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In underground mining, loading and haulage operations have as their main goal to be
efficient, and the deeper they can reach the higher their costs are. The selection of a proper
system, or a combination of systems, depends upon the associated costs, as well as the
expected return on investment. Therefore, it is very important to properly evaluate the options
so as to make the right decision.
In this work, it is shown the sizing of a hoisting system depends on calculating the motor
power, rope diameter, sheave diameter, material volume to be moved, and work cycle
variables like frictional resistance, inertia, and acceleration that allow the system to reach
appropriate speeds. The rope, it should resist the tensile stress, considering safety factors. To
obtain an optimal solution to this multivariable problem, it is necessary to use nonlinear
modelling, which will provide a solution based on an objective function subjected to
restrictions.
Keywords: sizing, optimization, hoisting, nonlinear programming.
Introduction
After technical studies have proved the feasibility of mining an orebody by an underground mining method, there are two
ways to bring the ore to the surface: (1) building a ramp and haulage of the ore with trucks, or (2) building a shaft and
hoisting the ore in a skip. The choice between the systems is closely connected with operational costs. When hoisting
system is chosen rather than haulage operation, it is so because the latter would be economically and technically unfeasible
(Harmant, 1992).
Therefore, the choice of the hoisting system allows solving the ore extraction problems with trucks. Consequently,
hoisting improves productivity and moreover, the profit to the mining company.
The following information is important to a thorough analysis in evaluating the force applied to the motor. (Hartman,
1992; Bise, 2003): (1) work layout, (2) shaft or inclined plane, (3) load weight, (4) skip and cage weight, (5) hoist rope
length and weight, (6) shaft depth, (7) drum dimensions, (8) equivalent effective weight, (9) hoisting speed, (10) required
production, (11) components and total cycle time, (12) acceleration and braking.
Methodology
The present study involves an in-depth literature review, relating equipment sizing and physical and rational mechanics
in order to evaluate the forces and strains that act in a hoisting system; the theoretical study was done by numerical
methods using Mathcad 14. A mathematical analysis considering classical analyses with Excel and Microsoft Word was
used to demonstrate them.
13
SECTION a-a'
a'
Headframe
2 55 -CAT
SURFACE
Hoist
CATERPILLAR
255
Skip
Figure
1 Hoisting system in an underground mine
Rope: wire ropes are mechanical elements used for power transmission between large distances; this type of
transmission is very economical considering the relationship between large distances and high power.
The wire rope is composed basically of a set of steel wires combined into a helical bundle, forming a metal rope resistant
to tensile stress and having a very high flexibility.
The main objective of the wire rope in a hoisting system is to connect the transport vehicle to the hoist. It should be
selected in consideration of safety, compatibility, life, and cost. Safety requirements are higher when people are being
transported or when there is any damage risk, and usually follow rules imposed by international legislation. The life of a
rope is usually determined by the number of trips made, and its durability is affected by the rope construction mode, drum
and sheave size, type of load, environmental conditions, and maintenance.
Rope selection: for rope selection, initially four requirements must be considered: (1) strength, (2) fatigue resistance,
(3) abrasion resistance, and (4) resistance to crushing or distortion. The choice should be made after correctly estimating
the importance of each of the above requirements. Of course, the strength is the main concern.
To evaluate and improve the life of a wire rope, its performance and safety, it is necessary to take into consideration,
as well as dimensional and geometric factors, factors related to the environment, and to respect a predetermined
maintenance programme.
Rope tension
When the rope passes around the drum and the sheave, the outer wires are under tensile stresses while the inner wire
suffers compression. To analyse the induced stress, the principle of the elastic beam (Nash., 1982; Beer et al., 2006) is
adopted and therefore the equations that govern the state of tension in the beam are considered valid for the rope, provided
that they are within the limits of elastic deformation. On the other hand, the forces acting on the rope must be measured
in order to define the appropriate section that can withstand the tensile stresses to which it is subjected.
Re-arranging the Euler-Bernoulli equation relating bending to deformations in a folded cable, one can obtain the
equation
= Eyc R
which evaluates the fatigue produced by folding, where is the induced stress, E is the elasticity module, yc the
distance between the center of the cross-section of the cable to the outer fibres, and R is the radius of curvature, which is
defined by the radius of the sheave or drum.
Considerations for calculating the hoisting cable
Safety factor
According to the Mine Safety and Health Administration (MSHA) in the code of federal regulations in section 55/56 /
57.19-21 and 75 / 77.1431, the minimum safety factor is the ratio between the permissible resistance (
aplic
applied resistance (
) and should be equal to: 7 - 0.001L; where L is the length of the cable suspended from the
sheave to the skip, as shown in Figure 1 (Hartman, 1992).
On the other hand, there are standards adopted by each country and in them are specified safety factor values for ore
lifting operational rope (hoisting ore in underground mining), as may be illustrated by the Brazilian standard NBR ISO
2408, which follows international standards.
Safety
factor
Static cord
3-4
4-5
Cranes
6-8
15
Rope fleet angle is the angle ( = ) subtended by the hoist rope and the centre line from the idler sheave to the drum,
and this angle should be the least possible ( 2.0 for non-rotary steel ropes and drum surface with groove), to avoid
chafing between the rope sheave contact (Hartman, 1992). A large angle can be a major factor in the breakup of the cable
on the winch, and a small deviation angle makes the cable tangle.
Stresses in a hoisting system
In the process of hoisting, the motor must apply a force F required to lift the material at a certain speed. The force is
transmitted through the rope. The amount of force F should consider the equipment efficiency, as well as forces opposed
to displacement.
In an ore hoisting system, the situation in which there is a greater force required for the motor to move the load should
be analysed. This is considered the most adverse condition, so that the design of the motor power and the components are
in line with the force required. Given this, the critical stage in hoisting material is when the skip is fully loaded (ore or
sterile) an at rest, effective gravity, friction in contacts, rate of production, production requirement. In addition, the force
should meet the security demands set for the rope, permissible speeds in production, and strength increases due to inertia.
16
F2
= e
F1
[1]
where
F2: required force to move the rope (clockwise)
F1: set of forces acting in the opposite direction to the displacement and against the force F2
K: constant dependent on the characteristics of the cable and tangential velocity of the sheave
u: coefficient of friction that exists between the rope-sheave contact
a: angle that corresponds to the the contact surface between rope and sheave.
17
Depth
Skip weight
Ore weight
Production
acceleration, retardation time
Fixed times
traction resistance (x1000)
Ratio rope /sheave diameter
Rope diameter
Sheave diamater
Sheave diamater
Sheave diamater
Rope linear weight
ft
lb
lb
tonne/h
s
s
lb
in
in
ft
m
lb/ft
1969
####
####
####
7,5
45,0
432
####
####
120
10
3,05
8,46