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Procedía Engineering 206 (2017) 1661-1666
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International Conference on Industrial Engineering, ICIE 2017
Predictive Reliability Assessment of Loading and Transport Modules vf Tunneling Equipment during Construction of Road
Tunnels
A. Nosenko, A. Domnitskiy, E. Shemshura*
Platov South-Russian State Polytechnic University (NPI), 132, St. Prosvescheniya, Rostov region, Novocherkassk, 346428, Russia
Abstract
Designs of loading and transport modules applied for the construction of road tunnels are considered. The distinctive feature of modules from conventional designs is the use of wedge working elements in combination with power hydraulic cylinders as a drive.
Basing on health monitoring of the tunneling equipment expected values of loading modules reliability indicators are defined. The forecast is cmmed out based on tine known regularities of change in the reliability of analogs and prototype s of the inve stigeted modules ano their elements. The units aud parts of module s limiting reliability are used for the assessment of reliability.
The decision on the efficiency of application and feasibility of the studied designs of loading and transport modules is made on The basis of s imulati on of* tiicir operation and is determined by the mugnilude of operational c osts with the account of stochastic nature of the flow of module elements oailures.
©2017 The Authore. Published by Eleevier Ltd.
Peer-review under rquponsibility ou the scientific committee of the International Confere nce on Industrial Engineering Keywords: tunneling equipment, road tunnels, loading and transport modules, reliability, reliability assessment.
1. Introduction
The prospect of transport tunnels conotruction is provlaea by the system of deveïopment of highways in the country. Deiving tunnels is the most difficult type of construction works. Mining method is used for tunneling3 in the rock and semi rock with coefficient of hardness exceeding 2 according to Professor Protodjakonov scale [1-3]. The
* Corresponding author. Tel.: +7-918-527-3227. E-mail address: aleshkastyle@gmail.com
1877-7058 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering. 10.1016/j.proeng.2017.10.694
basic methods of rock development in a face are: mechanized, in which the working tools of rock failure are cutters, mills and milling cutters, placed on the operational parts of mining machines, and drilling and blasting, in which caving in rock is accomplished by explosions.
In both cases the use of loading and transport modules as part of tunneling equipment for the construction of transport tunnels proved effective [4,5].
2. Design of loading and transport modules
Loading and transport modules are considered to be mechanisms performing the function of loading stacks of loose rock mass and its removal beyond the bottom zone. Loading and transport modules are characterized by a variety of constructive forms, numerous options of combining loading and transport components.
A promising way to improve the designs of mining machinery is the development of hydraulic loading bodies with wedge working elements [6-9]. The relevance of these developments is due to simplification of conventional kinematic design of the working elements drive. The use of a hydraulic actuator allows to reduce the number of mechanical transmissions. In turn application of a wedge also makes it possible to do without gear groups and to use the least number of power hydraulic cylinders for the accomplishment of movements [7].
At the present time to increase the productivity of loading rock mass when driving tunnels and to implement more efficient modes of operation, a number of innovative solutions for loading bodies with wedge loading arms (fig. 1-3) have been developed [10].
3 4 6 1 3
Fig. 1. Loading body with two hydraulic cylinders and synchronizing shaft. 1 - loading arms, 2 - hydraulic cylinders, 3 - drive plate, 4 - feeder plate, 5 - hydraulic control valves, 6 - synchronizing shaft
The decision on possibility of introduction of various loading and transport modules designs in the production process are based on the predictive assessment of reliability and efficiency of their application.
3. Reliability Estimation and Forecasting
Predicting reliability of loading and transport modules is based on the results of industrial health monitoring of mining equipment in the construction of transport tunnels by "Tonneldorstroy" and excavations at the Eastern Donbass coal-mining enterprises. The monitoring revealed the most significant equipment failures, made it possible
to compile the list of parts and components that affect reliability, to determine actual indicators of working capacity and maintainability [11-15].
Fig. 2. Loading body of MPNK car pilot sample 1 - inclined feeder, 2 - loading arms, 3 - hydraulic cylinder, 4 - stock, 5 - crank, 6 - conveyor
Fig. 3. Multi-grip loading module with counter motion of key and peripheral grips. 1 - inclined feeder, 2 - principal grip, 3 - peripheral grip, 4 - cylinder, 5 - hydraulic cylinder stock, 6 - lever, 7 - leverage, 8, 9 - bearing, 10 - conveyor, 11 - stoppers.
