By Steve Fiscor, Editor-in-Chief

Unless international visitors arrived at bauma 2010 a week or so prior to the event or paid a huge sum to hire a car from outlying areas in Europe to Munich, it’s safe to say their travel plans were canceled by a volcano spewing ash into one of the region’s busiest air travel corridors. For those in continental Europe and the Near East, it was business as usual at bauma 2010 except for the excessive amounts of the traffic on the autobahn. The event, which took place during the third week of April, had been planned for three years and the organizers decided wisely to move forward. Likewise, several companies made big announcements.

Bauma 2010, the 29th bauma, set another record for exposition space, 555,000 m2 (370,000 m2 outdoors and 185,000 m2 in the halls). “This year bauma is once again bigger than ever before,” said Klaus Dittrich, chairman and CEO,  Messe München GmbH. “We now have 3,150 exhibitors from 53 countries—that’s also a new record. Also remarkable, the fair once again attracted more exhibitors from outside Germany—the figure for bauma 2010 was 60%.”

In 2007, the fair set a record with 540,000 m2 of exhibition space, 3,002 exhibitors from 49 countries and more than 500,000 visitors from 190 countries. For the first time, the proportion of exhibitors from outside Germany reached 54%. “The exhibitors from Germany are still in the majority—although at 1,273 there has been a slight fall since 2007, when we had 1,363.”

The ban on air travel at the start of the fair did impact the final figures for visitor numbers: more than 415,000 visitors from more than 200 countries attended bauma 2010. In comparison to bauma 2007, this was 17% fewer. Most of the visitors came from Germany (65%). Many of the speeches planned for the first two days of the bauma Forum were canceled. However, events were able to take place as scheduled from the third day onward. The foot traffic at the Mining Hall was slow, but miners were on hand reportedly from Poland, Ukraine, Czech Republic, Turkey, Russia, China and other regions. Mining-related equipment suppliers displayed new equipment  and technology, and existing lines with new colors.

Eickhoff Wins Innovation Award
Eickhoff won the prestigious Innovation Award for the advanced technology incoporated into theSL 750 EiControlPlus for longwall shearing machines. With this system, it is possible for the first time, according to Eickhoff, to fully automate the shearing process on longwall mining units. Longwall miners could monitor the cutting process from a remote location. Equipped with linked infrared cameras and newly developed sensors, the system constantly monitors its surroundings. Using a navigation system based on radar and a few cameras, the machine is able to avoid collision, detect and follow the coal-rock horizon and run the entire haulage and extraction automatically. In addition to protecting longwall miners, the system also avoids in-seam dilution.

Liebherr Unleashes the T 282C
The star of the exposition in the outside area was the new Liebherr T 282C ultra class haul truck. For the last seven years, Liebherr has been manufacturing the 363-metric-ton (400 ton) T 282B haul truck. This ultra class haul truck has set benchmarks worldwide for production with low fuel consumption improving its reputation as the lowest cost per ton option, according to Liebherr. Over that time, there have been numerous design improvements to increase the efficiency and reliability of the truck. However, recent improvements have resulted in a substantial evolution of the product and a change in name from T 282B to T 282C.

With an empty vehicle weight of 237 mt (261 tons), the T 282C can carry a payload of up to 363 mt (400 tons). Available engine options for the T 282C include the MTU DD 20V4000 (20-cylinder/2,800 kW/3,755 hp) or the Cummins QSK 78 (18-cylinder/2,610 kW/3,500 hp). Its top speed is 64 km/h (40 mph).

With the first pre-series units already in testing and the official product release being scheduled for the fourth quarter of 2010, the T 282C builds upon the performance of its predecessor and provides improvements that minimize downtime and maximize production. The new frame, axle box, cabin, IGBT AC drive system, Liebherr vertical integration and load management design philosophy will increase performance and provide a designed reliability in the T 282C. This culminates in a truck with superior performance and reliability, ultimately providing the end-user with the lowest possible cost per ton, according to Liebherr.

The vertical integration philosophy incorporates proprietary truck components, specifically developed to serve the needs of the mining industry. By being in control of all components of the drive system, innovative design solutions can be developed within the Liebherr group to accommodate operations with high altitudes, high ambient temperatures and other unique mining applications.

The largest and one of the most important structures on any mining truck is the truck frame. It is upon which the truck’s dump body, superstructure and power module rest. The new T 282C frame is unique. It uses strategically located castings only in high stress areas. Unlike its competitors whose frames are predominantly cast material, the T 282C frame has castings only in strategic areas to minimize the empty vehicle weight of the truck.

In addition to the new frame, a completely redesigned axle box is now available with the T 282C. The new axle box now has two service doors, improved cable routing, vertical linkage and greater air flow across the electric drive motors and service brakes. With both increased service accessibility and better airflow, especially in high altitudes and ambient temperatures, the T 282C’s axle box has been re-designed for reduced downtime and increased reliability.

