掘进机在采矿和隧道业中的应用外文翻译.doc

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1、附录A 译文掘进机在采矿和隧道业中的应用摘要掘进机为方便的挖掘中硬岩石提供了一个独特的能力。因此，广泛地被用于地下，采矿和隧道掘进。在成功使用掘进机方面的一个具有决定性的议题是提高机器生产率和降低钻掘成本的可靠性分析。这篇文章提出并且讨论科罗拉多学校地球力学研究会最近完成的工作对于挖掘在历史上的使用数据当作一个动态的性能模型。这个模型是从不同的掘进机在各式各样的地质条件下工作为基础来广泛收集的数据。这篇文章也讨论这一数据库的发展和含量被源自估计掘进机的截割率和截割头能耗的预测为程序。介绍目前，机械挖掘系统广大的使用在采矿和市政建造行业上，主要的趋势是提高生产率和减低成本。这些主要的好处就是减少

2、了土地的占有量；同时，增强了工人的安全性。这些优点主要取决于机器性能的大幅度提高，这些可靠性已经造成采掘市场的扩大，并且工人的水平得到了提高。掘进机是一种广泛应用在地下软硬岩石的挖掘上的机器，特别是对于那些沉积岩。他们用在软岩采矿行业的生产和发展（也就是，巷道掘进、支护，打洞，等等）。特别是用在煤矿，矿山上。在市政建设中，经常使用在较软地面的管道开掘（铁路、公路、排水沟、导流管道等等）。 连同于扩大巷道或者地下结构的复原。而且掘进机的应用能力非常广泛，基本可以挖掘任何结构和断面的尺寸，不管巷道断面有复杂，都能满足人们的需求。因此，受到人们的一致欢迎。除了那些高的机动灵活性和适应性之外，掘进机另

3、外一个最大的优点就是成本低廉，经济性好。一般的掘进机都有很大的功率，但却是通过电磁方便的控制。因此，与其他机器相比，它能够较好的掘进硬岩和粉碎。例如连续开采和挖掘。掘进机近50年的发展掘进机最初的使用是在上世纪50年代煤矿的开采中。今天，在科技高速发展的推动下，人们设计的掘进机性能和其他方面都有了很大的进步，它们的应用已经远远超过了煤炭开采的范围。主要的改进发生在最近这50年。包括，机器的重量和尺寸比以往增大了很多，截割头功率加大、支护杆，耙抓机构和控制系统都得到了很大的改进。高效率截割头的设计，高截割率截割齿的发展，高压水细射流辅助截割，电液一体化，较大地方使用自动控制系统以及根据不同地质条

4、件间接控制。所以的这些都使机器的截割能力、工作效率、功率等都得到了长足的提高。机器的重量已经高达120吨左右，那样接地比压得到提高。使机器更加稳定和坚固，那么，在截割较硬的岩石时，面对大的冲击机器仍然能保证较少的振动，维修率降低。目前，掘进机的功率可达到500KW左右，使扭矩得到提高。现在的机器截割断面可达到100m2。采用计算机辅助设计，使截割头的布置可达到一个最佳点切入岩石表面，那样的话截割头的工作效率达到最佳状态。截齿已经从简单的钻发展到了锥形。煤岩装载机构和转运机构也得到了很大的进步，可达到生产率的要求。中间输送机现在被制造成可伸缩式，使结构简单化，装运方便。前面装有防护设施，使截割下

5、来的岩石以及截割过程中产生的粉尘挡在外面，保证了操作人员的安全。掘进机也能配备激光指导的对准控制系统，由计算机先分析出最佳的截割轮廓，如果按照此顺序截割的话，截割效率和生产力都有成倍的提高。图1展示的是一个横轴式悬臂掘进机以及耙抓机构。图-1 横轴式掘进机普遍性、良好的控制性、和选择性的采矿能力是掘进机发展中需要大力改进的因素，普遍性即指我们设计的掘进机能够适应大多数矿山发展的需要。良好的控制性就是机器在过载时能够自动保护，这样不至于烧损机器。部分尺寸，摆角，（上摆角可达20度，下摆角可达30度）。回转半径几乎能达到90度。选择性指的是在不同的工作环境下可以采取不同的截割功率挖掘矿石的能力，两

6、者能够极大的改进生产率。因为，我们所指的掘进机是部分断面掘进机，可以接近断面，因此，可以很容易的调整刀头，并且顶板架能够很方便地接近顶面。除了这些之外，高的生产率也取决于岩石的内部特性。合理的改进通风设备，降低地表的压力，所有的这些都可以降低成本，提高生产率。切削硬岩的能力是影响掘进机应用的最重要因素。这可能是由于在切割尖而硬的岩石时截齿的磨损非常厉害。目前，如果采用良好的连接和配套设备，主轴的抗压强度能达到100MPa。最大转矩也提高了很多。当岩石是脆性岩，岩石是在截割的时候崩落下来的而不是挖掘下来的，那么，就使采掘变的相当容易。如果岩石是粘性的或者单位能耗超过一时，那么掘进的挖掘就变的很不

