1964, the machine SchRs P25, designed by DEMAG Lavchhammer and bull primarily inthe USA. by McDowell Wellman Eng. Co. Was put into service for overburden removal in the lignite fopencst mine ofthe Trax Tree Cos Co in Noth Dakota (K. Garner, 1956) (ce Fig. 120, ‘Aer har formation wth large boulders and sand- stone les had to be mined toa incresing extent,4 ‘THE BUCKET WHEEL EXCAVATORORIGIN AND DEVELOPMENT OF THE WHFFI. PXCAVATOR 2s 3-22 Suing 8 Se ot oun it min (lt iy DEMAG Lach) 7-260 mm (3899-4708 cu YI gs ‘When dome 925 me what Gv 690: sree wet 270026 ‘THE BUCKET WHEEL EXCAVATOR Calf (tin 1962 by DEMAG (0008420 /n [14-7688 ym). Fo, 1-24 Comeying ston fo Orovlle Dam constuction wih AWE, bs wagon an sible bet conveyer Cult by eDowa Wosman and DEMAG Lavobhanens).ORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR 2 ‘his machine wasre designed forthe mining conditions {n linos and pa to serie agin io he Nor ‘opencist mine ofthe Consolidated Coal Co, The r= Align of the machine involved leogthening of the ‘eke wheel boom by 63m, the discharge Boom by 165 m and raising the Door hinge points by 65m. Fig. 1-22 shows the exenvator afer it eaestructon. “Te iting factors forthe use of srpmining (ve cating) BWES ae 1, Increasing overburden thickness 2 Crieal overburden pe stably. 4. The are coal reserves required by powerplants ‘Buropean BWE design have also been used ia the US.A. on cil engineering projets such a8 the construction of age earth dams. | particualy suconsflexample of integrate toch ogy ithe BWE designed by DEMAG Laucham- ‘her pty manufstorel in the U.S.A. by MeDowell ‘Wellman Eaginerng Co of Cleveland, Oia for the ia ‘Oroville Dam in California at present the highest ctl dam i the wodd (ee Eig 123). The shor, leva aabl nd lowerabledicharge belt of the fvo cravier machine SchRs JB? 14 pasted the spo (lings om ca gold dredging) by way ofa crawler ‘mounted 110m lag betwagon, onto 2.30 long, ‘hilabl face conepor (ee Fig. 1-24). From there Combined tlt anc wit tan alae stem brought ‘he dam material othe construction ste more than 2D kmaay (K,Gitoer, 1960. The complete haulage ‘stem designed by MeDowell Wellman bad handled ‘bout 160 milion me of dam material by the tne ‘constroton was completa in Oztoer 1967 For such BWEs ofthe Oroville type with age outputs witha shor wheel boom, and smal eating eights the term “compact” ins been coined. Fore constrastin af the San Lois Damn Califor S°BWE bull by Busrovtrie was wed. Ts was Snwir-mousted and bad Toading equipent for livery lato dies-drventrocks wih 2 capacity of TO tone (NN, 108) ee Fie 1-29, A Fig. 1-25: BWE dung consrcton of he San ue Dam in Calton (a by Buca). ‘Sommer 80 10 uch smh of 195 a, when! Gv 880 KH; conucton weight B18 Shy 6.900 7 [one yan28 THE BUCKET WHEEL EXCAVATOR ——————— BIE Type te 740 | ra00 | 2000 | 3000 | sooo Gp Cetermined fram I+I,\Meu yath]| 2250 | 3270 | 5400 | 2060 | 410 fe ec eral ee | eee Shipping Weight {mt} 728 | 198 | 231 | 325 | 40% Wheel 800% tength (it) 19! | aor |arer aacere bom tagir in) wre | os | ae = Wheel Diometer [HJ th 8 | 8° 20 25° 3" | avcte Capacity Lew yet} as |oes | 10 | 25 | 20 Number of Buckets 6 a a é 10 | Whee! Speed nam) w | a7 | a7 | zs | a Wheel discharges per min} | 60 | 7 | 7 | 60 | 03 Belt Widths Cinehp we | me | 2 len | om Overall length — Eft e'10"| a’ | 90° Coe trae) (aon | 89 | 202 | 28 | 228 | 227 | ore some enrtoemre) [anne | 2-209 ae | nso so a ata ‘Table 6 Convector ype BWEx bak by Mechanic Epetvat ne(ORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR » For the exrthmoving work for the Abiquiu Dam, the eomractor Bill Mitry ofthe Mitry Construction Co, devgned a digging whee! and mounted it onthe crawler chasis ofa shovel (26 13462). I achived uprsingly large outputs A new BWE design on uber ies wat made in 1940 and was eeported {0 ven output of 550 bask mh The new Founded Company of Mechanical Excavators (MX) in Los ‘Angsesacquzed the construction rights (oe 61.2) find developed six wel deviet BWE types with futpts in the range of 230 bank mh to 2700 bank nh for eathmoving (ee Table 6). The primary tries are high sped diesel engines; electric motors fie offered as an alerative All machines hve ai Conditioned operators esing the Inger (pes are fully notated (oe Fig 1-26 and 6.12) ‘The MeDowel Wellman Engineering Co.of Cleveland Ohio, (which had partmsnufactured and asembled bucks whee equipment designed by DEMAG Lauh- ‘hammer of West Germany) bas developed a compact BBWE for earthmoving. This was used among other sppiations for excavating thin ituminogs coal ‘exis, loading int islet age capac special al baler teks (Chesk, 1966) (Fig. 3. Cite, understand, the wrld-senowned American Standardized aes rodctin, with many oustanding ‘model elevons, and excelleat spare pars and stock fervice for dagies, shovels and bulldozers ee “pproacd theconruction of BWEsrather hesitant. ‘The American eari-moving engocer i aqusioted sith the applieatio of cosventional equipment. Over {he years he bas developed sufcient design and ‘eletion experience concerning. the inoence, of ‘Slate, ook hardness, jb conditions, te. Addition fly, be & used t conventional equipment being falable within «reasonably shot tie after pling the order. (00 the other hand, he Mechanical Excavators Tn. evopnized demand fortis type of machiery in thmoving and developed slout eay-dutyequ- ‘neat for haré an stony sols and lamp outputs. Ths ‘company ha ao exported BW to Peru, Japan 20d Koes. ‘Only of late bas American techni iterate om the vgn and operation of BWEs depart frm de- Scripive contributions {0 give fundamental analyses (Kendal, 1960; Ramil, 1961; Aiken, 1966; Aiken tnd Wor, 1968 1.6. Wheel Excavator Construction in Japan es not surprising tha Japan, highly industri ‘country wih numerous land reclamation projets, tas recognized the advantages of BWEs and begun their manufacture. Since tis volume covers only Initig and digging machine, whereas in Japan brcket wel equipment usd primanly for reca- ing balk materials storage arts, only the folowing ‘huervstions ean be made 1 Kobe Steel Works Li. ntodoed in 1967 sal troche whee excavator bull o thee om design (Gee Fig 127A prototype was tae in land feslamation project. I was planed to develop & Sere of BWEs with outputs of 350, S00, 750 and 1000 nh, searing in 1968, 2, Ishikawalima-Harima Heavy Industries Co.Ltd, “oly, have Been developing a BWE-Type 100 [BWE (ee Fig. 128, with an output of 100m, ich can be transported on Towoader. In the Ineanime a ein of BWE with capacities of 20, 2, 809 and 1.200 ms ave bees develope. 3. Kawasaki Heavy Indies Lid, Kobe, a Ie cesee of Fre. Krupp Maschines- nd Sthba, Rhenbausen. The manuftturing program com rss the standard typex C 300 and C500 Gee Sesion 32. 4. Nisa MX Bucket Wheel Excsator ippon ‘argo Seizo Kaisa Lt) This fim manvfectares fundard type under een from. Mechanical Exenvators Ine, Los Angeles (ee Table 6 and Fig 19), 5S. HitactiZoten Shipbuilding & Eaginering Co Lid Ota Licenerof DEMAG Lauehhamne. ‘The manufacturing program includes the standard bucket wel exarator Type 85 (Fig 1-29).