The cab is the operator’s office for up to 12 hours a day. With that in mind, significant design focus has been dedicated to making the cab of the T 282C more operator-friendly. Some of the cab’s major upgrades include new dash display gauges and a 12-inch integrated color touch screen for all operator alerts, faults, warnings, cameras and other control functions.

Another technical step forward and major part of Liebherr vertical integration is the new Liebherr drive system with IGBT frequency inverters. Together with the Liebherr regulating system, the liquid-cooled IGBT power modules optimize control of the traction motors. The frequency inverters for auxiliary equipment are supplied with electrical energy regenerated, if circumstances permit, when the vehicle is braked. The new system includes wheel motors and planetary gear sets developed by Liebherr. It guarantees the diesel engine runs independently of travel speed and its fuel consumption can therefore be optimized.

Bucyrus Exhibits Integrated Line of Mining Equipment
Bauma visitors were greeted by a Bucyrus RH40E excavator hoisting a banner that directed people to the Mining Hall and the Bucyrus outside exhibit. This would be the first time visitors would see the Bucyrus integration for open-pit mining with the new color scheme replacing the traditional O&K red and white. This was also the first exhibition were the “old Bucyrus” employees (formerly DBT) met the “new Bucyrus” (formerly Terex Mining) employees.

The centerpiece for the Bucyrus outside stand was an RH120E excavator. With an operating weight: 287 metric tons (mt) and an engine output of 1,140 kW (1,530 hp) / 2 x 570 kW (765 hp), the excavator has a bucket capacity of 15.0 m³ (19.6 yd³).

On the new RH120E, a Cat C27 engine replaces the former C18 version. The C27 is Tier 2 certified and offers the highest engine output in class for maximum performance, according to Bucyrus. The larger displacement provides extended lifetime. The excavator has been completely rewired with an electrical system that contains less parts and one type only off-the-shelf hardware controllers. A large 12-inch touch screen and on-board documentation in PDF-format assists quick service. Advanced trouble-shooting and self-diagnostic functions will help reduce downtime. The machine also has a new central lube system that is 100% monitored for pressure drops. The outside exhibit also had a scale model of the highwall miner system.

The focal point for the Bucyrus stand in the Mining Hall was the enormous 55-mt Narrabi longwall roof support. Fully extended the 1,362 mt (1,501 ton) roof support would reach 4,700 mm (185 inches). The 2.05-m wide shield’s closed height is 2,500 mm (98 inches). The roof support at the stand is on the inside. The leg diameter is 450 mm (nearly 16 inches). The electronically controlled roof support sports a video camera system for visual control of the entire face, powerful DN32 hydraulics for fast advance times, and inclinometers for height measurement using inclinometers. It conforms to the Australian mining design guidelines (MDG 41) and it can be retrofitted for longwall top-coal caving applications.

In addition to the roof support, Bucyrus also had its high seam pan line on display, the PF6 H/1542, which is capable of conveying 6,200 mtph (6,834 tph). The wear resistant deck plate is 25-mm (nearly an inch) thick. The length is the same as the Narrabi roof support (2.05 m), while the width is 1,542 mm (a little more than 60 inches). The Dogbones have a breaking force 4,500 kN and the pans can articulate +/- 6˚ vertically and 0.8˚-1.2˚ horizontally. The recommended seam height for the pan (and the roof support) are greater than 6 m with heavy-weight shearers.

The stand in the Mining Hall also showcased belt and idler systems, CST drives, a headgate drive frame along with scale models of rotary blasthole drills, electric shovels and haul trucks.

MTU Discusses Truck Repowering Capabilities
For many mining class haul trucks and large excavators, MTU says it has a matching engine that will perform better. Vehicles can be refitted with Series 4000 engines offering outputs of up to 3,750 bhp. In the past five years, more than 30 vehicles have been re-equipped with MTU Series 4000 engines at Codelco’s Chuquicamata mine, one of the largest copper mines in South America.

The repowering process has to be handled quickly and efficiently to keep the mine operator’s losses to a minimum. That is where the careful preparation and planning by the MTU experts on site pays off. When a vehicle is approaching its repowering appointment, it first undergoes a thorough examination. That is the only way to be sure all interfaces with the truck such as electrical, piping and electronic connections exactly match the new engine. The ultimate aim is to complete the repowering operation as swiftly as possible.

Often, the package includes a matching radiator and air intake and exhaust systems along with the new engine, so the customer gets all of the necessary parts for repowering from one supplier. Despite undergoing a major transplant, the dump trucks require very little recovery time. Once the right replacement engine is ordered, it takes no more than a week including installation and system configuration for the vehicle to be back on its wheels and ready for thousands of more hours of continuous duty.

Wirtgen Presents the Biggest Surface Miner
The 4200SM really represents the success of Wirtgen’s surface mining division. These miners offer cutting widths ranging from 2.2 m to 4.2 m and cutting depths of between 20 cm and 83 cm. Wirtgen said it’s the only manufacturer covering a scope of performance ranging from 100 mtph to 3,000 mtph. This high measure of productivity is attributable to the miners’ efficient cutting technology plus a wealth of experience gained in three decades of application technology, according to the company.