7、经济，还可能导致机器振动加大，维修费用成倍增加。一个很重要的量，关于增加掘进机截割硬岩的能力被放置了很多年。这些年人们都把主要精力放在机器结构方面的改进上。例如，增加重量，截割头功率等。通过这些机器广泛的现场试验表明，截割工具仍然是截割硬岩时最大的弱点。除非一个很大的进步就是在截割时增加截齿的寿命，因此，对于掘进机而言，截割硬岩还是一个难题。科罗拉多学校地理力学研究会已经发现了一种新的切削技术：锥形截割头。这种截割头实现了圆盘切削时提高截割硬岩的能力。用这种横的截割头在实验室试验出，当用较少的截齿时它的截割图-2锥形截割头能力比一般的截齿大了很多，这种新的切割技术应用在掘进机上，为经济性的截割

8、硬岩带来了希望。除此之外，使用这种截齿，一种新的开采技术已经被申请，为截割硬岩的发展起到很大的促进作用。图-2展示的是实验室测定的截割硬岩的图象。实验数据性能预测是掘进机应用成功的一个重要因素。这通常取决于机器的选择，生产率，和掘进时的消耗。掘进机的技术对于任何的采掘命令，准确而可靠的估计是达到生产率的保证。除此之外，在采掘过程中，它也是对掘进路线设计，截割头掘进岩石表面状态的最佳选择。性能预测也是不同地质条件下截割率、截齿消耗率、机器损耗率的表现。截割率单位时间截割的煤岩量，单位能耗指的是在截割单位面积或质量的煤岩所耗的电量。机器利用率是指在计划期间作为挖掘时间所用的百分率。科罗拉多学校的地

9、球力学学会与其他一些有关这方面技术的大学，已经建立了正确而可靠的性能预测发展经验模型。通过这个模型，在挖掘过程收集了广泛的数据，组建成一个数据库。这个数据库收集了来自全世界多数采矿和市政建设过程中不同的地质条件下所得的挖掘数据。表-1数据库中的数据数据组内 容基本数据采掘目的（修路、铁路、管道修建、排水渠、采矿巷道等等）承包人、顾问、开工和完成日期等等。掘进机数据制造商，掘进机概况（新的、直接重复使用）掘进机说明书，重量，截割头直径，电力控制，截齿数量和型式，辅助设备（内外喷雾设施，自动轮廓控制，等等）。技术和操作上数据掘进长度，深度和梯度，挖掘断面，操作者经验，每日和每周的采掘量，煤岩装载形

10、式，顶板支护。等等动过的岩石区的数据地质学区，岩石质量分类，地质学起源，水文地质学状况，（定向，结构高度，粗度等等。）每个岩石区的尚未被人碰过的岩石数据岩石可截割特性，抗拉强度，柔性率，表面硬度，纹理（多孔，矿物石英含量。颗粒大小，等等）冲蚀度特性等等。每个岩石区的性能记录截割率，截齿损耗量，掘进机利用和可用性，平均和最好的超前率（变化/每日，每周，每月）主要挖掘障碍物，停工时间分析，等等。经验的性能预测方法主要地以先前记录的数据和过去的经验和统计为基础。为了以一个可使用的和意义深长的图纸幅面获得必需的磁场数据，一个数据的收集从准备到送至主修收缩器，还有掘进机的制造商。除此之外数据收集来以后，

11、还要经过优化处理，这是对数据收集的继续。数据库包含六种数据，如表-1所示。在数据库的地质学特性里通常有岩石质量和尚未被人们碰过的岩石特性。被包含在数据库的最重要的和最相关的岩石质量特性含岩石性质指示 (RQD), 固定联合组和水文学状态的厚度山。 尚未被人碰过的岩石特性是单桥的抗压强度，抗拉强度，石英含量，纹理。岩石形成被区分开，使最小在机器性能数据的变化范围提供正确的分析。这也为每个区性能数据分析单一化分类。结论通过这些评估和数据分析，数据库已经成功的产生能够为掘进机预测瞬时截割率和截齿损耗率的一组方程。这些方程被发现主要适用于起源的软岩，现在的分析是详细化的，可以通用的，含有很多复杂的岩石