‘THE BUCKET WHEEL EXCAVATORORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR 31 ieee Fo, 128: WE Type 100 BW marutacured bythe shikawaina Haima Hey Insti‘THE BUCKET WHEEL EXCAVATOR —— aes wae Fo 1-28: Sunda type BYE Type 65 but by DEMAG tavchhanne nd ia ome.ORIGIN AND DEVELOPMENT OF THE WHEEL EXCAVATOR a References {is cr: ow che te ihn ig Boosey). Pe ‘Conca Ec (ne el nC De). ‘Sots. AM fo, oer a7 ‘Soe eras Atif Tah ‘Sern 9) 1 “Tei er arate Taemaimes e ‘Sere ‘Sean Sundar Whe Sar Co. ‘owe Wetme pers Cmpay 18 ‘im 1 8) No 1 ‘Teo anne ee ‘Wenger Mahara der Ener i ‘Seon Knees Mesng Es ad ‘Schrag in CSR ren nahn 9 (196, 9-206 ‘Sei apecrag (360), pam 337 ‘Ste Enwcug der Thrive er DDR ‘Fei Iuomatoe 1 Nos 0 ‘De Eng Stuer in Aner ‘Derbuunpntr (350, Nose ‘Beh Eoeng et wnrtaren rien Sie Soest wee eos ‘Eugene uss ‘Sn nd dec (188). 310 ‘eaxRneen Sense ds evans Tangri in ‘SCESTIIN iene ein, cia [BEGIN waters lout be ‘GRUSCIRA,G, ROLL, MOLLER... ‘De dot tomaete Baga Teche: he a ‘setng nt b peS egnseca 6 (e5, 39-07 Maing Congr Jura (1950), 70°73 Devt an ry of We xan a USA. PPoowcng of noe ne 88), SSO cng rts nt Sets a509, No 31,3408 ‘Germs ae ow at renin Sg Coop oe earageiosy oso Demucant (syne ss ‘Baunale aE 8). Ta Exeter ei Mm Taha Eepenami Ge ie 95 ‘Nine un Fear (st) 25-268 once. Boson wa eink 7 (1960, 1-2 ‘rc Tsuen a Univer ‘Eb Ver ety Hein 9 [oura ib nion Corsed Engzvem (957) No.2 ‘Sie hte wd fern 9) 1 ‘Monae er Setddtnggrten ner DOR, ‘Beppe 150), Exowing oper 0 (8) Nn 5201 ning Cone Jn) So ben tang Ea nove Se EM at Ken Magi) 1968, ‘eg Eager 9 (09M 8 evr pe Cat Ng Contant Aes ‘Rit Meng AME Rew Yr 1062M THE BUCKET WHEEL EXCAVATOR erases Ratt sa ses Ono ‘aoe, Von a Gio, se SRASPER L: ‘eR wi ar Techie ‘Avintedeecs iitbenen Sader rete intr ne Stes 2s, Scr tbe (191 No. 38 AOS. Gand Hast “ ‘ig ih ap, ae Se 982 Titec am Wet nee 12:0000 yep mont ‘iy Me SR ne 02-20 opera Perm Wh Eau ‘Rec Sow ier Co (Os) SE as rpm Bheetega apa ee See scien moore See endear ign Saar Shite een ‘oven eae cst a oc hie, stems 98 Stier wt are Vernendngsipehe Dew EES ono, sss women © Ee sang Le fen 1 ‘Bec 991-2040 25,262. Methods of Operation of Wheel Excavators Working procedures apply to machines of all sins, and they wil be lirgely described on te basis of framples provided by large excavators in opencast ‘ign and bituminous coal mines with ge anual bulk movements The wen diping overturn in excavating deep lignite deposi (Latrobe Valey ia Gipsling, Victoria, Australia) of special Imporce. In thew operons high degree of ciency and avaabity must beatin. ‘Te flloing working methods can bedifleatated 1. Face o rot werking 2. Fullback working Terrace Cut Fig. 2.1:Comporian of trace cut an doping it 43, Ha block working (ae blok arse block work ing. Each of theshove mathod stn bec out by terrace cut, by droping cus, or by a combination of both (Gee Fig 2-1) At guile an early date, sien i ‘etgnted the theoretical aspects of the BE avalb- ly eicency forthe india techniques Sni, 1940; Wagon, 1939, 160, Dee to the lagescale ‘opencast mines ip the Rhineland which required ‘elevation of an increasing amount of severely faulted Formations, many new factors were esonizd inthe Jae decade rearing peat techniques fr working with BES Dropping Cut36 ‘THE BUCKET WHEEL EXCAVATOR 2.1. Face or Front Working “The bucket whee excavator travels long the working face, smilar to the higheut books chain excavator. Taig the high cuter y tracing of dropping us ar, i nesesry, bya combination of both methods (Sebi, 1940 Face or front ding it pacts almost excusively ‘sng rail mouated BWEs. Thee dlver the spo ‘ail mounted overburden conveying brides. In these ‘eases the offen more important deep cut is reserved fora deepstng basket chun excavator, Sometimes bucket wbed exuvntor and bocket chain excavator ae combined ina single pce of equipment (Lauch ammer, 1936) In thi instance i not oltly secs that tbe BWE be provided wih slevable Supersractre, butt does equa long boom row ‘of peneraly 200 24m. Either the entre bucket wheel oom, on th case ofa teesopi design, only part isi exendble towards the digging fae Compare with these of high cutting buck chain txeavaton, the BWE has the following advantages 4, Layers can be separated, eg fries curing in overburden oF sand tata i bigueting (ype antes 2. Contain ind fol g wateatered cy anes, ‘am be separated out for subrequent uma. 4. Prevention of oi ubsdence when cting a beach by reliving the loa Face woking, however, can only be applied if bench lope angi eauling in pod stability canbe mina ‘This offen requires hes boom with ulenly long boomerowd action Raitmounted BWEs were manufictared by ATG Leiaig and Miuldeusche Stahwerde AG at he ead of he tease and during the eal thes and ins lad atthe lige mines of Ben, Koyne and Pessa in Central Germany The eat mouna BWE Sehs "1421.9 out ia 1935 forthe open pt mine “Marianne”, haa theo retical outpt of 1470 ma boom erowd distance #22: BW Schs 2814 -215 nthe BUBIAG ope pt mine “Marana” (tn 1995 by 08 K/LMG). ter 83m whl ive 6D mee weg O68 mt 44S mi 328 phyMETHODS OF OPERATION OF WHEEL EXCAVATORS ” 66215 m, an excavating height of 140 m and was Imousied oa 22 tack wheel (se Fig. 2-2). The ‘machine bad a ecletype wheel of 82 m diameter, ‘The dening function served manly o permit the ee ating ofthe basket whee atthe end of « working foe I could, however, also be used for recovering ‘patel which had sloughed from the Bench eaching fhe excavator allay ack ‘This BWE replaced a high cating bucket chan ex cavator. It was intended to separate he eile top sil, ftom the remaining overburden and to dig lay and Jom formation coaining water lass from the top ofthe bench. The purpose beng o establish sale ‘bench slopes. When conveying spol by means of ‘all mounted owrburden conveying bridges, the whole for 8 part of te al trick forthe bridge traveling ‘mechani can often be used forthe BWE as well ‘Therefor, the ost of tack instalation and malnt= anor canbe ompleely or at lest party ignored in {he esonomi onsiertions ‘The averse fc of cotinuoas traveling oa cawler ‘maintenance were already kaowa from bucket chin {soavator operon (ee 62 and 863). Wagon (1939) and Schmit (1940) stated the econo: ics of BWES aud could, show for the fist ine the shiftable belt conveyor3 ‘THE BUCKET WHEEL EXCAVATOR speroriy of rasersnounted units ever railmount: Sd machines with increasing ine face lengths wing fall face block working 2.2. Full Block Working Block working in ming operations as well asin ‘earth wovag posts represtas the predominant ‘Yorking proces for BWEs today. Haulage from ‘the working face 5 ether by ra shiftable face belt Sonveyore ith cr Mithout craviermounted bel Sraoos of by dice overasting ono the dump. “Tuck haulage i Germany ony sed oocasioaly incarhmoving wo “Opencast mining webigues wing crawler mounted ‘unt provide gretmobity with eect 1 excavating height