With a total exhibition space of 605,000 m2, bauma is the largest trade show in the world. The event takes place every three years in Munich. In 2013, bauma broke all previous records, attracting a total of 3,421 exhibitors from 57 countries, and more than 535,000 visitors from more than 200 countries. From April 11-17, 2016, Messe München, the group that organizes bauma, is expecting another record turnout.
Prior to the event, Messe München will present five companies with its highly coveted Innovation Award. For 2016, the organizer is also experimenting with an exercise in cross-pollination: the Open Invitation. Also, they are starting a new tradition of giving back with a Charity Alliance. “Corporate societal and social commitment is no contradiction,” said Klaus Dittrich, chairman and CEO of Messe München GmbH. “On the contrary: long-term success requires both factors to go hand-in-hand. Many bauma exhibitors have long since taken this on board and are acting accordingly.” Inspired by the “Pilosio Building Peace Award,” bauma has established the Charity Alliance to coincide with the forthcoming event. The network intends to promote dialog between members on the implementation of social projects and to attract additional interested parties to become actively involved. Applications are restricted to companies exhibiting at bauma 2016, who are carrying on projects in the fields of education, nutrition, health, social integration or the environment and that bring about a lasting improvement in the living conditions of people in need living in, or hailing from, crisis areas, emerging or developing countries.
Messe München is launching another platform related to improving business, the “bauma Open Invitation.” The online platform allows bauma participants and other professionals interested in a particular sector to solve their innovation-related challenges by calling upon the expertise of Messe München’s entire cross-disciplinary network of contacts. The object is to get companies to engage on this platform in applications or technology “scouting.” For example, companies can seek out new industries or fields of application for their existing products and services, and/or find appropriate technological solutions to meet specific challenges they are facing.
By trade show standards, bauma is huge and it’s important. It’s mostly a construction event, but many European mining suppliers will be on hand and several of them are exhibiting new products and services. With this bauma Preview 2016, Coal Age offers a glimpse of what readers can expect to see this spring in Munich.
LIEBHERR TO DEBUT NEW DOZER AND EXCAVATOR
Delegates do not need a map to find the Liebherr Group at bauma. They simply look for the overhead cranes to get a bearing and then walk toward the 240-metric-ton (mt) haul truck.
Liebherr will showcase its extensive range of construction machines, mobile and crawler cranes, material handling technology, mining, as well as components, on a total display area of more than 14,000 m2. For miners, the highlights include a large crawler tractor, the company’s first in the 70-mt category, and a newly developed 200-mt excavator.
The R 9200 excavator was built to complement Liebherr’s broad range of mining-class excavators. Equipped with a 12.5-m3 bucket, the company said it offers sustainable performance while delivering peak fuel burn efficiency, even in the most challenging conditions. The excavator is a pass match for 140-mt haul trucks.
The R 9200 is available in backhoe and face shovel configurations and is fitted with the company’s advanced bucket and ground engaging tools (GET). The bucket has been engineered to deliver superior digging performance and high fill factors, according to Liebherr. It is powered by the Cummins QSK38 diesel engine that has a rated output of 810 kW. The cutting-edge cab of the R 9200 provides the operator with a panoramic view of their operation. The R 9200 integrates an advanced electronic piloting control system, which is both intuitive and versatile.
Liebherr will also unveil the new PR776 crawler tractor, which is powered by a Liebherr 12-cylinder diesel engine developing 565 kW (768 hp). The dozer has a maximum operating weight of 74 mt and is equipped with blade capacities of 18 m3 (semi-U blade) or 22 m3 (U blade).
The modern drive concept of the new PR 776 offers extremely efficient and safe operation to customers. A new feature in this machine class is the infinitely variable hydrostatic travel drive. Another advantage of the modern drive concept is the optimization of pressure flow. Hydraulic servo pressure is based on-demand according to the task. If, for example, the full feed of pressure supply is not required when operating, this is automatically returned.
