Mine operators are now increasingly calling for machines that are mobile, highly manoeuvrable, and capable of undertaking a wide range of roadway and tunnel drivage and reconstruction works.

HBL in position ready for drillingFigure 1: HBL in position ready for drilling
When choosing a particular machine type, its degree of mechanisation has to be weighed up against the multipurpose nature of the deployment, which will then depend on the type of application and operating environment. While a “simple” all-hydraulic control system will not feature all the available sensor technology, and will have certain limitations when it comes to the automation of individual procedures, when compared to an all-automatic machine, it will be more robust under certain operating conditions, will require less maintenance effort, and will entail lower procurement costs.

Many manufacturers in India can supply crawler-mounted base vehicles in a number of weight categories, which can be equipped with different drive units, and can be supplied with or without quick-release attachments. The range of ancillary equipment available includes working platforms, drill feed, side-tipping shovels, and activated dinting shovels and special solutions such as cutting heads with air-water external spray systems and special shovels for laying curb stones.

Conventional equipment for small-profile tunnelling

HBL trans loading material in a small-profile tunnelFigure 2: HBL trans loading material in a small-profile tunnel
Excavating small roadway and tunnel profiles using drilling and blasting methods, traditionally required manoeuvring hitches to be provided in the side-walls for materials transport, and to allow the different vehicles and items of equipment to pass each other, or be parked-ready for operation, as each process in the road heading cycle generally calls for a different machine with its own running gear. This means providing a large fleet of vehicles, resulting in high procurement and operating costs. Manoeuvring the individual machines into place takes time and further delays the sequence of operations.

Multifunction machines like the HBL 800 drill-loader (Fig1) have the potential to increase the rate of advance in that the main operations in the road heading cycle, namely drilling and loading, are combined in one carrier vehicle. This multipurpose machine is designed to operate on its own at the heading face. A drill feed attachment is fitted for shot hole drilling and roof bolting work (Fig 1), this being replaced by a side-tipping shovel (Figure 2) for the loading cycle. There is also the option of connecting a shot-crete manipulator. The installation is designed to operate in arch-profile tunnels with cross sections of 10 m2 and over. A two-to-one turnout and a preassembled section of track are also integrated into the system to serve as a floor-rail transport route. Other available attachments include telescopic drill feeds, a range of dinting shovels, hydraulic hammer drills, and various specialised tools for carrying out tunnel stabilisation work.

The HBL 800 drill-loader is equipped with electro-hydraulic drive and is operated from a driver’s cab with an overhead canopy to protect against falling stone. Using the machine as a stand-alone multifunction system for road head operations places higher stresses on the base vehicle when it comes to handling and servicing. However, procurement and operating costs are lower than for conventional machine systems, which comprise a drill jumbo and loader, as only the basic machine has to be purchased and serviced. Any maintenance work needed can be carried out during non-operating periods, e. g. when the shot holes are being prepared. More extensive repairs are undertaken during the maintenance shifts, if need be. In its standard version, the machine features a fairly simple sensor system that most users prefer because of its ease of operation. However, there are essentially no limits to the control technology that can be fitted if the customer wishes.

The increased efficiency of this HBL drill-loader machine compared with conventional technology is reflected in a higher rate of advance, provided that the road head zone is properly organised. The scheduled movement of heading debris and materials has to be adapted to the operations of the road heading machine. There is no waiting for machine change-overs and long travelling-in times, and the number of passing places and machine refuges is reduced as a result. Tool change-over is fairly quick and easy as the attachments are coupled up to the machine with the aid of a hydraulic quick-change device.

The control and supply lines are connected using individually marked quick-release couplings. The various machine attachments are incorporated into the turn-round circuit in order to further reduce the change-over times. When used in combination with continuous conveyors for debris clearance, the machine attachments can be held ready in mobile rigs or slung from chains close to the road head.

The HBL 800 drill-loader’s manoeuvrability, gradient capacity of ± 18 ° and electric drive also make it a suitable option for the tunnel construction industry, e. g. for excavating head race tunnels.