12、，使程序变的更万用。在有裂缝的岩石中，这种分析将会被利用来自一个掘进机的可截割性观点对岩石特性的衡量。所以，我们可以认为，这些努力将会作为掘进机在不同的岩石类型中实现经济截割的性能预测公式。附录B 外文文献Roadheader applications in mining and tunneling industriesABSTRACT Roadheaders offer a unique capability and flexibility for the excavation of soft to medium strength rock formations, therefore, ar

13、e widely used in underground mining and tunneling operations. A critical issue in successful roadheader application is the ability to develop accurate and reliable estimates of machine production capacity and the associated bit costs. This paper presents and discusses the recent work completed at th

14、e Earth Mechanics Institute of Colorado School of Mines on the use of historical data for use as a performance predictor model. The model is based on extensive field data collected from different roadheader operations in a wide variety of geologic formations. The paper also discusses the development

15、 of this database and the resultant empirical performance prediction equations derived to estimate roadheader cutting rates and bit consumption.INTRODUCTION The more widespread use of the mechanical excavation systems is a trend set by increasing pressure on the mining and civil construction industr

16、ies to move away from the conventional drill and blast methods to improve productivity and reduce costs. The additional benefits of mechanical mining include significantly improved safety, reduced ground support requirements and fewer personnel. These advantages coupled with recent enhancements in m

17、achine performance and reliability have resulted in mechanical miners taking a larger share of the rock excavation market. Roadheaders are the most widely used underground partial-face excavation machines for soft to medium strength rocks, particularly for sedimentary rocks. They are used for both d

18、evelopment and production in soft rock mining industry (i.e. main haulage drifts, roadways, cross-cuts, etc.) particularly in coal, industrial minerals and evaporitic rocks. In civil construction, they find extensive use for excavation of tunnels (railway, roadway, sewer, diversion tunnels, etc.) in

19、 soft ground conditions, as well as for enlargement and rehabilitation of various underground structures. Their ability to excavate almost any profile opening also makes them very attractive to those mining and civil construction projects where various opening sizes and profiles need to be construct

20、ed. In addition to their high mobility and versatility, roadheaders are generally low capital cost systems compared to the most other mechanical excavators. Because of higher cutting power density due to a smaller cutting drum, they offer the capability to excavate rocks harder and more abrasive tha

21、n their counterparts, such as the continuous miners and the borers. ROADHEADERS IN LAST 50 YEARS Roadheaders were first developed for mechanical excavation of coal in the early 50s. Today, their application areas have expanded beyond coal mining as a result of continual performance increases brought

22、 about by new technological developments and design improvements. The major improvements achieved in the last 50 years consist of steadily increased machine weight, size and cutterhead power, improved design of boom, muck pick up and loading system, more efficient cutterhead design, metallurgical de

23、velopments in cutting bits, advances in hydraulic and electrical systems, and more widespread use of automation and remote control features. All these have led to drastic enhancements in machine cutting capabilities, system availability and the service life. Machine weights have reached up to 120 to

24、ns providing more stable and stiffer (less vibration, less maintenance) platforms from which higher thrust forces can be generated for attacking harder rock formations. . The cutterhead power has increased significantly, approaching 500 kW to allow for higher torque capacities. Modern machines have

25、the ability to cut cross-sections over 100m2 from a stationary point. Computer aided cutterhead lacing design has developed to a stage to enable the design of optimal bit layout to achieve the maximum efficiency in the rock and geologic conditions to be encountered. The cutting bits have evolved fro

26、m simple chisel to robust conical bits. The muck collection and transport systems have also undergone major improvements, increasing attainable production rates. The loading apron can now be manufactured as an extendible piece providing for more mobility and flexibility. The machines can be equipped

27、 with rock bolting and automatic dust suppression equipment to enhance the safety of personnel working at the heading. They can also be fitted with laser-guided alignment control systems, computer profile controlling and remote control systems allowing for reduced operator sensitivity coupled with i

28、ncreased efficiency and productivity. Figure-1 shows a picture of a modern transverse type roadheader with telescopic boom and bolting system.Mobility, flexibility and the selective mining capability constitute some of the most important application advantages of roadheaders leading to cost effectiv

29、e operations. Mobility means easy relocation from one face to another to meet the daily development and production requirements of a mine. Flexibility allows for quick changes in operational conditions such as Figure-1: A Transverse Cutterhead Roadheader (Courtesy of Voest Alpine)different opening p

30、rofiles (horse-shoe, rectangular, etc.), cross-sectional sizes, gradients (up to 20, sometimes 30 degrees), and the turning radius (can make an almost 90 degree turn). Selectivity refers to the ability to excavate different parts of a mixed face where the ore can be mined separately to reduce diluti

31、on and to minimize waste handling, both contributing to improved productivity. Since roadheaders are partial-face machines, the face is accessible, and therefore, cutters can be inspected and changed easily, and the roof support can be installed very close to the face. In addition to these, high pro

