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Date submitted2023-03-14
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Date accepted2023-06-20
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Date published2023-07-19
A reliability study of the traction drive system in haul trucks based on failure analysis of their functional parts
The efficiency of a mining and processing plant depends on the level of complex mechanization of the production process. In mineral extraction, haulage is a major cost category, with haul trucks being the key component of the mining transportation system. To improve production performance, mining operations can increase their haulage turnover and reduce transportation costs, which necessitates making haul trucks more reliable. This can be done by improving their mean time to first failure (MTFF) indicators. This article analyzes the reliability status of the traction drive system inhaul trucks operating in the mineral resources sector. It provides a quantitative assessment of traction drive system failures resulting from part defects and discusses the associated repair costs. By examining failure data from 2018 to 2022 and the results of vibration tests performed on a diesel generator, the study reveals that the most expensive failures are associated with defects in the synchronous generator, which are primarily caused by elevated external vibrations. Based on basic vibration tests and vibration spectra tests at different operating modes, recommendations have been formulated concerning the generator’s robustness to external mechanical forces and the ways to increase the generator’s protection grade to prevent dust intrusion. The study also identifies the frequency range that poses the greatest risk of damage to the windings.
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Date submitted2022-08-10
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Date accepted2023-02-28
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Date published2024-02-29
Selection of the required number of circulating subs in a special assembly and investigation of their performance during drilling of radial branching channels by sectional positive displacement motors
The task of sludge removal to the surface during construction of directional and horizontal wells and strongly curved radial channels is relevant. For stable operation of technical system “Perfobore”, it is proposed to use a circulating sub that ensures efficient cleaning of channel wellbore from the drilled rock. Two schemes of technical system “Perfobore” are considered, consisting of two seven-meter coiled tubing, a positive displacement motor, a bit and one circulating sub in the first scheme and two subs in the second scheme. For each of the schemes CFD modeling was implemented to determine values of pressure and speed. It was found out that the use of two circulating subs in the assembly is more efficient. In order to confirm the numerical experiment, bench tests were carried out. It was determined that the designed circulating sub can eject up to 25 % of pumped drilling fluid. The bench tests of full-size technical system “Perfobore” for drilling 14-meter channels with two circulating subs showed that the axial load on positive displacement motor produced by hydraulic loader was 3000 N and pressure drop depending on flow rate was 1.5-2.0 MPa. This allows the motor to operate at maximum power.
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Date submitted2021-02-20
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Date accepted2021-05-21
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Date published2021-09-20
Analysis of the screw press mouthpiece parameters for 3D extrusion of peat pieces of tubular type
The results of theoretical and experimental studies on the creation of a screw press composite mouthpiece screw press for 3D-forming of peat pieces of a tubular type in the field for intensifying the process of field drying of material in a complex mechanized pit are presented. The main purpose of the study was to substantiate the geometric and design parameters of the screw press composite mouthpiece of the spread machine for the production of peat-agglomerated products of the tubular type. The parameters of the mouthpiece are selected based on the geometric characteristics of the peat pieces. An increase in moisture loss during drying of peat-agglomerated products is provided by forming a peat piece in the form of a thick-walled pipe made of a peat raw materials composed of low and high decomposition degrees in a ratio of 1:3. Additive production of polymer-fiber peat composites by extrusion allows to produce products with improved mechanical properties in comparison with non-reinforced raw materials. The vertical arrangement of the peat tubular piece on the drying field allows to increase the loading of the field area by 10 %, increase the convective heat supply to the piece and reduce the contact coefficient of the piece with the field by three times in comparison with the peat spreading of the pieces in the form of a horizontal tape. Based on the analysis of the shape and size of the agglomerated products, the design of a screw press composite mouthpiece consisting of two conditional molding zones of various configurations has been developed. The article presents a parametric analysis of the volumetric productivity of a screw press with a composite mouthpiece of a tubular type, the energy intensity of mechanical processing is determined, the degree of mechanical processing of peat raw materials is estimated with the optimization of the screw parameters for the production of agglomerated products of a tubular type.