An engine management system combined with a power efficiency system and the hydrostatic driveline allows the PR 776 to maintain constant engine speed, increase overall machine efficiency and reduce fuel consumption. This differentiates Liebherr’s travel drive concept from other drive concepts available on the market, where the engine speed fluctuates sharply during operation.
SIZERS FOR CRUSHING COAL
For miners on the soft rock side of the business, thyssenkrupp will also display its RollSizer DRS 660X3000 S. Tailored to meet the requirements of the coal industry, the unit is also capable of crushing medium-hard rock as well as sticky and soft material. The complete series has recently been standardized and further models have been added. As a result, the entire range of applications, from primary to tertiary crushing of coal, can now be handled by thyssenkrupp RollSizers.
With a roll length of 3 m and shaft center distance of 660 mm, the RollSizer DRS 660X3000 S is the second largest member of the family of secondary and tertiary RollSizers from thyssenkrupp. The model is designed as a SideSizer. Its rolls rotate outwards in opposite directions and crushing takes place between the rolls and the end walls of the housing. This is key to the crusher’s extremely high throughput rates, clearly defined final product, and very compact design.
The unit is fitted with exchangeable crusher segments made of wear-resistant steel which are durable and also quick and easy to replace. In addition, all sections of the housing that come into contact with the material during crushing are lined with wear plates. This maximizes the service life of the overall machine and minimizes maintenance requirements. The crushing combs arranged laterally on the end walls are available in various designs. Both the crushing combs and the end wall plating are horizontally adjustable so that product particle size can be precisely adjusted in line with requirements.
The DRS 660X3000 S operates with an extremely robust direct drive system consisting of two spur gears with fluid couplings. The couplings allow startup of the sizer even under the load of a full crushing chamber and at the same time provide overload protection. In the presence of a foreign body, the slip of the fluid couplings protects the machine against damage. The required drive torque is provided by two powerful 250-kW electric motors.
To ensure maximum operating safety, all thyssenkrupp RollSizers are fitted with sensors for monitoring the main machine parameters such as drive speed, bearing temperature and lubrication.
NEW BUCKETWHEEL FOR HARDER FORMATIONS
For the open-pit mining side of the business, thyssekrupp will present a new generation of compact bucketwheel excavators (BWEs): the Barracuda and the Mine Shark. Both machines will be able to work in hard materials with compressive strengths up to 50 MPa.
While BWEs today mostly work in soft and medium-hard rock with a compressive strength of up to 20 MPa, this machine has been designed to work in a broad range of materials including coal, limestone, phosphate rock, potash, frozen materials in winter conditions as well as in its corresponding overburden layers.
To fulfill the requirements of the severe working conditions, special bucket and tooth designs have been applied by thyssenkrupp. These designs are based on innovative testing methods and include a larger number of teeth and buckets.
This stage of development of BWE demonstrates the changing character of the extraction process from digging to cutting.
The combined extracting and loading process with a single machine eliminates the need for blasting as well as additional loading activities. The new BWEs are able to produce throughputs of more than 3,000 mtph. thyssenkrupp will have a model of the Barracuda on display (Hall B2, Stand 203).
BEUMER CONVEYOR BELTS
The Beumer portfolio includes curved belt conveyors for fast and cost-efficient transport of large quantities of bulk material from the mine to mill. Belt conveyors are able to navigate long distances, high angles of inclination and tight curve radii, and can be adapted individually to the belt or pipe conveyor bulk handling solutions. Depending on the customer’s requirements, Beumer provides either troughed belt or pipe conveyor bulk handling solutions. Open troughed belt conveyors are recommended for larger throughputs, higher mass flows and wider curved radii. Closed pipe conveyors protect both transported items from environmental influences and the environment from falling items. Troughed belt conveyors can also be covered or encased to minimise dust formation during transport. This seal guarantees dust-free transport.