32、duction rates in favorable ground conditions, improved safety, reduced ground support and ventilation requirements, all resulting in reduced excavation costs are the other important advantages of roadheaders. The hard rock cutting ability of roadheaders is the most important limiting factor affectin

33、g their applications. This is mostly due to the high wear experienced by drag bits in hard, abrasive rocks. The present day, heavy-duty roadheaders can economically cut most rock formations up to 100 MPa (14,500 psi) uniaxial compressive strength (UCS) and rocks up to 160 MPa (23,000 psi) UCS if fav

34、orable jointing or bedding is present with low RQD numbers. Increasing frequency of joints or other rock weaknesses make the rock excavation easier as the machine simply pulls or rips out the blocks instead of cutting them. If the rock is very abrasive, or the pick consumption rate is more than 1-pi

35、ck/m3, then roadheader excavation usually becomes uneconomical due to frequent bit changes coupled with increased machine vibrations and maintenance costs. A significant amount of effort has been placed over the years on increasing the ability of roadheaders to cut hard rock. Most of these efforts h

36、ave focused on structural changes in the machines, such as increased weight, stiffer frames and more cutterhead power. Extensive field trials of these machines showed that the cutting tool is still the weakest point in hard rock excavation. Unless a drastic improvement is achieved in bit life, the t

37、rue hard rock cutting is still beyond the realm of possibility with roadheaders. The Earth Mechanics Institute(EMI) of the Colorado School of Mines has been developing a new cutter technology, the Mini-Disc Cutter, to implement the hard rock cutting ability of disc cutters on roadheaders, as well as

38、 other types of mechanical excavators (Ozdemir et al, 1995). The full-scale laboratory tests with a standard transverse cutterhead showed that MiniDisc Cutters could increase the ability of the roadheaders for hard rock excavation while providing for lesser cutter change and maintenance stoppages. T

39、his new cutting technology holds great promise for application on roadheaders to extend their capability into economical excavation of hard rocks. In addition, using the mini-disc cutters, a drum miner concept has been developed by EMI for application to hard rock mine development. A picture of the

40、drum miner during full-scale laboratory testing is shown in Figure-2.Figure-2: Drum Miner CutterheadFIELD PERFORMANCE DATABASE Performance prediction is an important factor for successful roadheader application. This deals generally with machine selection, production rate and bit cost estimation. Su

41、ccessful application of roadheader technology to any mining operation dictates that accurate and reliable estimates are developed for attainable production rates and the accompanying bit costs. In addition, it is of crucial importance that the bit design and cutterhead layout is optimized for the ro

42、ck conditions to be encountered during excavation. Performance prediction encompasses the assessment of instantaneous cutting rates, bit consumption rates and machine utilization for different geological units. The instantaneous cutting rate (ICR) is the production rate during actual cutting time, (

43、tons or m3 / cutting hour). Pick consumption rate refers to the number of picks changed per unit volume or weight of rock excavated, (picks / m3 or ton). Machine utilization is the percentage of time used for excavation during the project Table-I: Classification of the Information in the DatabaseINF

44、ORMATION GROUPDETAILSGeneral InformationType/purpose of excavation (roadway, railway, sewer, mining gallery, etc.), contractor, owner, consultant, location, starting and completion date, etc.Roadheader InformationManufacturer, condition of the roadheader (new, refurbished, direct reuse), specificati

45、ons of roadheader, machine weight, cutterhead power and diameter, bit number and type, ancillary equipment (automatic profile control, water sprays, grippers, etc.)Technical and Operational InformationExcavation length, depth, and gradients, dimensions of excavation profile, operator experience, cut

46、ting sequence at the face, daily and weekly mining hours, muck evacuation system, ground support system, etc.Rock Mass Information For Each Rock ZoneGeological origin, number and character of geological zones, hydrogeological conditions, rock mass classifications, RQD, bedding properties, joint set

47、properties (orientation, spacing, roughness, filling, etc.)Intact Rock Information For Each Rock ZoneRock cuttability properties, uniaxial and tensile strength, elasticity modulus, surface hardness, texture (porosity, mineral / quartz content & grain sizes, microfractures, etc.), abrasivity properti

48、es, etc.Performance Records For Each Rock ZoneCutting rates, bit and holder consumption, roadheader utilization and availability, energy consumption, average and best advance rates (shiftly/daily/weekly/monthly), major obstructions to excavation operation, downtime analysis (roadheader related stopp

49、ages, backup system stoppages, ground and support stoppages, etc.)The Earth Mechanics Institute of the Colorado School of Mines jointly with the Mining Department of the Istanbul Technical University has established an extensive database related to the field performance of roadheaders with the objective of developing empirical models for accurate and reliable performance