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Date submitted2020-05-16
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Date accepted2021-03-02
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Date published2021-04-26
Study of drive currents for lifting bridge cranes of metallurgical enterprises for early diagnosis of load excess weight
The article discusses an approach based on the analysis of the drive motor currents to create an additional means of protection against emergency situations during the operation of bridge cranes associated with lifting a load with a mass exceeding the permissible one . A mathematical model of an overhead crane drive is described, as well as the results of computer simulation. It is shown that in the process of lifting up, before the stage of lifting the load, the stator current of the drive electric motor does not depend of the load mass, but when the load is detached, already for several periods of the mains voltage after the rope is pulled, when the mass of the load is exceeded, a measurable excess of the amplitude value of the current is recorded. This pattern has been confirmed for a number of cranes of various lifting capacities used at metallurgical enterprises. The possibility of diagnosing excess weight of the lifted load with a higher speed than existing mechanical methods of overload control is demonstrated, at the same time it is not required to make changes to the structural elements of overhead cranes.
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Date submitted2019-10-30
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Date accepted2019-11-23
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Date published2020-02-25
Methodology for determining the parameters of drilling mode for directional straight sections of well using screw downhole motors
- Authors:
- Vladimir S. Litvinenko
- M. V. Dvoinikov
Article presents results of study on possibility of increasing the efficiency of drilling directional straight sections of wells using screw downhole motors (SDM) with a combined method of drilling with rotation of drilling string (DS). Goal is to ensure steady-state operation of SDM with simultaneous rotation of DS by reducing the amplitude of oscillations with adjusting the parameters of drilling mode on the basis of mathematical modeling for SDM – DS system. Results of experimental study on determination of extrema distribution of lateral and axial oscillations of SDM frame depending on geometrical parameters of gerotor mechanism and modes ensuring stable operation are presented. Approaches to development of a mathematical model and methodology are conceptually outlined that allow determining the range of self-oscillations for SDM – DS system and boundaries of rotational and translational wave perturbations for a heterogeneous rod with an installed SDM at drilling directional straight sections of well. This mathematical model of SDM – DS system's dynamics makes it possible to predict optimal parameters of directional drilling mode that ensure stable operation of borehole assembly.
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Date submitted2019-07-07
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Date accepted2019-09-13
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Date published2019-12-24
Installation for experimental research of multiphase electromechanical systems
- Authors:
- V. M. Tereshkin
- D. A. Grishin
- I. A. Makulov
The subject of this study is an installation for experimental research designed to study the characteristics and control algorithms of multiphase motors with the number of working phases from 3 to 8, connected by a star, a triangle, or in another way, allowing phase currents to flow, creating a rotating electromagnetic field. The installation consists of two separate independent units: a controller, or a human-machine control interface, and a power inverter module (converter). The controller is connected to the converter by a two-wire half-duplex interface (RS485) via the Modbus RTU communication protocol. The installation also includes synchronous motors with the number of phases 3, 5, 7. Using the developed installation for experimental research, it is possible to carry out experimental studies of multiphase motors when implementing various control algorithms for a converter that implements pulse-width vector modulation. The time required to implement control algorithms is minimal. According to the results of the experiments, it is possible to carry out a comparative analysis of multiphase motors in terms of energy efficiency, in terms of vibration of electromagnetic origin, in dynamic parameters. An experimental assessment of the load of the converter keys is possible. The created installation is an effective tool for checking the reliability of the results of theoretical studies of electromechanical systems based on multiphase motors.