and making feasible the economical mining of ‘realy fauld seams (Ge for example Fi 133, 142, 1620 and 1422. “The posi of esting high and dep cuts With the same HWE inreis the excavation range consider thiy-especly nth cas offlong bucket wheel booms (Fig, 29). Machies with Long intermediate brides tlko make it posible forthe excavator ceawleruit 0 front on a iferat level than the conveyor Belt loading station (ne Seton 13-31). Thus, wih giant frewatorsoveal: digging Beight of trie the high ‘atenn be scieved [A face block is excavated in several beach cts by ‘aking loweringand continuously sewingothebucket ‘wheel Tn dings, the excavator wih boom crowd {ete the depth ofeach se ext by thesting forward the bucket whe! Soom along a ack i the tas of the supertuctte A crowlese BWE. determines slice depth by adtening the ears Fig. 23 shows shew diferent working methods. Whereas the eronddype BWE can cot the litera lope up to an age of 9° with respect to the xis ofthe exavator path (apper diagram), he croméless ‘avator hs toe te ange of tle i the 1ower ‘te lomer iagran). The erodes excavator ba 0 ‘el with the prdlem ofthe ikl et (ee Fig 2-4 ‘upper dingram). The “Fortuna” largesse open pit ripe in Germany was the fat in which fie gant Comdless BWEs, cach with an outpe of 100,000 Dank m/d, were atin Service for te excavation of ‘overburden and pte, , Girne (1953) has gen reaon forthe eboice of sppving the simpler, leas expensive cronies: BWE, [He shoms the parallel block operation (ee Fiz. 2) sith a contant block wid of approximately 80 m ‘ver the whole length of the face allows a higher ‘depres of efciency than in the previously practiced ‘method of eting the lok io angular segment. The ‘ptimam Back with results from slewing angle of |" onthe digging side apd 45-50? onthe conveyor ‘orloadng side mensre rom the excavator traveling Suis AF the slope comers onthe conveyor side the hel pusbes the material pay sdewards, resulting in output edutions ce Figs 23 and 2, ‘romd can ct bench slopes down 038" Ofimportance here ithe clearance angle ofthe bucket wheel under the Intealy arranged Neal reduction gar and the ‘oom bel (ee Fig. 612). When digging the lowest ‘ct mmasiately above crawler level its noes) (0 feduce the alice eight to less than the customary (6400.7 este chet whee diameter Deus he fre eating ange leuranc) seduce, Rasper (1955) shows thatthe appareat losses of the slekleshipe cut ofthe crowcless BWE ar no longer ‘of any sinifnce, compared with she constant depth ‘ut of the crowd-ype if abort cat repeated far times an the bec slewing spend i ncteased by the recprocal value of exe during the proces ofeach ut oe Fig 2489p A tboom cowdype machine i therfore not equted for ite working method, butts posuble use depends ‘ently upo te solbensing characteristics over which {he craves have to travel ee Section 8.6.3), 1, for example, a block 260 m high, about 430 m wide and witha cuting depth of 100 m is to be Crevated with an output of 2400 bank mh ia ‘i, the distance traveled bythe crowé-ype WE 1230.0, On the other hand, the distance travelled by the cress type is 1460 m, Le. an increase in he Aistancetevelo of 487-1 renal. The crowd action fof uch an excavator therefore takes over path of 126m, Te greater distance travelled by the crawlers ‘an lead to churning up the erie ground sree, ‘rpc i th case of cohesive soe ane unfavorable ‘condions of soi consistency nthe soil of the open pit mines ofthe Rhineland igite dst no suche fects have been observed. The design of crave for ‘rowdls excavators bast ake into acount prea In Seton 8.6.4 i shown that cohesive soils with aMETHODS OF OPERATION OF WHEEL EXCAVATORS 2» low permissible ground besting pressure ca cll for thectewd-ype BWE, and under certain creamstanes, even walking mechanions may be reqied “The block excavation method can be cari out by [BWES of al sizes. Fig. 27 shows the excavation of ‘90 m vide face block of Schits 48-12 working to- ‘gether with a crawler mounted slewale blazon inked toa shitabl face conveyor Bet ‘Loses in output are unavoidable when selective ‘mining fe veuied because of ological faults in the Tigi o ore seams, or when shallow intermediate formations zur In order to permit raise 2m prisons of excavator output, Lubvich (1967) ws the ‘Seady Known term “oction output, maasing the ‘Supa duo lei conditions 2.2.1. Outpot Determination “Wapoe (1940) was the isto publish investigations on the reduced degree of efcency which osu when ‘excavating blocks with a cromless BWE a constant ‘sewing spend, ce depts decease continually with increasing sevng angles, away ffom the exavator travel path, and become aro a slewing angio 0 tbe degree ofeficeny forthe front orice working smathod put at 10% then the crowds excevator chicves an efiencyof 647 at constant Jewing sped ‘block operation wihin's slewing ange of 97 ‘Aslowing range of 120° rests in 72% Ith sto catsweremadeuptoaslewingange ool 60” andthe ‘hid cut to the fll ange of 88" oF 120, eficiencies (0f 73%; and 79% respectively would res (ee Fi 2-4, upper dxgram), By introduction of the “cosine @ control” in the slewing prose, ie, by ioressng the deing spend from Wars in the excivator traveling ais, By the reciprocal value of cos gt the vale 2 je being reached a! p=", higher eficiensios we obtained EMciencis of 92%, result, if only every second et is sewed through 90" or 120° resect. In deter- Iining the eflectve output, Wagon (940) and ‘Schmit (1940 id not consider the unavoidable time lower involved in stings forthe net et Even ‘with 10%; bucket il and an exact depth of eu, the ‘Hfecive output Oye i lower Beouse of time loses ee 10 seting up. Thistme losis due the ever ofthe sewing direction, and the height and depth of fut adjustment when moving iat th sobesuent ‘bench iaging postion. nation tothe time lowes ‘re thve wich feu fom oveiond sey delet Fig. 24 Scie snap ct ofa crowsos BWE (Jt eageam) and crowd type BWE (ght agra) intl loc ‘xcaation,[METHODS OF OPERATION OF WHEEL EXCAVATORS. a Sim Sim 15m 15m 05m fSmi Fe 27; Econ of 0 m wd ac wing a rae nouns Dowagon: BWE tack with 18m. lnverrpting the operations atthe wheel or inthe sb sequent conveyor system, to Wink 1963) the eflectve outpet an Bifean-oasten’n) Hereby the mom ofl eig-up and downtimes ‘the acu excavating tie within a observation Frou of sll fe thevecirocl value of +1, (Oy #specibe machine characteristic resulting fom the parameters ofthe euipment 2460.1 [mPfmof loose masses] 2) where 7 nomial capacity of single bucket ‘sccording tothe manlactarer (2) (Gee Seaton 138.2) Swgon:€ hope sar Ohta ao bak bak sting tence 4 numberof bucket discharges per min J Tease 1 geometrical volume ofa single bucket f=") 1h ili pace ofthe annular ing oF gude chute of the elles bucket wheal [a (ee Fig. 61 and Section 1382) inp eoetient ‘When determining Qa the filing space ofthe annular fing o gue chute) taken ito aoount by mani factre™ in the Federal Republic of Germany te tardies of is actual volume and isl wit