INDUSTRIAL GRADE FILTRATION
Mahle (Hall A5, Stand 431) will display its new e-protect filter elements as well as a completely new generation of fluid filter elements. The new products are distinguished by an optimum cleaning performance and intelligent functions even under difficult ambient conditions.
The e-protect filter element prevents damage in the filter layers caused by electrostatic discharge. New zinc and ash-free hydraulic oils initiated this development. These fluids have very low conductivity that can increasingly lead to the electro-charging of the oil. This charge separation in fluid systems has been a well-known phenomenon in high-performance filters for a long time. It is usually equalized through local discharge with high energy. Indicators of this range from audible crackling through to damage in the filter layers.
ADDITIVES ENHANCE HYDRAULIC FLUIDS
The word is out — high-performance hydraulic fluids formulated with Dynavis technology from Evonik Industries save more money than they cost. “A simple change of hydraulic fluid can help save fuel, even — and particularly — in used construction machines,” said Rolf Fianke, Dynavis technology aftermarket support manager at Evonik. As one who knows the sector well, Fianke has noticed increasing demand for technologies that contribute significantly to increasing efficiency. Those who want to more fully exploit the potential of their machine, or their fleet, would find it well worth their while to drop in at the Dynavis technology team’s exhibit (Hall A6, Stand 245).
GET BUCKET PROTECTION SOLUTIONS
A little more than seven years ago, MTG was well-known in the European construction business for its GET, and started its global expansion into the mining market. With this objective in mind, in 2013, the company built a new large foundry in Monzón, around 300 km west of Barcelona, Spain. The plant specializes in the production of large wear parts for large surface mining equipment, something very special in the wear parts market given the huge investment in technology necessary to produce such parts. Today, the company has protection systems installed on loaders, excavators and rope shovels in Latin America, South Africa, Australia and throughout North America.
To stand out, José Luis García, marketing manager for MTG, believes a company needs to do focus on system performance, quality and the cost efficiency for ground engaging tools (GET) as it relates to efficiency and hassle-free operations.
For bauma, MTG (Hall A6, Stand 437) will display a wider range of its ProMet wing and blade shrouds, which offer increased wear life as well as an improved bucket performance in both construction as well as mining machinery. For rope shovels in particular, the company has launched a new hammerless lip locking system along with new designs for teeth and adaptor systems, developed specifically for mining applications. “We have proven that our systems can work in mining,” García said. “We are now building on that line in a way that adds new elements, which make the system more complete. We do not speak just about GET anymore, we offer full bucket protection systems, and are capable to find the best option, depending on the client’s bucket.”
New locking systems for mining, the 3 x 1 MTGTwist hammerless locking systems, are easy to assemble and disassemble. ProMet mechanical shrouds protect the side of the dipper. The company offers a range of weldable and bolt-on shrouds. Realizing that mining conditions are site specific, the metallurgy can be engineered for more abrasive or less abrasive loading applications. “Similarly, the crowding action differs between shovels and loaders and MTG adds more wear protection in certain areas depending on the application,” García said.
A new range of wing and blade shrouds offer increased bucket protection and ensure improved performance for large mining machinery. “The design of the blade shrouds has been specifically optimized to offer up to 30% more wear material than comparable systems,” García said. The front of the MTG shroud contains between 10% and 20% more steel. The fitting system only requires welded base for each shroud, making installation easy and quick while reducing downtime. MTG is also offering a reversible 1-m-long wing shroud for mining-class loaders.
OFF-HIGHWAY EQUIPMENT RESEARCH
Global sales of construction equipment are forecast to grow 3.9% in unit terms in 2016, to 760,508 machines, according to Off-Highway Research. The expected improvement follows a weak performance in 2015, when global unit sales fell more than 10% from the total of nearly 818,000 machines sold in 2014.