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Date submitted2019-07-10
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Date accepted2019-08-30
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Date published2019-12-24
Methodology for calculating technical efficiency of power sections in small-sized screw downhole motors for the «Perfobur» system
With an increase in the share of old and low-yield wells and for the efficient exploitation of fields, it is necessary to include low-capacity formations into production. There are many wells where sidetracking and hydraulic fracturing are difficult due to the close proximity of the gas cap and underlying water caused by geological and technological reasons, and the use of existing secondary drilling-in technologies is not effective due to the extensive colmatated zone or annular circulation. Relevance of radial drilling technologies is growing, which allows drilling-in of the formation with a network of extended channels to establish high-quality hydraulic communication between the formation and the well without affecting the permeability of the formation. In contrast to radial drilling technologies using hydraulic washing, technical system (TS) «Perfobur» uses small-sized screw downhole motors (SDM) and rock cutting tools for channel construction. For efficient milling of production casing and destruction of rock, the hydraulic downhole motor must have high torque, and for the possibility of drilling with a high rate of angle gain, it must have short power section. Existing Russian and foreign SDM have limited number of standard sizes and do not meet the requirements specified for the development of the downhole module of TS «Perfobur». The paper discusses the development of universal small-sized sectional screw downhole motors for milling casing strings and drilling a network of branched channels of super-small diameter and radius of curvature as a part of the TS «Perfobur». Methodology proposed in the article for selecting optimal configuration of the SDM power sections allows constructing small-sized sectional downhole motor that meets the technical requirements and has improved characteristics compared to standard SDM.
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Date submitted2019-05-05
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Date accepted2019-07-03
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Date published2019-10-23
Scraper Face Conveyors Dynamic Load Control
- Authors:
- E. K. Eshchin
The task of controlling the dynamic loading of scraper face conveyors (SC) is considered and the unsatisfactory state of loading of mechanical and electrical components of the SC is recorded. The possibility of the appearance of a self-oscillatory nature of the entire system load due to the peculiarities of the movement of the traction chain along the lattice frame of the SC is indicated. The property of the system is noted – the cyclic nature of the loading of the circuit during movement, which causes energy exchange processes between the mechanical and electromotive components of the conveyor (when using the head and tail electric drives) through the common cable network of the power supply system of the SC. A high level of dynamic loading of the electromechanical system causes the problem of eliminating the self-oscillating operating mode of the SC that generates it which is proposed to be solved by changing the angular rotation speeds of the SC drive sprockets. Angular speeds can be changed by applying frequency control of asynchronous electric motors. The efficiency of setting the frequency of electric motor stator currents of the head and tail drives of the conveyor is established in proportion to the frequency of rotors rotation to eliminate self- oscillating modes of operation in the main operating mode. The possibility of reducing the starting shock values of the electromagnetic moments of electric motors is considered. The results of the calculation of the start-up and liquidation of the self-oscillating operating mode are presented on the example of the scraper face conveyor Anzhera-34. The results of calculations of the start-up modes and the main operational transportation of coal in an uncontrolled mode of operation and after the introduction of control are compared, based on which it is concluded that it is advisable to use active control of the dynamic loading ofSC.
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Date submitted2019-03-21
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Date accepted2019-05-05
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Date published2019-08-23
Stimulation of the Drilling Process with the Top Driven Screw Downhole Motor
- Authors:
- S. L. Simonyants
- M. Al Taee
Paper considers application of the top driven screw downhole motor during drilling of directional wells. The advantages and disadvantages of the rotation-sliding technology with implementation of top drive together with screw downhole motor are shown. It has been proven that the use of a screw downhole motor with simultaneous rotation of drilling pipes using the drilling rig's top drive allows increasing the bit rotation frequency without additional loading of the drilling string. Field data for the work out of one-type PDC bits in identical geological and technical conditions with different types of drives during the construction of three directed wells at the Rumaila oil field of the Republic of Iraq were obtained. A regular increase in the mechanical penetration rate, which is explained by an increase in the bit rotation frequency, has been proved. According to the data obtained, a comparative analysis of the drilling indices was carried out, as a result of which the feasibility of joint use of top power drive with screw downhole motor at drilling oil and gas wells was proved.