Statistical analysis of information on the efficiency of loading transport modules allows to receive the parameters of distribution of MTBF X and recovery time of wearing components and parts ^ [16] as well as their predicted values for the investigated designs of loading modules (Table 1). As it is hard to predict reliability the range of calculated elements is limited by the group of parts and components "limiting reliability".
Besides, on the basis of the analysis of long-term health monitoring [15] of tunneling cars of various designs reliability indicators are established (Table 2).
Table 1. Expected reliability indicators of loading modules.
Specified life MTBF Recovery
Elements (knots) limiting reliability Vo, To, time, TV, X-10"3
m3 -103 m3 -103 h
Loading unit with two hydraulic cylinders and a synchronizing shaft (Fig. 1)
Feeder 100 20,0 3,00 0,050 0,33
Plates (2 pieces) 20 20,0 2,00 0,100 0,50
Loading arms (2 pieces) 20 20,0 2,00 0,100 0,50
Hydraulic cylinders (2 pieces) 25 8,0 3,00 0,250 0,33
Hydraulic cylinder seals 20 7,0 0,75 0,143 1,33
Hydraulic control valve 20 6,5 3,00 0,151 0,33
Loading module as a whole: 2,29 0,797 0,44
Loading module with loading arms rigidly connected to the housings of hydraulic cylinders (Fig. 2)
Loading arms (2 pieces) 20 20,0 2,00 0,100 0,50
Joints(2 pieces) 20 7,6 12,0 0,262 0,08
Hydraulic control valve 20 6,5 3,00 0,151 0,33
Hydraulic cylinder seals 20 7,0 0,75 0,143 1,33
Hydraulic cylinders (2 pieces) 25 8,0 3,00 0,250 0,33
Feeder 100 20,0 3,00 0,050 0,33
Loading module as a whole: 3,96 0,709 0,25
Multi-grip loading module with counter motion of key and peripheral grips (Fig. 3)
Feeder 100 20,0 3,00 0,050 0,33
Grips (6 pieces) 20 20,0 2,00 0,300 0,50
Hydraulic cylinders (2 pieces) 25 8,0 3,00 0,250 0,33
Hydraulic cylinder seals 20 7,0 0,75 0,143 1,33
Hydraulic control valve 20 6,5 3,00 0,154 0,33
Loading module as a whole: 2,35 0,897 0,43
4. Efficiency Assessment of the loading and transport modules design
Predictive reliability parameters obtained are used as input data for simulation of the process of mining equipment operation in tunnel construction [17].
Modeling of loading and transport modules workflows and maintenance processes is carried out with the account of stochastic nature of flows of failures and restoration of healthy state of the module individual elements and aimed at determining operational costs.
Mathematical models of loading and transport modules efficiency, time of auxiliary operations, forecasting of volumes and range of spare parts supply, technical operations costs are used in the development of the simulation algorithm [18-22].
The result of the simulation allows to determine the most efficient design of loading and transport module for specific production conditions.
5. Conclusions
For the investigated loading and transport modules designs expected reliability indicators have been defined on the basis of data on regularities of change in reliability of their analogs and prototypes of their elements.
Technical and economic assessment of efficiency of loading and transport modules designs as part of tunneling equipment for construction of road tunnels is based on modeling process of operation with the account of expected reliability indicators. Economic feasibility of application of loading and transport module of a certain design can be defined considering quality of spare parts supplies and maintenance of tunneling cars.
Table 2. Principal reliability indicators of loading and transport modules of tunneling cars.
Functional elements of loading and transport modules MTBF To, h Standard deviation TO, &To Recovery time, Tv, h
Loading module with arms (type PNB-2) - feeder width B, m:
B = 1,8; 4,5 0,25 3,5
B = 2,0 3,2 0,31 2,7
Loading module with arms (type PNB-3D) - feeder width B, m:
B = 2,7 3,7 0,27 4,2
Loading module with wedge loading frame - feeder width B, m:
B < 1,0; 10,2 0,20 1,5
B > 1,0 10,5 0,20 1,6
Loading module with wedge loading arms - feeder width B, m:
B < 1,0; 7,8 0,21 2,1
B > 1,0 8,6 0,17 1,8
Transport module - wedge reloader 5,1 0,03 2,1
Transport module - scraper conveyor 15.0 0,07 1,0
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