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Maximum performance in large-scale opencast mining
Surface Miner 4200 SM
Cut, crush and load in a single working pass
The 4200 SM surface miner is the ideal choice for the
mining of hard rock or soft rock on a truly grand scale.
Tremendous mining capacity, unmatched economic efficien-
cy and flexible adaptability to most diverse operating condi-
tions and mining regulations count among the outstanding
hallmarks of this high-performance machine. Up to 3,000 tons
per hour of material can be mined in a single operation, with
a single machine and a one-man crew. The four conventional
work steps of drilling, blasting, loading and crushing are
eliminated, as are the unpleasant side effects of dust and
noise. And what’s more: the simple process incurs low
levels of capital expenditure and operating costs, and the
reliable Wirtgen after-sales organisation ensures excellent
availability around the globe.
Reaching new performancedimensions with the 4200 SM
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The 4200 SM surface miner is on offer in two different
model versions – one for the mining of hard rock, and
one for the mining of soft rock.
The diameter of the cutting drum installed in the
4200 SM model for hard rock permits high cutting
performance.
The 4200 SM for soft rock has been designed for a high
conveying capacity – its cutting drum with large diameter
permits the throughput of large material quantities.
Discharge conveyors of different lengths and variable
loading height ensure optimum loading of the trucks on
hand.
Just one machine in operation
Surface mining does away with a whole bundle of time-consuming work processes
High yield rates make the miner aneconomical, cost-effective machine
Wirtgen surface miner
Drilling Blasting Loading Crushing
Mining rock in a single cutting operation
Cutting drum dimensions customized to performance
The cutting drums of the 4200 SM from Wirtgen are
made-to-measure products: they are adapted to the
required grain size, hardness of the material to be mined,
and other customer-specific requirements. Tailoring the de-
sign of the cutting drum – such as the best choice of cutting
tools and their arrangement on the drum – to any given ap-
plication is based on the unique expertise gained in several
decades of experience in the field of cutting technology.
The cutting drum works against the miner’s direction of
travel in an effective way: the favourable angle of penetration
produces a comma-shaped chip which breaks out upwards.
Energy consumption during the mining operation is thus
reduced, vibration levels are kept to a minimum, and the
machine works much more efficiently.
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Using cutting tools of top quality, which are specially
tailored to both the operation and the machine, the
4200 SM achieves top production rates at low tool
wear and tear.
Unlike drilling and blasting, mining by cutting easily
complies with the strict requirements in terms of safety,
vibrations, dust and noise.
In tough opencast mining operation, the miner’s
mechanical cutting drum drive with multiple V-belts is
distinctive for its high efficiency and ease of maintenance.
The fluid coupling installed upstream of the drive system
absorbs vibrations, operates wear-free and requires little
maintenance.
Cutting proves moreeffective than drilling
and blasting
The new HT14 heavy-duty quick-change toolholder system (option)for the quick replacement of toolsand reduced machine downtimes
Each cutting drum is designed in line with the specific
operating conditions it isintended for, using state-of-the-
art 3D CAD technology
Clamping sleevemade of spring
steel for easy toolreplacement
Unique wear plate for easy insertion of tools andoptimum tool protection
Toolholder welded into the prism of thebottom part
High-qualitycarbide
metal for top-quality
cutting results
Heavy-duty design withlarger diameter compared
to the HT6 system
Forged steel part for exceptionally high resistance to wear and tear
Especially tough and wear-resistant, yet easily weldable
Flexibility comes as standard
Optimized loading is of vital importance to ensure the
economical mining of large mineral deposits. Not only
the ample conveying capacity of the 4200 SM’s loading
conveyor leads by example in this regard, however, but also
its outstanding flexibility: a tremendous slewing angle of
180°, height adjustment and continuously adjustable belt
speed ensure the smooth loading of large transport trucks
even in space-restricted conditions. The material is passed
onto the loading conveyor immediately after cutting,
dispensing with laborious and time-consuming loading after
blasting by means of separate loading equipment – one
machine and one operator is all that it takes. It is not only
this part of the operation, however, but the entire process of
mining, crushing and loading that is completed in a smooth
and cost-effective way.