a valve 8F 0.28 1100.5 As long as there no definite data tvallable fr @ and fan exact comparison of the Qn sated ty the manusctrer is impor (6 1382) For lad assumptions (se Section 521), however, the real volume off as to Be ued, and J, <03 F the value of 0 /should be appli (canals beexprese bythe product ofthe suri tes ofthe cut sekle and the slong speed Eye EE Fe 44): (0480 fe fa loose material] (23)2 ‘THE BUCKET WHEEL EXCAVATOR where tax ce dept nthe exeaator rave axe (ot the slewing sale of» =09, anda H=Hiy~R x) Height of sickle ut) ‘Relais (m om slowing sped at @=0" refered to the diance between the centroid of the scle cut and the superstructure sewing axis (m/mi] (eominal spect) J Amouot of sl de othe loosening and fling proces; this varies between 13 for sand and travel witha small amount of ey and 165 for Orerburden Wh more than 50% cl), Equation (23) apie to Block exavation for erm ‘ype BWES, for hich ig is constant over the fll, width ofthe block ee Fg. 2-3, upper and Fi. 2-4 lowe, Without changing the somal seat fe, a warm flow of ecard material rvuke, For erodes type BYES, tom changes with the slewing angle 9 acording to 1 2998] e9 quan (23) remains vali, o the digging capacity constant, oly te erated continously he ‘cipro value os 9. 2 ni Tere ofthe sewing set tue 10 (Df nw of etn oe eh ar ‘hen rng dln orig se sno Ihe sona spe gn mn const ow cated smh stn ead ob ‘Sel nop tossewg ego 0 oe es a = Bae Fhiks (1972) inuoduces an analysis which combines cquaions 22) and (23), re combine the infenee ofthe equipnents parameters and the citing 20 ety. ‘This analysis may include variable sewing speed ad ‘variable sewing angles. Considering the times Tq ted for stingup and other outages, equation 2.5) an also be applied to calculate the festive oxtput Oe German Standard DIN 22266 recommends the flow ing reltioaship forthe determination of gunratend t sed apy 1nge. Motorized seraers, mechanial diggers, hydraulic shovels, Gages and up 1001 boom dump sucks are the ost commonly used eath-moviag equipment “The economics of BWE operation cl fora minizmum quantity ofabout one milion of oil beexcaated ie order to achieve a reascable wrt-of period ‘Aiken, 1968) Ar the BWE. is a sigle-purpose ‘machine, iis usualy writen over the course of ‘one constriction prec. Hydmuithovel ad ater ‘onventonal aulpmet can be wed i high and ow ‘cot operations and can be equiped with lmshll, ‘Buckets or backhoes as dtcher in iffeent materials. “Hence iite-f pevids can be extended over several projects and therefore, ove a reater length of tne. ‘Thecontractorwithoalyalimted umber of machines, sherefore, prefers equipment vith a wide range of pplictions uaies more favorable resuls can te ‘hiainod by BWEs in peil css, “The appleatons of contractoriype BWE,reondad in erature, are sully cowbined with conveyor Delt tanipore systems. They ae moly employed on longterm projets where the esonomie requirement of ‘moving large amount of material can be me. The expectations raed in Heature regnrding the introduction of BWEs in ea-moviag, unt now have only been party realied, (Krumrey, 1968; Frank, 1968; Frank, 1955 The development of standardized equipment has, revert fed fo new and valuable eign fenures. Te has alo led to the w-aled “compact wheal sxoavator”. Thaw machines are of filly welded construction and have short bucket whee! booms for relatively low digging beihts. Greater eights are cleved by cating auiiay intermediate levels and the use of addtional eravleemounedbetwagons. ‘These standasiand BWEs are can by bucket, capaitesand excavating eights. They can beeguipped titer with dee eactie or allalectic dive and tealingeable feed. For all machines spacesaving ‘motorised pulley drives are used forthe conveyor elt, The wheel dive of smaller standard pee Frequently basa chain transmission driven through bevel pur redsion sear. ‘The vasous types are ented by their bucket, apaiy i ters such a8 Type 4, $0, 70,85, 100, 150, ‘30et. comparing ses, however, tisoftendifielt to determine whether the data gien rele to somical ‘ene Bucket capacities ‘The group of small machines has thorescal outputs ‘of up to about 300 hor effective outputs of up 10 1S mh and service weights of up to SO mt. Lager equipment with theoreti outputs of wp 002 for efi outpats of up 40 1000 mp and seve Weights of up fo 200 mt must be clase inthe ‘medi sz eategory- Table gives the main standard ‘aed BWE types produce by West Geran manufct- urers. Type 500 (Krupp) and Type 1989 (DEMAG TLayebhammes) exceed the upper fit of standard ‘ypemachines. nthe USSR, too, series of standard land machine is known (Tables? and 3). [At this point the development of full Hyde Sandardize BWEs should alo be mentioned Prope made ia ol hydeauic technology has completely changed the design of the erty cable ‘operated BWEs. The hydrtulcally operated shovel {er hyerauic excavator Toe short) only Teves the limited scope of the daglne to cable operated nuchiner The rapid. development of font cad Toaders (whet loaders) ad dumping devices for trucks ‘was only posible because of hydraulic techniques, ‘These ew machine designs, which have changed the whole range of contractors! machinery, have alo ad great influence on the BW Cit dao mechansms as drive motors are suitable for diel engine dsven machinery. By way of & Ascibing ger box te ol hyde pumps can be ‘diet connected with the dine engines without ‘universal couplings. Hydaule motors take up lite Space and permit stepless variation of the rotational ‘ped. The number of aicharger of he bucket whee,o ‘THE BUCKET WHEEL EXCAVATOR Fo 3-18, 8 St M12 tn 57 by OBKILMG) fhe mnt ol Caio Pe ink Cra ‘Hosier 2 sereewaghthecenaeyn 2} 007465 =Bebe Te Snape batty sunconvatr DEMAG Lau[BUCKET WHEEL EXCAVAIUK DESIGN 61 Fig. se: Contnuse‘THE BUCKET WHEEL EXCAVATOR @ ‘unui yo endo pas i upon eg ods pmpUES Lge on 20 | 50] 20] 90| zex| cor] 12 [260] cx |ooo| sz] | oe | et] BSE oy [eee 2] ats |oo0t | or+ | ose | oovi| ose | en] ex snake poem n| 9 | or |s60| s2e| 22x | ove | exe| sox |cxo2| one | ou | 07 SPH MHz we| ex | vz | m| oe | ore| ror| ccc | 9 | one | | co | eco | om | | c2| Lau] bigu armies a | 28 |7%|7e,| co | ev | oe | el ee | 9 | 9 | «| c| femufuu] poo jonny o1| 0|90| ox) eo | 90) zt | ot | Lo\ 4| 2+\ 60| ex | Ox | eO| FO fu] YPM 18 aziloz| oz | on| on| r|oa| oze| ou| oe| o| 02 | om |Mal%,| e+ |tareore ater toe ve1| 96 | 29 | o8| #2 | 9¢| on| ex] oz | onl oo | eo [om | 66 | 09 | €> | car7 wooe roman 4p) ¢0| €0 | 20| eo| ¢0| zo| 90 | s0| ¢0| 90| 90 | +0 | v0 | #0 | co | vo [ui] #70 29 ee| ez | oe | 60 | ou | oe o0:| 26 | v0 | om| on| 00 | se | cay whey Subba 019 |“Beo| Yo] 01 | cee| oF an | ONY 289 | cort| ovet| ann | eee | Luft erro raaqavoouy 2 weil es |e | o| ez| oz] | Lou) amy Arta eo] le | es Pied el el 0 | | | pes La tr 46 \es/e0)ze/ee) ce | 96 |25/0%) |au/9e \49/or|e9/eeja9/z2| us | 06 | 96 une sod sabio7sig elelele|s[e[al el e[a| el 9| e| «| el o| snewmqum #9 [ee |wz|ze| en | ec | e9|er| oz | ex[ oe [ev [oe [ee | ve | ce] cay sepa om ec2| oa | » | ove | ozs | or loons) oss | ax | coe | aoe | cor Jara: | are | 0 | on ooh, 38 worps | onr/490 gory |usansoyyanoy ovuga | —sunpooynuatyBUCKET WHREL EXCAVATOR DESIGN 6 6 3 LSE ere Ss F317: Fly deus BWE Type SH 400 (Bult 1972 by OBK/LMG) Working in «Geos ‘THE BUCKET WHEEL EXCAVATOR andthe slewing and travelling speed canbe varied by Simply changing the oll thought. At the driving Side of the Booket whet a beter fe exting angle 8 fcleved de to the compat space-saving deen of the hydraulic motor. Trowblesome inertia moment of the transmission gaat the drvngeod ote overoad Chueh are elinnated. Acting lke an overload etch frst ia the bucket hee, the Kinetic behaviour fails tong heise rem of every BWE deiner. I the hyrauloty driven bucket whee acount faege rorky it ops without casing any damage When slewed away fom the obstacle, it resumes is ‘motion. The prototype of the fly hydraulic BWE (Gel drives were excluded) went into operation ip one fof the Rhineland open pit mies around 1857. Ae ording to K. Glstoer (1967 the bydvaui elements ave proved sues over nae years of operation. Alveay inthe early Sixes, individual elements of fhe BWE, suc atthe hoirting mechanisms forthe ‘cket wheel and dichage booms and teeing scm Shas for crawler unite had been converted 19 oll hdres, The sndard Type 43 0f DEMAG Lauch- References ‘BORE et cata: Howie alton ‘tn cg (10H Noe cal debe mace Si Kernan sven 32 (0 soba ‘Se ng ee Strep. ‘timc Wear a8 no dr Seeger en aes Kt snd aon ts Go) 25837 eating runtetes Lonmpyts DEMAG in sna Ben (Be aero (90) 837, 6 ‘ammer canbe delivered if deied, with a hydrele ‘cket whee drive of 110 KW. This rive bas proved soul stsnctry inthe U.S.A andin the Spanish Sahar. In 1972, Orenstein & Koppel (0 & K/LMG) into veed Type SH 40, » moder fly hydrate BWE of large output cama (ox Fig. 3.17, Two diel Engines, each of 338 HP, are the pine movers the WE, che valle power tthe pac motors 16495 kW. “The bucket wheel, witha cuting re damier of 63 m and 10 buckets each witha nominal eapcity fr 400 asa drive power of 160 KW for 4 1075 bck Gacharges per minute. Three Wentcly sized dre motors ive an aternlly peared rim inside ‘he ody of the whee! va am epiyee spr asa train “Te pamip peso ie shih a 250 kt Diem? [3.858 pl The bit conveyors have geared drums driven by nea of ani-pston hydraulic motor. The hydalic prestce tthe ck for asing and lowering te wheel Pom is 170 ken [2817 pi and at he dscharze boom eck is 210 kg [2986 pil ‘oan TER. Sg sa re te ‘Sula W oad & 5 095, 86.73 (ure {See then 7 OO SNS Settee sae 6 ‘Saletan (180, 8.10 ‘ic React er Saetcany DE ange Biosys.BUCKET WHEEL EXCAVATOR DESION 65 ‘gp irae Denker [ToRt hry Deutee Dis Ne 2-92 ‘Sec anti. eins in Si Soin tons Daehn opener ter tewedang nr Statue enna hte 9 GS). TS ASTER L- ‘Die erin ett Decl Brnataue W tna 7 (989, Saal ‘Sherine Sng open Sea tee od bi 18 (1989) 25-8 Seteestige in Kanaan, ‘Sloundacee CT) =U noponts, .¢.6: ce Ops Apion ake Whe Fr Fehr Asul Contec Vc 197, The Asean In nogTHE BUCKET WHEEL EXCAVATOR4. Cutting Resistance and Digging Power 4.1, Determination of Cutting, Resistance ‘The digging fore exerted by the crtng knife of & ‘ska hau hae components a ight angle 6 each other 1. The tangential force, acting ow the bie ~ oF eating ore The ltr fore, normal 1 the conesing line tetween Bucket whe anand the excavator slew ing axis “The foward thst force, acting eadlly tothe Iie or eating ee ‘When excavating in loose homogeneous unconslda: esol the tangent forces by far the largest compo- feat It determines the torgue af the bucket wel Arve. Therefor thsforces the mest import factor for the determination of the digging power and ie enerally know ate cuting or digging force Garbo (1937) as the fst to publish an arc on ‘he diging power of bucket chain excavators: oye 2k pew a aX kw) a where Qu the effective hourly output of materi “in sito” (tank 2/8) 1X sresitanee coetcint which chraceriaes the kin of 0; for example: forloowe sands A607 forGerman lignite -X=7109 formedium overburden X=12t015 forharé clay xeupt023 ‘This "rule of deb originate around 1910 and was eserally Known and ued in German bucket chain botineeredthesmalleresitancecoe cents 6 << 12. Wagon (1939) designates the power required for igging 1 bask mk of sil as the "pec bucket ‘wheel power requirement. After subtraction of the Spent Ming power regutement (equred 1 Wi themateril inthe whe, he “specie dgag power” Isoblsne. By means of power consumption measure ment on BWEs working m overburden Wagon (939) ‘clas for examples specif bucket whee! power quirement of 04 kWhibank a at an output of 750 bank mk (Qy=970 mh) or specie ding power contumpiion of 082 KWh per bank a? of overburden ‘Kina (1937) adi the cuting proces of bucket ‘hin excavators in oder to determine she opium thee crowvsetion for the minimum bucket kale ‘set. He determined mathematically the ium sce creumference taking into consideration the rounding ofthe bucket cores. In the ease ofthe parallel cu of the bucket chain ‘excavator (ttsiable by continous shilling of the treks of by forward thrust or er of the lade) the opin rvalted in le of equarecrsbsecion, Resper (1955) calculated the digging power of the ‘bucket whe! without considering the rounded commer ofthe bucket Kafe. He coosiudd that the sere ‘igingresistace& referred to 1 em legth of ki depends entiely on the Kind of soi. Mulipiation by the tangential speed gives the minimum dieing owe: ys Roem x wow «2os ‘THE BUCKET WHEEL EXCAVATOR where 1 onrlefclnerefrd tothe ackt whe shat 2a thor outer oo ase) Fount of wl ‘digo effective ouput ofan) 37 Saber ot bctet dare per in Jk tad of ating ce ofthe bake wee Ftp ipo eae Tao This proves thatthe relationship between diging power and houry output, contrary to equation (1), Snot ner, bua perabolie function, Large outpats equi atively fs diag power Pajer (1960) publishes the general mathematic! solution forthe "specie dieing resistance” refercod (othe meine cros-secioal aren ofthe ct scle tthe bucket whe (Fig 41). The optim ooo teston i ot square and the mos favorable sexton ‘ato depends onthe quotient of ae by andthe aio H)Roe for symbol See Table 8). ‘There have teen diferenees of opinion among esearcrs so the bet referee unit forthe tango {lor diging force acting tthe eating cle of « ‘bucket wel The following parametrscoa be we: 27 Re tnicwet 2, The specie digging fore etre to 1 en af the ‘mean sce crows aeton of the Hike eu ia cn! (ee Fig. 42, lover. 