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Date submitted2018-09-08
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Date accepted2018-10-27
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Date published2019-02-22
Special strategy of treatment of difficulty-profile conical screw surfaces of single-screw compressors working bodies
- Authors:
- A. S. Vasilev
- A. A. Goncharov
The article deals with the problems arising during the shaping of complex profile tapered helical surfaces. These surfaces form the geometry of the working bodies of single-screw miniature compressors, which have great prospects for use in mobile miniature compressor plants, which is especially important for medical and space technology, robotics, oil and gas and mining industries. Due to the fact that the capabilities of existing CAD systems do not allow obtaining three-dimensional models of these surfaces, the problem of preparing a control program for a CNC machine arises, since the calculation of the tool path in CAM systems when processing complex surfaces is impossible without a three-dimensional surface model. To solve the problem, an automated programming system was developed that implements a formalized toolpath calculation in accordance with the proposed special processing strategy for conical helical surfaces. As the initial data for calculating the toolpath, the system needs information about the tool geometry and the helical surface in a parametric form, which makes it possible to abandon the construction of a three-dimensional surface model. The results of processing prototypes for the proposed strategy are given.
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Date submitted2018-09-07
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Date accepted2018-11-10
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Date published2019-02-22
Justification of the technological parameters choice for well drilling by rotary steerable systems
- Authors:
- Vladimir S. Litvinenko
- M. V. Dvoinikov
Paper presents the analysis of the investigation results of vibrational accelerations and beating amplitudes of the downhole drilling motor, which help to define the ranges of optimum energy characteristics of the gerotor mechanism, ensuring its stable operation. Dependencies describing the operation of the «drilling bit – rotary steerable system with power screw section – drilling string» system and the values of the self-oscillation boundaries and the onset of system resonance when it is used jointly, were defined as a result of computational and full-scale experimental research. A mathematical model is proposed, which allows determining the optimal range of technological parameters for well drilling, reducing the extreme vibration accelerations of the bottomhole assembly by controlling the torque-power and frequency characteristics of the drilling string, taking into account the energy characteristics of the power screw section of the rotary steerable system. Recommendations on the choice of drilling mode parameters were given.
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Date submitted2018-05-05
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Date accepted2018-07-18
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Date published2018-10-24
Calculations of dynamic operating modes of electric drives self-propelled mining machines
- Authors:
- E. K. Eshchin
The task of improving the calculations of the dynamic modes of electric drives of self-propelled mining machines, particulary, tunneling machines, is considered. Attention is drawn to the possibility to opearte in dynamic modes of a spatial change in the an asynchronous electric motor stator housing position, included in the electric drive, around the axis of its rotor due to the ultimate rigidity of the supports of the mining machine. In connection to this, it is possible to change the absolute angular velocity of rotation of the electromagnetic field of the stator of this electric motor. The necessity of introducing into existing mathematical models that determine the state and behavior of asynchronous electric motors, additional differential and algebraic relations for calculating the absolute speed of the electromagnetic field of the stator and the nature of the motion of the stator housing of the electric motor as part of the mining machine is noted. The results of calculations of the idle start mode of the electric motor of the executive body of the mining combine are shown, showing the difference in the nature of its electromagnetic moment variation, rotor rotation speed, as well as efforts in individual reducer elements of the driving body driving the stator body from similar calculation results without taking into account the stator body movement. The conclusion is made about the possible discrepancy between the calculated and experimental results in the study of the dynamic modes of self-propelled mining machines.
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Date submitted2017-09-03
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Date accepted2017-11-04
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Date published2018-02-22
Development of sensorless vector control system for permanent magnet synchronous motor in Matlab Simulink
- Authors:
- V. Ya. Frolov
- R. I. Zhiligotov
In last 20 years segment of electric drives with permanent magnet synchronous motors has increased. This type of motors has better technical characteristics compared to induction motors, but has problems in actual implementation, one of which is the requirement of rotor position data. It is possible to implement with use of sensors or without them by means of motor state observer. The paper describes problems of sensorless vector control system for permanent magnet synchronous motors. The vector control system with state observer for permanent magnet synchronous motors is described. Synthesis of sliding mode observer for rotor speed and position is presented. The algorithm is implemented by development of model in Matlab Simulink environment with support by Texas Instruments processors support blocks. Experimental comparison of results of rotor angle state calculation and the data obtained by rotor position sensors was conducted. Research objective is a development of control algorithm, which has required precision for calculation of rotor start angle, high range of speed regulation and resistance to drift of motor parameters.