The new 4200SM is ideally suited for mine operators whose goal is to achieve an annual mining capacity in soft rock of up to 12 million mt while wanting to make full use of the benefits offered by Wirtgen’s selective mining technology that enables cutting, crushing and loading in a single working pass.

The 4200SM is available in two different configurations for operations in either hard or soft rock. For applications in soft rock with unconfined compressive strengths of up to 50 MPa, the machine is equipped with a 4.2-m wide cutting drum unit with larger cutting diameter, thus permitting a cutting depth of up to 83 cm. The largest Wirtgen miner can alternatively be equipped with a drum assembly offering a cutting width of 4.2 m and a cutting depth of 65 cm for applications in hard rock with unconfined compressive strengths ranging from 30 MPa to 80 MPa.

The heavy-duty machine is equipped with a 16-cylinder diesel engine from Cummins, making it the ideal candidate for a wide range of applications as its power of 1,194 kW / 1,623 PS offers tremendous reserve capacity. Generously dimensioned tanks offering capacities of 2,900 liters for diesel and 10,000 liters for water additionally increase the miner’s uptime.

A two-stage conveyor system with 1,800 mm wide primary and discharge conveyors and optional discharge conveyor lengths of 12,000 mm or 16,000 supports the surface miner’s impressive cutting performance of up to 3,000 mtph. The conveyor’s large slewing angle of 180˚, flexible height adjustment and variable conveyor belt speed ensure smooth loading of large transport trucks even in restricted space conditions.

The professional knowledge of and experience gained in application by Wirtgen’s experts and consultants in action around the globe have now been compiled in a surface mining manual that was distributed on the stand. The work describes the advantages offered by the Wirtgen surface mining technology and addresses all aspects from cutting technology to material transport. It is complemented by planning guides facilitating the economical operation of the surface miners and application examples showing miners in operation around the globe and in all types of rock. The updated edition of the Wirtgen Surface Mining Manual in compact book size is available in German and English. The freshly issued manuals can be ordered or downloaded in PDF format from Wirtgen GmbH’s Web site: www.wirtgen.com.

Dana Unveils New Drivetrains
Dana displayed a drivetrain system for 17.5-mt (19-ton) wheeled excavators. This system is composed of a Spicer Model 263 planetary steering axle, a Spicer Model 163 planetary rigid axle with a directly flanged Spicer Model 369 shift-on-fly hydrostatic transmission, and a Spicer Life Series Model SPL55 driveshaft.

Specially designed to enhance mobility, comfort and ease of use, the shift-on-fly hydrostatic transmission provides a proven alternative to expensive powershift solutions and the operational limitations of sliding-collar range-shift transmissions.  

Vehicles equipped with traditional range-shift solutions must completely stop before shifting between ranges, but the gearbox on the Spicer Model 369 transmission allows for quick shifting from low to high range while moving. The Spicer Model 369 transmission enables seamless operation from reverse, full stop, and forward up to speeds of 40 km/h (25 mph).

Godwin Debuts New Pump
Godwin Pumps, which was recently acquired by ITT (See Suppliers News, p. 56), displayed the newest addition to the HL series—the HL260M Dri-Prime pump. Capable of flow rates to 1,810 m3/h (4,760 GPM) and heads to 150 m (500 ft), the 250- x 200-mm (10- x 8-inch) HL260M is a single-stage, automatic priming centrifugal pump with solids handling capability to 50 mm (2 in.) in diameter.

The single-stage impeller design, close coupling, solids handling capability and Dri-Prime priming system combine to provide a very unique offering for portable pumps generating discharge heads to 150 m (500 ft), according to Godwin. The industry is trending toward larger pumps and the Godwin engineering team said it is dedicated to developing the most reliable range of high lift pumps on the market.

Built with a cast iron pump volute, cast chromium steel impeller and nickel chrome cast iron wearplates, the HL260M is engineered for tough pumping applications.

The Dri-Prime venturi priming system on the HL260M provides suction lift capability to 8.5 m (28 feet) and continuous uninterrupted operation. In addition, its dry running, double high-pressure oil bath mechanical seal with abrasion-resistant solid silicon carbide faces enables the pump to run indefinitely without risk of overheating or failure.

The HL260M is offered with several engine options, including the standard 600-hp Cat C-18 Tier 3 diesel engine. Mounted on a skid, the HL260M is built with an integral bundled fuel tank to provide hours of continuous operation and spill protection. For easy lifting and transporting, a single-point lifting frame and built-in fork truck pockets are standard on all machines. For applications requiring utility power or lower emissions, the HL260M is available with an electric motor configuration. Noise reducing, sound-attenuated canopies are also available.

The 30th bauma, International Trade Fair for Construction Machinery, Building Material Machines, Mining Machines, Construction Vehicles and Construction Equipment, will take place as planned in three years time, from April 15-21, 2013,
in Munich.