3. The specie dinsing force fy for em? ofthe mean seated sle sion rfred to 1 om of the cuting blade length fur BOE gine "rom the beginning the parameter has been many used inthe Federal Repub of Germany and ct ‘Svein the German Democrat Repub nthe USSR nd Cechosovakia the parameter f has uni recently ben prefered, The tend there, however, is ‘more and mote towards the we of ja the reference 1 the pact tn yar the elatinship btwn dian rater and specie digging resitance for whe ‘operton have bee investigated hot theoretical aed practi, Among the more important invests fave teen Himmel (GDR), Limberk and Marcel (Czechosiovakial, Brack (Poland), Dombromst (USSR) and Kan (West Germany). fo A Cutan ne Ca aloCUTTING RESISTANCE AND DIGGING POWER ‘The caution method published by Hime (1963) {aes into account the rounded Kaife comer. He ‘sows that the specie digging ressance refered (0 the cutting knife length the only parameter which {slagaly independent ofthe soe cre sectional rea, iy is practally constant. Himes lrgescleet- ‘erient of 1960 on large BWES i open pit ines in {he GDR confi tha this vali noose wins ‘ated ao forall sce cross-section ratios =a, and for cohesive noonsnidated soit in the range of 73220 (ee Table 8, “The optimum So ie dept (10 wi () 4 fegttifem} 4 ® ofte mean she eos seton ofthe esc ess ‘nthe smallest cutigresstance. This functions given numerically in Table. ‘Thelare scale experiments about 150) already men: ional were cared ut the Insite for Ming ‘Machinery atthe Mining Academy at Freiberg (GDR) jn various open pit mines of the Senfenbers, Bora and Buea late dstits They shored good tgrement between the measurements and the resus bine fom calealatons The specie digingre- Sisunces, refered tow unit eagth ofthe bucket els, bot is loos and cohesive yneonsolidatal soi, ae sol susan £ 804 § 70+ % 60 . 2 50 = ae = 2 «0 8 30-| 320] 10+ So 0 500 1006 1500 2000 _—chip cross sectional area A [cm?] —— he tnifem? cee g 8 Parameter: ee AS &m =1.2 =const, 3 6 : ce ‘ 2 4 ; Ss a 3 =e go eo ° 500 1000 1500 2000 — chip cross sectional orea Alem?) —> Fg 42: Spee cating tans nk fom Yep) and fm glam! (low) 8 uncon of eit css ‘eotan imma 198),70 ‘THE BUCKET WHEEL EXCAVATOR hea Basic Outpt Formulae Qa =60 1) (Ge Sesto 15.1) Oa =60 J (2?) 60 tft (0) ‘When sting the slce crossction aren (4: Ata 0] 96 0) Og 60 54H with (=) “ete 6 Anal cotton of he apna sacs. © aay ° ° ea) ob) « Gs) ° O Sum of he sverage engaged cuting leg: she kX (baer cals using 100 Fo Fa Seto the exnene of pre-etes Par My (bur 8) /Z wan ow Foy calelted wing ‘Jcisobsined fromthe Marcel carve Fi ing to the secretion area en") D. Determination of Backet Whee Deve NaN Man 1M) oo ae teat TW] 108) Ng =0168 75mJBR HOW] (108)CUTTING RESISTANCE AND DIGGING POWER 09) wherein mi] Mean values f for oliype and celles wheels ommlly seper2 for cohesive sis Pale, 1960: pstas 1. Symbols ‘theoretical outpt (8 15.41) [7h] fective output (2) f=] ‘orginal volume of exavated materi before removal bank] swell 13 a ry expressed in terms of. fg Ue then ‘heappleation ofthis simple reatonship pesippore tutnemapneat/ carat for the comparison ae equ Fig. 4-6 dapa the function ofthe power requirement [N(QW) versas the effective outpl Qf loos) ofa whe! excavator SH 1200 in har ft clay (ith fi=32 kg (jem) oF the open pt mine of Lachan, pr. Fig. 45 shows asa function of the efetve output. ‘Theetetve output ascontrmed by eising machines increases proportionately ore than the bucket whee dave power rogirment (te Fig 45408 4-6), °q thih/m- ose} 200 980 — i ts { Fe. 45: Specie whe die power conunoson gibi) aes Wncon of the teste out teh low) fe BE Sanh 1200 (wea ameter 12m) aseoring to Hint (1968) 1, for exmpl, the eonveying equipment of « BWE ‘working a Quy 100 07h can tanspor’ up to 1,300 mh, then wi the sme {the motor of the ‘bucket whee ive sould be icreated from 140 KW 10 175 RW, or by 125% However, overloading the "40 RW bucket wheel rive would tot oer at 1,500 ‘mf ifthe machine were working ia a soit with Kan08 hay Teele La ia 46: Wel dive asa (A) a fanin of the ofecne autut en loan hand cay SWE Senke1200 ace 1 Hime (1965. By farther measurements made on wheel excavator SH 1200, Himmel fovad that with new ripping teeth the output increased by 2657, Simultaneously, the speciic power requrement went down by 13% ‘Theron, in heavy si, riping eth of appropiate form are of great importance, ‘The avalale sper power for dgsng Nag= 1 = Nj) hs been come a Table 13, fora seston of 10 pert BWE: of various snes. Av the elective ‘outputs depend on the kind of sd tobe excavated and the method of operaon, tbe theoretical ouput, Oy tas ben chosen asthe efrence unit Wi the stalled rated whee eve power “Table 8 shows the specific whel dive power tequire ‘ment in overburden ith diferent ol properties nd in chalk obeined from measurement, “The results of reseech publabed are aot always suitable for supporting the Frequently eld opinion {that elcultion bad on conespond eter tthe izing force F, detained by measurement, than the eof imme! has shown that only outsige the range 1Oez<20 does the Fycurve, of digging Tore calelate fom jf, eespond bee othe measured Aging force (cure) than the ,- {om Ine of Loa Angeles placed the ees Bucket ‘wel by a il of to to the dncarg ide and by Aout 45" to 6" tothe loagitudinal boom axis (se Figs 67 apd 1.26, In more reeeat machines, the ‘usket are arranged symmetrically othe center plane ofthewhel Thereaze ode suracesand the buckets ‘emp diet oto te boom bet. Thus, the eying of ‘the boekts sure Long before tbe et as bea com ‘ltd, provided suletcuting height i avalable, ‘The manafactre io the opinion tat the following cating ices, pushing against one another caourage the complete empiying of te Buckets wien working Inte oil The tation without sliding suracesisoe THE BUCKET WHEEL EXCAVATOR lg 66: Rotary ac feeder with aati plough fr Tigh and deap et (chown enotna pce ug nigh ot) (Oa). 6:7 Uneerupted mat icy oot ta carveyor SR see ow rn oan of advantage when handling corse stones. The smaller Gamer of the cultag cece as compared. with ‘European standards rests in greater ging forces forthe same drive power. Acoding to information plied by the minufactore thes He Between 14 tnd 176 mi) according 1 pe In spite fan anol cutting ome, this mantic turer has achieved large outpate with comparatively igh machines (e Section 136.2), 6.1.3. The Semi-Coll-type Wheel ‘The semicell type whet bas been introduced for Wheel diameters in excess of 11m oe ig 68) Ia the lindeical ring body, tanvesely sloping ellchutes sr ted under eich becket, and there empy onto & Slope sect fed infront o° he exe large hub Compared with the other two forms of whe! dein, ‘he semicell whe! has the advantage ofthe rete ‘eke lie Fig. 69) with he best poole emping churacterisis eve for sch wil Thi also means the east amount of spillage ae the least overthrow of partly emptied buckets onto the crawler level For example, the 2.6 m whe! of SARS 6300 has hel body diameter of about 180m and = bub Giameter of 136m, Between te later dames it theeylindria plate ring with he emptying el-chuts. 