Innovative machinery for small-section tunnels

Road heading cycle based on HRE technologyFigure 3: Road heading cycle based on HRE technology
The advantages of the HBL 800 drill-loader combination led to considerations as to whether efficiency could be further improved by placing all the road heading components on one base machine, this comprising the tools required for drilling, blasting preparation works, loading, clearing out and support setting (Figure 3).

Such a development would scale down the size of the vehicle fleet, cut tool change-over times and reduce the number of passing bays and refuges needed for the machines (Figure 4).

The hydro electrically-powered, crawler-mounted HRE which has been developed, has the following technical features and specifications:
  • Active loading apron at the front of the machine that operates in conjunction with a cantilever boom that has been specially designed for mining and tunnelling applications. The boom drags or tips the road heading debris on to the apron, depending on the type of bucket fitted, and loader bars then push the material towards a central chain scraper conveyor operating along the length of the machine.
  • The tool attachments, which are parked on a sliding track, can be rapidly changed over, thanks to a mechanical quick-release unit.
Road heading cycle based on HRE technologyFigure 4: Operating equipment and bay spacing in roadway drivages using LHD machinery, conventional tunnel excavators and HRE technology
The boom unit features both vertical and horizontal parallel kinematics. As well as fitting scoops and drill feeds the hydraulic quick-release unit can also be used to attach a range of other accessories such as working platforms, hydraulic breakers and rotary tools.

The drill feed and shotcrete manipulator are mounted on offset slides positioned to the right and left of the conveyor. The tools are picked up by the boom, when required, in response to commands from a remote control system.

The HRE, along with its main operating tools and structural elements, has been designed and equipped for mining and tunnelling applications. The essential features of the machine have patents pending.

The HRE can attain the unlimited drilling capacity of a conventional jumbo, thanks to the dimensional design of its driveline set-up, the potential power category of the hammer drill, the boom kinematics and the degree of freedom available to the drill feed. The main technical data for the HRE are presented in Table 1.

The introduction of the HRE has reduced machine costs and personnel costs; cut to minimum time-consuming and cost-intensive work of preparing machine bays and refuges; and delivered an overall reduction in energy consumption. The machine’s electric drive system has also significantly reduced the expenditure on providing underground ventilation.

Opting for the HRE as a system solution for drill and blast drivage operations in small-profile roadways is likely to result in higher rates of advance and lower operating costs when compared with conventional equipment combinations.

The machine’s effectiveness has been demonstrated in a study undertaken by RWTH Aachen University using the Discrete Event Simulation method (Figures 5 and 6). This project, which was based on the case of a roadway 3,000-m in length and with a cross section of 10 m2, sought to draw a comparison between the conventional system of LHD, drill jumbo and shotcrete manipulator, the combined arrangement of crawler-mounted road-heading excavator (RHE), jumbo and shotcrete manipulator, and the new HRE machine, each of the three systems operating with a maximum of three dump trucks. The average cycle times depicted in Figure 5, include both the change-overs for each operating sequence and the additional work associated with the excavation of the machine change-over bays.

Discrete Event Simulation method

Click Here
To Know More or to Contact the Manufacturer
Please let us know your name.
Invalid Input
Please let us know your Designation.
Please let us know your Contact Number.
Please let us know your email address.
Please brief your query.
Our other Value-Added Services:

To receive updates through e-mail on Products, New Technologies & Equipment, please select the Product Category(s) you are interested in and click 'Submit'. This will help you save time plus you will get the best price quotations from many manufacturers, which you can then evaluate and negotiate.

Invalid Input
Invalid Input
Invalid Input
CDE Asia on its 16th anniversary, has added yet another feather to its cap with its key contribution to the construction of India’s largest greenfield route alignment - the Samruddhi Mahamarg Expressway

Read more ...

Manish Bhartia, Promoter & Managing Director, CDE Asia, discusses the company’s role in increased manufactured sand penetration in India, their aim to create a sustainable sand ecosystem, and making improvisations to the Combo range of sand production technology

Read more ...

Laterite quarry owners switch to MB Crusher Screening Unit to segregate pebbles from the soil and obtain M-Sand. An established laterite quarry in south India was looking for a solution to segregate very precisely the pebbles from the soil from a farm land located near

Read more ...