Reliable loading of large quantities of rock
6 // 7
The primary conveyor transports the material to the dis-
charge conveyor, which is available in two different
lengths to ensure optimum loading of different truck
sizes in opencast mining.
The conveyor drive has tremendous power reserves
to ensure full conveying capacity even when mining
ores of high specific weight.
Loading towards the rear, combined with the counter-
rotating cutting drum, guarantees an excellent material
flow.
The 16-m long discharge conveyor (optional) permits
the powerful loading of all heavy-duty trucks in the 240-t
class.
Economic efficiency,high power
The crusher bar prevents thematerial from breaking into largeslabs, protecting the conveyors
from wear and tear
Slewing angles of up to 90° toboth sides allow perfect adjust-ment to conditions in the deposit
The movable counterweightprovides stability and is easilyretracted when working along
steep sidewalls
Moving into position without losing time
Despite its huge size, the 4200 SM is surprisingly
manoeuvrable and easy to handle. This is due in no
small measure to the surface miner’s all-track steering,
which no other steering system is able to match up to. The
smooth hydraulic steering system enables large angles of all
four crawler track units. In addition, two switchable flow
dividers act as differential lock and ensure uniform traction
even when working on extremely difficult ground. The
system permits three different steering modes: the rear and
front crawler tracks are steered in opposite directions when
moving into position; the front tracks are steered to produce
long, straight cuts; and all four crawler tracks are steered in
the same direction in crab mode to enable the miner to be
repositioned laterally.
Manoeuvrability – a key efficiency driver
8 // 9
Easy manoeuvring of the 4200 SM increases operator
comfort, enabling the machine operator to remain fully
focused on the actual job.
Effortless turning manoeuvres and modest space
requirements increase productivity by keeping non-
productive times as short as possible.
The four crawler tracks can be adjusted in height sepa-
rately via hydraulic cylinders to allow accurate setting of
the cutting depth and lateral inclination.
The advance rate of the surface miner can be adjusted
continuously from zero to maximum speed.
Quick and easy manoeuvring
The heavy-duty crawler track units are driven separately
by hydraulic motors
Small turning circle throughsteering the front and rear crawlertrack units in opposite directions
Separately height-adjustablecrawler track units
Ergonomic design of operator’s platform increases operator comfort
The productivity of the 4200 SM increases in propor-
tion to the miner operator being able to focus on his
job. We have therefore made sure that he can always feel
well and safe. The cabin is located above the front, left-hand
crawler track unit – far away from the cutting drum and the
engine, soundproof and isolated against vibration. To ensure
perfect visibility during loading and steering, the entire, fully
glazed cabin can be swivelled about 45° to both sides. The
individually adjustable driver’s seat can additionally be
swivelled about 135° to either side. Effortless control of the
entire mining operation is ensured by the clearly structured
control panel and controls integrated in the armrests.
Air-conditioning and heating systems come as standard,
permitting work independent of weather conditions and
complementing the 4200 SM’s comfort package.
No compromises in operator comfort and safety
The standardized FOPS roofeffectively protects the operatorfrom falling objects
The panorama cabin can beswivelled about 45° in all directions
to guarantee optimum visibility
10 // 11
The comprehensive lighting system with numerous
Xenon spotlights brightly illuminates the entire machine,
the surface ahead of the machine and the discharge
area.
The access ladders and walkways made of anti-skid
grating are illuminated to comply with specific mining
regulations.
Additional, authority-approved safety features include
the FOPS roof, a second emergency exit, fire extinguish-
ers and covers on all rotating parts.
The cabin’s location on the side of the machine oppo-
site the embankment wall is yet another major criterion
for safety at work.
Safety at work comes first
The driver’s seat can be swivelledabout 135° to either side – including
the controls in the armrests
All major control functions and joysticks are convenientlyintegrated in the seat’s armrests
Wide, hydraulically operatedaccess ladders provide safety
and convenient access
Keeping downtimes to a minimum
Machine maintenance is synonymous not only with
costs but also with costly downtimes. The 4200 SM
impresses with low maintenance requirements, prolonged
maintenance intervals and thus extremely short downtimes.