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Date submitted2016-09-01
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Date accepted2016-11-05
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Date published2017-02-22
Research on technical and technological parameters of inclined drilling
- Authors:
- M. V. Dvoinikov
An analysis of operational capabilities of inclined drilling equipment and technology is presented. Two options of rotary drilling are reviewed as technical and technological solutions, facilitating construction of wells with difficult profiles. The first option implies that the driver unit of the drill bit is represented by downhole drilling motor, the second one utilizes sophisticated rotary steerable systems. Practical results of drilling wells with difficult profiles are presented. A quality assessment of drilling is provided through the example of comparing designed and actual trajectories, using different driver units for the drill bit, as well as properties of surrounding rocks, rheology of the drill fluid and other characteristics of dynamically active systems. A range of rotation speed has been determined that allows rotary steerable systems to have minimal oscillation amplitude of the bottom-hole assembly. Analysis of investigation results showed that the main source of oscillations is linked to bending and compressing stresses, caused by well deviations as well as rigidity of the drilling tool. In effect, in the bottom-hole assembly occur auto-oscillations, making it impossible to correct azimuth and zenith angles. Alteration of rigidity in the bottom part of the tool and drilling parameters, implying reduced rotation speed of the drill string and regulation of drill bit pressure, can partially solve this problem, though increase in rotation speed is limited by technical characteristics of existing top drive systems.
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Date submitted2015-08-12
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Date accepted2015-10-05
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Date published2016-04-22
Energy efficient electromechanical systems of mining andtransport machines
- Authors:
- A. E. Kozyaruk
The problems of selecting the type and the structure of mining and transport machines elec-tromechanical control system, providing energy efficiency and performance. The conclusion about the most admissibility of variable frequency drives with induction motors and power semiconduc-tor converters was made. The methods and technical means of improving the energy efficiency of asynchronous electric motors due to the choice of increased power characteristics motors, design of special motor control algorithms and applying of semiconductor converters with active rectifi-ers, providing high power factor and improving of the electricity supply quality were reviewed. To improve the operational characteristics prompted use of diagnostic systems and residual life as-sessment of electrical equipment. Implementation of designs tied to the excavator-transport sector. The schemes of the excavator power drive, mining truck and implemented complex picture at coal mine are shown.
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Date submitted2015-08-03
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Date accepted2015-10-06
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Date published2016-04-22
Technical and technological solutions to ensure stability of downhole drilling motors
- Authors:
- M. V. Dvoinikov
- Yu. D. Muraev
The article shows research analysis of engineering and technological solutions that aimed at improving the efficiency of drilling wells using optimization of dynamic of work downhole drill-ing motors. As the technical solutions that reduce vibration, considered two options of construc-tion of the power section. A first embodiment involves the production of a hollow rotor which can reduce its moment of inertia. The second solution is the production of modular rotor, which are changing the eccentricity (misalignment) of rotating parts of the engine. The research of fluctuations throughout the length of the power section of the working bodies and the spindle of the engine, taking into account changes in its energy characteristics has been con-ducted to ensure stable operation of the engine in a well, identifying optimal loading parameters. Indicators of shaft speed ensuring minimum vibration amplitude of the engine has been Iden-tified. Optimal speed range of the rotor to prevent buckling of the BHA and to sustain its operation is shown to be between 15-20 % of the frequency of the engine at idle. The maximum reduction in speed during the drilling process should not exceed 30 % by conducted research.