Afcons Igatpuri’s mega tunnels of the 700 km Mumbai-Nagpur Super Communication Expressway project, which are also Maharashtra’s longest and India’s widest road tunnels (8km long and 17.6m wide), have become a source of fascination

Read more ...

Coimbatore-based mineral processing equipment manufacturing major, Propel Industries, has widened its product portfolio to include mechanical sensor pavers, the new concrete batch mix plants, and the new battery-operated tipper trucks

Read more ...

Marsman India is a leading manufacturer of crushing & screening equipment, with two manufacturing units equipped with CNC, VMC, boring machines, plasma and profile cutting machines, welding, and heat treatment plants etc. It is also ISO 9001-2008 certified

Read more ...

Proman is offering Dry Classifiers of 10-40-75 tph, which come with bucket elevators for ease of output removal and require a small quantity of air for purging. The classifier is fitted with hoppers with rotary air lock valve for facilitating fines removal

Read more ...

Taurian has launched its SWIFT series of primary (jaw) and secondary (cone) crushers. While, on the face of it, these crushers look like typical track/skid mounted, they have some unique features which make them stand out in the market

Read more ...

Titan Crushing, which manufactures crushing and screening solutions under the brand name Diamond Crushers, has expanded its range from toggle crushers to grizzly, jaw cones, and vertical shaft impactors for stationary crushing. The range includes the new DP-Series

Read more ...

Siddhi Equipments, which is in the field of Industrial and Security Metal Detectors, Security Equipment, and Electronic Test & Measurement products, has once again come up with a new product - Industrial Aggregate (Blue Metal) Stone Crusher Metal Detector

Read more ...

Nashik-based aggregate/minerals crushing and screening solutions manufacturer RD Infra Equipments is expanding its production facility by about 50,000 sqft and upgrading its machines for higher capacity production and efficiency

Read more ...

CDE Asia exhibited its latest advancements in sustainable technology at Excon that will empower customers with hassle-free, energy-efficient, and eco-friendly solutions for producing high-quality manufactured sand. The new 2022 model of Combo Alpha

Read more ...

Terex India has officially unveiled 8 brand new products from 6 of their brands - Franna, Powerscreen, Finlay, MPS, TWS and EvoQuip at Excon. FR 17 Pick and Carry Crane: The main USP of Franna brand is its safety features. Franna pick and carry

Read more ...

The star attraction at Puzzolana’s stand at Excon were its newly launched Milling machine and Pavers for road construction. The machines have been exclusively designed for the application in India, while keeping Indian customer requirements in mind

Read more ...

Propel produces a diversified range of Crushing and Screening equipment for the construction and mining sectors at its world-class, vertically integrated manufacturing units with stringent quality control measures in place. At Excon, it displayed more

Read more ...

Hailstone showcased its cost competitive, smart crushing solutions at Excon that included vertical shaft impactors under its HW Series, JC series jaw crushers, HF series cone crushers, and EC series cone crushers, as well Plants on Wheels

Read more ...

Ashar Locker’s anti-clogging screens have proved to be highly successful in the manufacture of M-sand and P-sand over the past couple of years. These handmade and uniquely designed screens utilize every motion of the screen efficiently

Read more ...

Torsa introduced Smart IVX series of crushers of 150-200 tph at Excon that have a very compact footprint with a combination of jaw-cone and screen mounted on a skid mounted platform. The modular design of the skid mounted plant enables ease of transportation

Read more ...

Excon marked the launch of eight new products by Terex India from six of their brands - Franna, Powerscreen, Finlay, MPS, TWS and EvoQuip FR 17 Pick and Carry Crane: This compact pick and carry mobile crane from Franna product range is specially designed

Read more ...

AESHA Conveyors & Crushing Equipment is committed to provide innovative material handling solutions for the needs of its customers, and to improve the efficiency of their crushing processes for specific applications

Read more ...

×
Sign-up for Free Subscription
'India Construction Week'
Weekly e-Newsletter on Construction Industry
Get the latest news, product launches, projects announced / awarded, government policies, investments, and expert views.
Click here to subscribe.