Off-Highway Research is a management consultancy specializing in the research and analysis of equipment markets, and is the largest of its kind in the world. The consultancy was formed in 1981 as part of The Economist Intelligence Unit (EIU) and is now part of KHL Group, the world’s largest and most respected provider of international construction information. The group offers a unique level of international research expertise. Off-Highway Research (Hall B5, Stand 227/B) will present updated forecasts for the equipment sector across its Chinese, European and Indian subscription services, its Chinese, Indian and International databases and the global Volume & Value service.
The EMOS camera from Orlaco (Hall C4, Stand 336) adds a new dimension to the digital camera world. It is a compact camera that can be used universally on all types of monitors. Simply connect the camera to a network and a high-quality video stream appear with only a minor delay (less than 100 mps).
EMOS is designed for use in the most challenging situations and is fully shock and vibration-resistant. The super compact camera is the size of a matchbook and has a solid aluminum housing. The interior is fully protected with potting compound that holds everything in place. No risk of damage and the system is fully waterproof (IP68) and resistant to high-pressure washing (IP69K). The universal bracket allows users to mount the camera in numerous positions on any type of vehicle.
SURFACE MINING MEANS SIMPLE MINING
Wirtgen’s Surface Miners (Hall FS, Stand 1010-1111) replace drilling, blasting, crushing and loading with one single machine. These machines cut and crush the rock with a special cutting drum and load it onto haul trucks in a single pass via a slewable conveyor system. Alternatively, the rock can be deposited as windrows between the crawler tracks or sidecast. These three different processes make for a high level of versatility in surface mining applications.
With cutting widths of between 2.2 m and 4.2 m, it can cut to a depth of up to 83 cm and to an unconfined compressive strength of 120 MPa. “Wirtgen is the only manufacturer that can offer a performance range of 100 tph to 3,000 tph with direct loading by conveyor belt,” said Bernhard Schimm, product manager for Wirtgen’s mining division.
Wirtgen offers three time-proven performance classes, which can be configured variably to meet the needs of each project: the 2200 SM/2200 SM 3.8, the 2500 SM and the 4200 SM.
“Selective extraction not only improves the quality of the material mined, but permits as much as 95% of the deposits to be exploited. Only some 70% of deposits can be exploited on average with the conventional method. This offers companies considerable quality and cost benefits in material extraction and subsequent processing,” Schimm said.
Wirtgen has developed two innovations: a camera system for rock interface detection and a cutting drum unit for the flagship Surface Miner 4200 SM that is set to sustainably optimize the mining of mineral deposits.
Because the cutting depth can be adjusted and regulated precisely, even thin seams of valuable mineral can be extracted precisely along bedding planes.
With the new camera system, selective mining is now even more precise thanks to simple visualization of the rock interface. To this end, two cameras are mounted at the level of the cutting drum. To compensate for the slope of the layers, which are not always horizontal, one camera is attached on the left and the other on the right. These cameras transmit 1:1 photos of the surface to a double monitor in the cabin. The machine operator can accurately detect the transition from valuable mineral to interburden based on the different colors and/or structures of the two minerals and can then adjust the cutting depth, if required. Reduced dilution saves costs with downstream processes.
The second innovation also maximizes profits. This is because Wirtgen’s newly developed cutting drum unit for the Surface Miner 4200 SM has been specially designed for the windrowing method. Capable of outputs up to 15% higher than a standard cutting drum unit, it will also reduce tool consumption by up to 15%. These advancements are the result of an optimized milling drum design. The essential feature here is the increased tool spacing of 75 mm — this being the horizontal distance between the tool cutting tracks. This boosts the cutting performance so that more minerals can be deposited behind the Surface Miner in windrows.
Increased tool spacing also means that there are fewer cutters on the cutting drum — and that means fewer tool changes. The immediate effect: downtime is also reduced. Overall, the surface miner can mine more minerals over a longer period of time than was possible to date working with a standard cutting drum in windrow mode. Offering a wide variety of cutting drum configurations, Wirtgen can deliver the most productive cutting drum unit for each application and to match the composition of the material to be mined, both for windrowing and for direct loading via a conveyor belt.