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Date submitted2010-07-06
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Date accepted2010-09-14
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Date published2011-03-21
Electromechanical processes in electric drives of mountain equipment on the basis of the synchronous electric motor
- Authors:
- A. O. Sviridenko
The description is given and the function chart of the bench installation is resulted, allowing to reproduce static and dynamic modes of adjustable electric drives of an alternating current. The modes considered during experimental researches of the electric drive on the basis of the synchronous electric motor, working in a mode of ventilniy electric motor are listed. Conclusions are drawn on character of course of dynamic modes, comparison of the electric drive to the synchronous electric motor and the electric drive of a direct current with the subordinated regulation is given.
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Date submitted2010-07-08
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Date accepted2010-09-02
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Date published2011-03-21
The autoresonant asynchronous electric drive of dynamically counterbalanced drilling string on carrying cable with swinging movement fluctuations amplitude stabilization
- Authors:
- E. A. Zagrivnyi
- V. V. Ivanik
The algorithm of resonant fluctuations amplitude stabilization of dynamically counterbalanced drilling string on carrying cable with swinging movement of jackbit is developed. Imitating modeling of the resonant asynchronous electric drive with swinging movement of jackbit with the frequency converter in various operating modes is resulted.
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Date submitted2010-07-26
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Date accepted2010-09-14
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Date published2011-03-21
Algorithm of control of the electric drive with ventilniy electric motor and the converter of frequency with the active rectifier
- Authors:
- A. P. Emelyanov
- A. O. Sviridenko
Advantages of application of the active rectifier as a part of converters of frequency for powerful drives with ventilniy electric motors are considered. The mathematical description of the processes proceeding in a power part of the active rectifier is given. The scheme of a drive with a vector control system with the gage of position of a rotor and the active rectifier is presented, schedules of power consumption and a current by a drive with the active rectifier are resulted.
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Date submitted1951-07-05
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Date accepted1951-09-25
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Date published1952-03-26
Testing of an electric motor with moisture-resistant insulation of a submersible motor-pump with a capacity of Q = 100 m³/hour at a pressure of H = 100 m
- Authors:
- L. F. Shklyarskii
This work was completed in 1950 as a joint venture between the Department of Mining Electrical Engineering of the Leningrad Mining Institute and one of the coal trusts. The electric motor of a submersible motor-pump designed for pumping water from wells in the conditions of the Leningrad coal deposit was tested. Both the pump and the electric motor are completely immersed in water during operation, which significantly distinguishes the design of this motor-pump from all existing ones, in which the electric motor is installed at the top of the wellhead and connected to the pump submerged in water by means of a long shaft (motor-pumps of the ATN type, etc.). The electric motor is made with moisture-resistant insulation of an open type without a hermetic shell.
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Date submitted1950-07-21
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Date accepted1950-09-18
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Date published1951-04-30
Testing the electric motors with new moisture-resistant insulation of submersible motor-pumps with a capacity of Q = 30 m3/hour
- Authors:
- L. F. Shklyarskii
The present work is the result of creative collaboration of the Department of Mining Electrical Engineering of the Leningrad Mining Institute with one of the coal trusts. Electric motors of two submersible motor-pumps were tested. The design data of both motor-pumps are absolutely identical. Only their electrical parts differ slightly: the stator of the electric motor of one of them (motor-pump No. 7) has slightly larger slot dimensions than the stator of the electric motor of the other motor-pump (motor-pump No. 9). Therefore, 16 wires are laid in each slot of the stator of the electric motor of motor-pump No. 7, and 11 wires are laid in the electric motor of motor-pump No. 9. The main data of the submersible motor-pumps with a star connection of the stator winding of the electric motor are as follows: electric motor power on the shaft Pn = 9.2 kW; voltage Un = 380 V; revolutions n = 2900 rpm. Three-phase asynchronous short-circuited electric motor (Fig. 1); pump capacity Qn = 30 m3/hour; pump head Na = 50 m. The total height of the motor-pump is 1400 mm, the height of the electric motor is 930 mm, the diameter of the unit is 183 mm. The electrical and mechanical parts of the submersible motor-pumps are manufactured by the assembly and mechanical workshops of the trust. Submersible motor-pumps of the proposed design, used for pumping water from wells, compare favorably with those currently existing in the following features.