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Comparative Analysis of the Failure Rates of Shearer and Plow Systems—A Case Study

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  • Łukasz Bołoz

    (Department of Machinery Engineering and Transport, Faculty of Mechanical Engineering and Robotics, AGH University of Science and Technology, A. Mickiewicza Av. 30, 30-059 Krakow, Poland)

  • Zbigniew Rak

    (Department of Mining Engineering and Occupational Safety, Faculty of Civil Engineering and Resource Management, AGH University of Science and Technology, A. Mickiewicza Av. 30, 30-059 Krakow, Poland)

  • Jerzy Stasica

    (Department of Mining Engineering and Occupational Safety, Faculty of Civil Engineering and Resource Management, AGH University of Science and Technology, A. Mickiewicza Av. 30, 30-059 Krakow, Poland)

Abstract

Mechanised plow and shearer systems are widely applied in underground mines all over the world. Both systems are used in the exploitation of hard coal deposited in the form of seams of various thickness. The selection of the appropriate complex depends on the mining and geological conditions and the thickness of the seam. However, with regard to thin and medium seams, these complexes are competitive solutions. Mines usually use either shearer or plow systems. Both have certain advantages and disadvantages resulting from their design and method of operation, which have been demonstrated and presented in many publications. However, in terms of their failure rate comparison, there are no relevant research and analysis results. Only selective studies of individual machines can be found. The article is concerned with the failure frequency of longwalls equipped with plow and shearer systems in the LW Bogdanka coal mine. The analysis covers a period of 13 months of the mine’s operation, during which 2589 failures were recorded. All failures were taken into account, irrespective of their type or cause. The analysis was conducted for all longwalls exploited in this period, i.e., five plow and five shearer systems working in six different sections. In the analysed period, these longwalls worked for a total of 1484 days. It should be emphasised that all the complexes worked in one mine, thanks to which the data are comparable. The analysis is unique material regarding the failure rate of machines. Both solutions were analysed independently and subjected to a detailed comparison. A comprehensive analysis revealed that the failure rate of longwalls equipped with plow systems is noticeably higher than that of shearer ones. The main purpose of the article was to conduct a comparative analysis of the failure rate of machines in shearer and plow complexes operating in the same conditions. The analysis results contradict the previous opinion on the failure frequency of plow and shearer systems. The final conclusion has been very well-argued and is supported by hard data. The comparison of both techniques in terms of their failure rate is new knowledge and can be treated as an argument when choosing an appropriate longwall complex.

Suggested Citation

  • Łukasz Bołoz & Zbigniew Rak & Jerzy Stasica, 2022. "Comparative Analysis of the Failure Rates of Shearer and Plow Systems—A Case Study," Energies, MDPI, vol. 15(17), pages 1-17, August.
    • Handle: RePEc:gam:jeners:v:15:y:2022:i:17:p:6170-:d:897302
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    References listed on IDEAS

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    1. Piotr Małkowski & Łukasz Ostrowski & Jerzy Stasica, 2022. "Modeling of Floor Heave in Underground Roadways in Dry and Waterlogged Conditions," Energies, MDPI, vol. 15(12), pages 1-27, June.
    2. Krzysztof Kotwica & Grzegorz Stopka & Marek Kalita & Dominik Bałaga & Michał Siegmund, 2021. "Impact of Geometry of Toothed Segments of the Innovative KOMTRACK Longwall Shearer Haulage System on Load and Slip during the Travel of a Track Wheel," Energies, MDPI, vol. 14(9), pages 1-25, May.
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    Cited by:

    1. Min Liu & Zhiqi Liu & Jinyuan Cui & Yigang Kong, 2023. "A Fault Diagnosis Method of the Shearer Hydraulic Heightening System Based on a Rough Set and RBF Neural Network," Energies, MDPI, vol. 16(2), pages 1-15, January.

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