Maintenance is due after every 1,000 hours only. The points
of maintenance are safely accessible via wide, brightly lit ac-
cess ladders and walkways, and are easily reached thanks
to wide-opening service panels. Maintenance procedures
on the clearly arranged points of servicing are completed in
just a few swift moves. It goes without saying that reliable
technical support on site and the supply of spare parts and
wearing parts pose no problem at all: the availability of the
4200 SM on an everyday basis is ensured by around
60 sales and service companies around the globe.
Cut costs with minimum service requirements
12 // 13
In addition to the prolonged maintenance intervals, extra
big fuel and water tanks ensure extended productive
uptimes.
The low investment costs in just one operator, one
machine, one maintenance crew and spare parts for
one machine pay off quickly.
The optional HT14 quick-change toolholder system
ensures quick tool replacement, low wear and tear, and
therefore high daily production rates.
Convenient access to the cutting drum and quick
positioning by means of the drum turning device
optimize the simple replacement of cutting tools.
Low servicingrequirements
Convenient access to the points of maintenance via
access ladders and walkways
The engine compartment insidethe machine offers ample room tomove for maintenance procedures
Hydraulic cutting tool driver and extractor for quick tool replacement
Complete regular procedures quickly and conveniently
Time-saving features that pay off quickly
It has been our top priority in the design of the 4200 SM
to permit regular procedures during operation to be
carried out quickly and easily. High-quality components and
design optimizations, such as a larger oil sump, enable the
maintenance intervals to be extended from 250 to 1,000
hours. After opening the service panel at the side of the ma-
chine, the readily accessible filling station allows easy supply
with operational materials and consumables. The long travel
range of the front height adjustment permits convenient,
spacious access to the cutting drum for the replacement of
cutting tools. Particularly effective: detachment of the pri-
mary conveyor is simple and does not require any additional
steps, thus preventing long machine downtimes during belt
replacement.
Intelligent detailsoffering soundfinancial benefits
The filling station is reached quicklyand easily from the ground
Replacing belts in the blink of an eye: lower conveyor frame
hydraulically, detach and remove
Discharge conveyor in working position
Primary conveyor in position for detachment
Primary conveyor in working position
2
Position of discharge conveyor fordetachment of primary conveyor
1
2
1
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4200 SM high-end miner: the perfectchoice for large-scale opencast mining
No job is too big for our biggest surface miner! It is the
prime choice for mine operators and customers in
large-scale opencast mining whose goal is to achieve an
annual mining capacity in soft rock of up to 12 million tons
with a single machine. Conventional methods, on the other
hand, require four working steps. The 4200 SM cuts, crush-
es and loads rock with unconfined compressive strengths of
up to around 80 MPa while producing even, stable surfaces
at the same time. The 4.20 m wide cutting drum has a small
diameter for working in hard rock, and a large diameter for
mining soft rock. The giant is driven by a powerful 16-cylin-
der diesel engine, yet impresses also in terms of economic
efficiency on account of its low specific fuel consumption
and automatically engageable power control.
Drum diameter: 1,500 mm Milling depth: 0 - 650 mm
Drum diameter: 1,860 mm Milling depth: 0 - 830 mm
Solid rock
Unconsolidated rock
Fine-grained rock
Coarse-grained rock
3000
2500
2000
1500
1000
500
0
Cut
ting
per
form
ance
(m3 /
h)
UCS (MPa)
10 20 30 40 50 60 70 80
Cutting performance of the Wirtgen 4200 SM surface miner
Illustrations are non-binding and may include customized fittings. Subject to technical changes. Performance data depend on operational conditions. No. 25-14 EN-04/09 © by Wirtgen GmbH 2009. Printed in Germany
Wirtgen GmbHReinhard-Wirtgen-Str. 2 · 53578 Windhagen · Germany
Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-242Internet: www.wirtgen.com · E-Mail: [email protected]