6.1.4, Bucket Filling Space For el-ype wheel the bucket ing space imme sitlyaacent to that (7 of the slide ctes which fre dvided upto form cel (ce Fig, 614) For the Galles whee, However, te chamber isimmeditly ‘elow the buckets Fig 69 shows how fr the excavated ‘atrial mus push is way ito the ling space of the atous bucket forms assuming 220" slope ‘When éigging sticky material a large opesing inthe eplindrclcoverpiate ofthe whee body a font of the bucket necessary ee Fig 68). This o permit ‘mater wich ae remained ie the bucket unt fer ‘aching the highest postion © drop dows onto the bscharge cel In Table 14 the bucket capaci is compared with he ailable ring pace of varios designs The more ot tes complete ling of these ell spices Frequently leads to output exceeding the theoreti! capacities ifthe were deermied only onthe bass ofthe bucket, capaci“THE BUCKET WHEEL, os Fin, 68: Sem-cal type whee! of BWE See “841 (OBKILMG). Fig. 6-9: Dogs of bucket acing sce or toe bucket ome. Amt pe nl of 20° has bon ses‘THE BUCKET WHEEL EXCAVATOR Schits £300. - 30 semi-cell fo 26 76 1st SchRs 2200. - 59 | cell-less 180 2m | 4s | 253 Sohts 3602. - 59 | cell-type 36 o 36 10 SchRs Type 150 | celi-less | 0% | 007% | oar | 155 SchRs Type 7 aos | 155 wr | 162 —_I Toble 14: Bucot when rd buch cpt an /,dsgnd and manutacurd by OB K/LMG,‘THE BUCKET WHEEL, ” For this reason the “nomi! capacity” J was intro- ced (ce Sion 221) Ia this case, 28% ta man ‘mum of 307; of the bucket capac is sugested as ‘ional lig space. The nominal expat Jie then 1251015 / As long at there is no binding regulation on all ‘manufacturer forthe determination of J, m0 ext ‘Somparzon betwen theoreti capa of diferent ‘whet possible ee Seton 221. (6.5. Lining the Bucket Wheel Chutes and Slope Sheets Standardized wear plates (€2. 500% 500m) with fastening hoes sully serve swear surfaces ortiners End or wedge pater ae usual formed on site by culag torch. In Germany high carbon ste knowa ‘under the trade mark of “VT Ste” is sed fr lege ‘machines excavating 30 millon bank m/year The ‘ining company RBW has carried ou cea test ‘vith 10 mm thick honeycomb sheets After 3 milion bank a? of overburden, the wear amousted to 6m. In very cohesive sols, good results were obtained with the following materi: 1. “Linater"*, soft kind of robber, achieves the best results when fastened only at the odes wile he Diate interior i fre. This solution Ie ued bythe SEC, Vitor, theclayey mostly non-Newtonian soils of the Latrobe Valley, Ausvalia (Rodgers, 1970). 2. The plastic material “Supralen RCH" (Geman produc) suse with good success when dieing ‘ery ahve soft chal fermations 3. The plc material “Tefon”* (Trademark of DuPont), hie great reduces the icon betwen sta and excavated teil can be en fastened to sel plates either with stews or adhesives. 6.2. Characteristic Values of Bucket ‘Wheels ‘As the bass for standardization of BWES, Hurl (0957) exalishe celationshipe for the sttinabe ‘viputs sing only the bucket wel diameter (D), the bucket capacity (tbe number of buckets (2) fand the wheat speed (jy) He shows that thee ‘elatonsips also apply 10 bucket chain exesators, i instead ofthe bucket spcig (bucket ite onthe ‘bucket whe a) the ptc ofthe chain (0) ppled (Camm, 1951). Hume! refer to Avckeroiom (0932), who found the following relationship trom statiszal evaluation of cain exevator buckets then salad 125? (w) 6 wher tis cain ite or cant ny ith c= 25a a character value, ‘Atercratutingthe meanwtilesobstanilyimproved ‘bueke shapes othe chain exorvators Hummel (1951) determined the conta sto 5, IF for BWE instead ofthe cin pitch (the bucket spacing (a), measured a he euting ee, chosen, Sefton waned (x te di b=) he 6 whereby +e numberof buckets D_ cutting ile ameter [n) iummel sowed that ia moat instances rset? sens 2-26 ‘hard facing Electrodes: Verdur (krepo) Fox Multi dtur (tungsten carbicle) 68-72 HRC (Babbler) Ledurit $6-60 HRC Wbdit for gers and are - welding “Teale 19: Dggog Toth: Mateo ine in ad oeTHE BUCKET WHEEL m Previous ton in thi book have show that corer tnd side text ean oly be arranged comet for one loving speed. Therefore, the sme of the damond taped teeth preferal i the U.S.A fo dralines and shovels ipeaccal Tt only seem posible to ‘ring the tp pin into the proper eating postion. “The position of the bucket wheel required for a8 op ‘som cating process, ithe center plane of the Stel radia othe superstacue slewing ais (ee Fig, 622, was sealnd in the BWEs Sehks 1000 ‘working inthe GCOS ol sand mine (Rasper, 169). [Every erative arrangemeat ofthe whe is unfavor Fig, 6:22; Optimum wheel arangemen fre dana 6-23 Mote showing: Come et hgh ira (sme tot, 8 comer toot € wade wn) befor operating in both slewing dcctions and mast be avoided even athe rik of absndoning the Bucket dumping advantages. However, inthis cae wheel lscharge by means of 2 roary plate dine Feder compensates for dumping disadvantages 10 large trent, The positon of the bucket text must be adap cf the cating proces (se Fig. 623), This means "trong core teeth a les {wo sie teeth and crater fee for tring the eat. The later may not be used fox procter: (Par, 1969, Shape and lifetime of bucket teeth depend o@ the brasion resistance ofthe toth mater abd on the properties of the ol eig excaated, “The most abrsive sie are those contning 8 high perentage of cxmeted quartz galas (Raspr, 1961, 1968; Petry, 196). The bucket tooth must ave 3 body of dale aut sted alloy, must tonto both fides ofthe bucket apr and be fstena with pre Jonded lati Blt (ightenad by means ofa torque wrench). The bucket toth eating edges are protected Sosine wear by means of abrasion resistant had face ‘elding Tab 19). The properie of the si 0 be ‘henvated and the desir iftime determine the spc festion of the welding materi In homogeneous soil ontinng only sal quantity of ily embedded ook, sive olerng-on of sal angen pes (eg, Wide GT 10) has proved sve ‘fu However, Reavy shocks due o Biting age boulders tend o cack the silver sole, Fig 6-24 Hard ntl ped bckt th, ‘resice agin B=weoge angle: # clan era 2 spsevting boi).Fry ‘THE BUCKET WHEEL EXCAVATOR Fig. 6-24 shows the sie clearance, wedge and chip angles of «ew tooth forthe Seb TOD at Ney, India. The bucket tothn Fig. 628 was developed for the bard ely of « West Geman open pit ie. Fi 626a shows a dawing of «corner loath developed fon the basis of previous experience for the BWES SEARS 1000 (GCOS oll sands Fg. 6266 ilusates the same corner tooth ns worn condition. Te deve lopment of side and center tnt shown in Fig. 627 ‘now as iper tee, has proved tobe succes at Nee 6.25: New and wom bck at ese cung (Co omar text ight: mide an siete) 1, in spite ofthe hardest materia, the required ie cannot be obtained, then the best solution i (0 increas the wear volume (ce Fi. 6268) Limit tot ite, which in abrasive soi i reguenty Jeu than S00 hour of operation, reguites quickly eX changeable ripping teh. For thi purpose bucket text with repaeble oot inert canbe Fecommend such thse ofered workwie by Eso Corpora ‘ion This manufacturer i prepared to meet individual requirements Experience gained with secre teed in the open pit mine Northern Minos (Petry, 1964) seems tobe ge fvorabe In he Canadian sand operations of GCOS the tendency ofthe welt ‘ipsto loosen fer repeated changing of oth created ‘ticle ‘When cuting in hard ol high temperatures cur at ‘the oot cating edges which canbe observed bythe evelopment of smoke Inthe Norther liais open ‘mine temperatures of300°Cto 400°C were ess ‘twit thermocolor chalk onthe oot suxfacs when tng har clayey shale (Pty, 1968 or tbe removal of overburden in the Rhineland inte istrict, spcilly fomed extensions to the basket, nies replice the comer teth Thee extensions are called “eat” because of thee shape When wea hs. resthed an advanced age, these “ere” canbe Burt ‘and replaced by now pats. According to Seen ‘scheid (1965) them have led nt only to a smoother ‘woking of the whe! forthe stme ovat, bat the power requtement bat been reload by 20% (ce Fig 625). In hard but homogenous si, moderate lasting with raid exploves prior to digging have considerably tended th iene of the Bucket eth, This method as been te soeesily in the hard overburden seams (Cudiore sandstone) ofthe Nevill openeast, ‘mine, wher the explosive “Opeacast Gelpite™ is ed 1567, the consumption of explosives Was ‘reported tobe 0.06 Kg/bank mat For MeMurry, ‘Alberts, thei sand is loosened op by blasting daring the summer months, hus permiting continuous ex sation wih BWEs during persistent winter rs 6.7. Bucket Wheel Gear Box Overload Safety Devices As cary a6 1950 Huey reopnized that when diggin in heterogeneous si aterspered with boulders the ‘bucket whe drive may be damaged by shock unless an overload cltch i provided. The United Electric Coal Con son afterward installed «compres air ‘operated mip die lth, 6.7.1. Operating Torque and Kinetic Energy “The nominal operating torque (,) is ten by the Aging fore acising due 10 the sol being excavated tnd the Kine eney ofthe revolving masses of the ‘wheel the par rains andthe dive motor. Work (0%) done by the instentansous torque (M) consumes te Kinetic energy (KE) released by the ‘edvcton in speed ofthese components WEA) yg yy-m naKe- eR where ARE change in total kinetic enegy of revolving Wa Flywieest e)—m') ‘mnt rotational speed (rpm) fm Sal oaion spat [rpmTHE BUCKET WHEEL 13 Fo. 628: 9) Desan of comer ofr Hone snd for BE Sch 26 lee canes 58 en. 8) Wor out tah 67m nr ty elon to OME ‘voting, n- Codsare somone i ap ‘ee (O4W 0)m4 ‘THE BUCKET WHEEL EXCAVATOR In onder o seat the mos suitable orion latch ‘tis necessary to know the operating torque aa fone ‘bon of tine. The following load conditions can be dierent 4) Steal increasing operating torque up to a vale inerces to torque (Mf) which oecus atthe nomi- nal outpt ofthe bucket whee dive motor. 'b) Shocktke urges in operating torque occurring de tohiting boulders finite size or when penetat- fing ard strata The inspect can be gure 28 slate and leas to “operating torques” exe of My. But since the wheel continues eating, a ‘ong braking length remains ao that theres no Anger of an ultimate sue facture ©) Shodkelke operating tora due to hiting fry ‘emented boulders weighing mt and more. Duet ‘short braking lng avaible, ractre un oldabe without sutable ovesoad sey devices “The atc uimatestres fracture decisive Because ‘heminimum requency necesary fra fatigue fractare is ot reacod (tigen). Nowadays suits taal records are avaiable concerning the frequency of witching of overload salty devies.‘THE BUCKET WHEEL us “Ths, for example, during vibration investigation ear ed out by Ocen (1968) on Shs 4000 working in ‘Shy the overload latch wat actuated on an averabe 32 rime, ad maximum of 45 tines pet Bou ‘Saving #15 howe operating period. During investiga ‘ows covering a perio of x months, Lubeih (1967) ound that on 2% ofthe operating days 20 swchines ‘ocurred andon!4cofthe operating dye s0sthings. Tn ths case onl few pak torques or perhaps none ‘tall occurred which would hae led oan ultimate ‘Sees facture without the protection afforded by a ‘lth “The Standard Reting Regulation ofthe GDR el for observance ofthe fatigue streagth when a as 000 Tous ocr per year and ofthe endurance limit when there are more ha 2,00 loads er year tis the tsk ofan overload safety device pret the weakest par ofthe gearing or the bucket wel shaft {sowrsection. Under every loading condition, the over Toad device must keep the stresses below theultimate tes lit or the fatigue sength of the respective ‘material. The nei energy of the drive, the backet ‘wel kate braking length and the fleiiliy ofthe fystem determine the mapntode of the dilerence Tongue in exces ofthe eitchin tongue For oad cass an) the existence ofa current over load lay isuflcet, The She 3600 print service in the Fortuna open pit mize i 1955 has operated fora lng time with sch an overload device. This ‘overload ely in Getmaey normaly dexenate S, “The depos of danger, the magnitude of he die rence moment lagey dependent upon the braking length, This i enfortunately monly unknown due 10 ‘he unpredictable mature ofthe sito be excavated. If ‘ebraking length mere sero, however, deformation oF destruction of buckets end eipping tech should pro tec the often dificult replace, expensive compo- ets agus fre. “The eflectvene of sn overlosd euch depends upon the aecuracy ofthe sete switching torge sting and on the alain of a age x quantity ofthe inee fneray from tke bucket wheel dive as posible however, only small portion ofthe tla ywhes! fect (WR) concerted in the ge tan ad the ‘bok wheel shat the stint satis posible with {tort raking length. ‘The problem would be est solved by alt arranged athe output sal ofthe Backet wheel eduction ear tox (Bahr, 1969) Sizes and weight considerations ‘ave not et allowed this easton to be realized ‘Nenvea to thee demands cones the dra bucket ie! dive a dss in Seton 3.2 “The following example shows the datrbution ofthe nd Aywheel effects of bucket whedl gear tain fd deve motor in the oveall ywhoa eet of & Docket wheel dre: BWE SehRs 4000 with = 2380 kW, D=140 m, y=40 of 50 of 60 pen (Ghrough frequency modulation). A torque alae on the motor shaft ats as an overload safety device ‘The remltantdisribaton ofthe fotal toque referred tothe motor shaftcan be reizded asa reference figure forthe conditions wth bucks whee of gant excava ‘Total Bye ef 1105 fa/)— (equivalent acting on motor sha) ‘Bucket whee! nd bucket wheal shaft Gear tochutch Motor ad parts on the input sie ofthectiteh ox Accordingly the tc ols 887 ofthe 2 {ns analier moder machine the folowing conditions Bucket wheet 26.25 5 n=625 pm Sauieleage etre motor =250 kW, n=~980 rn. (nerd safety device: Voih Turbocouping (ith ‘etading space) type Tvs 75) mounted on the motor shat ‘When reaching 5M the cleric motor isitehed of bythe over current circuit beaker after 0.2 20 If weve, the overcurrent cuit breaker fsa the fut peak moment (20M) is reached, and i the bucket whe! shoud be bloke, the secondary mo- ‘eat drop to 1.0 My, whe eats developed inthe coupling id ‘Total fywhel eet (WR) 39.2 hg f= (equivalent acting on motor ha) Bucket whee and bucket whe! shaft ‘Gear train wih ouplngtcondary poston (Coupling primary potion ard motor 790% Accordingly, the overload euch ates 797% ofthe neti crea