International Conference on Global Trends in Engineering, Technology and Management (ICGTETM-2016)
Up-gradation of Rollers in Track of Open Pit Mining Rig
Jagruti Patil
Department of Mechanical Engineering
Shrama Sadhana Bombay Trust’sCollege of Engineering and Technology,
Bambhori, Jalgaon, Maharashtra, India
Mr. P. G. Damle
Department of Mechanical Engineering
Shrama Sadhana Bombay Trust’sCollege of Engineering and Technology,
Bambhori, Jalgaon, Maharashtra, India
Mr. Gajendra Patil
Department of Mechanical Engineering
S.S.G.B. College of Engineering and Technology,
Bhusawal, Maharashtra, India
Abstract— The present project relates to the
modification of roller in track frame design. The work
will carried out with up gradation and design of roller
used in tracked vehicles. The Difficult geological
conditions and more intense mining processes taking
place today in many building sites lead to a high
mechanization level of building works. Because of
this, specialized self-propelled Drilling machines are
constructed, which enable a sufficient progress in the
mining works. Among the machines most frequently
used in the mining and building sites, there are those
directly used in the preliminary works.
In this project, track tension monitoring methodology
will develop so that the track tension can be estimated
under various manoeuvring tasks. That is, the
information of the track tension should be obtained
both in real-time and on-line when the proposed
methodology will implemented on tracked vehicles. So
the need of project is to upgrade the roller for track
frame to sustain the increased weight of new upgraded
technologies on the machine and by maintaining
minimum cost of manufacturing of machine so making
it compatible to all surface drilling machines.
Thus to validate the part as per specifications some
design modification needs to be done. This project
develops the dynamic equations of motion for the
planetary roller screw mechanism accounting for the
screw, rollers, and nut bodies. First, the linear and
angular velocities and accelerations of the
components are derived. Then, their angular
momentums are presented. Next, the slip velocities at
the contacts are derived in order to determine the
direction of the forces of friction.
Keywords—Track rollers, Track of Crawler.
I. INTRODUCTION
Surface Drilling Machines are large crawler
mounted mining machines which have various
component assemblies like boom, Feed assembly,
Rotation assembly and Track assembly etc. While
working in mines, machine needs to take various
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position of drilling for making a hole. Hence machine
need to move from one hole position to another by
tramming. Tramming is the process for moving the
machine from one place to another. Drilling is the
process of making a hole into a hard surface where the
length of the hole is very large compared to the
diameter. In the context of mining engineering drilling
refers to making holes into a rock mass. Surface
mining requires drilling for different purposes that
include:
1. Production drilling i.e. for making holes for
placement of explosives for blasting. The objective of
drilling and blasting is to prepare well-fragmented
loose rock amenable to excavation with better
productivity from the excavation machinery. The
holes drilled for this purpose are defined as blast hole.
2. Exploration drilling for sample collections to
estimate the quality and quantity of a mineral reserve.
The samples are collected as core and the drilling for
such purposes are referred as Core drilling. As
diamond bits are used for such drilling, core drilling is
often called diamond drilling.
3. Technical drilling during development of a mine
for drainage, slope stability and foundation testing
purposes. Opencast mining involves removal of waste
rock and subsequent winning of the mineral. In case of
deposits underlying hard and compact waste rock
called over burden loosening of the rock mass is
essential prior to excavation. Thus drilling and
blasting is the important ground preparation job.
Unless the rock mass is highly weathered and very
much unconsolidated drilling of holes for placement
of explosives and detonating them for blasting is
required for any mining operation. Modern machines
like continuous surface miner can however eliminate
the need of drilling and blasting in certain surface
mining operations. Successful drilling under specific
site conditions requires blending many technologies
and services into a coherent efficient team,
particularly if it is for deep exploration drilling. Blast
hole drilling is comparatively simpler. However, to
minimize costs and optimize the performance and post
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International Conference on Global Trends in Engineering, Technology and Management (ICGTETM-2016)
drilling operations technical managers and decision
managers must understand the language and
technology of drilling operations.
The modern hydraulically operated drills have
number of advantages over pneumatic drills. These are:
1. The self-contained diesel powered hydraulic
percussive drills do not require auxiliary compressor
for drill operation.
2. Energy delivered per stroke being higher,
hydraulic percussive drills offer higher penetration
rate compared to the pneumatic drill.
3. Less noisy
4. Many hydraulic drill claims energy saving as
high as 66% than pneumatic drilling. Vertical blast
holes are most common. However, to avoid formation
of hard toes and to obtain better fragmentation and
reduced vibration level inclined blast holes are more
useful in many situations. A hard strata occurring at
depth in the lower horizon of a high bench is better
blasted by horizontal blast holes. However, horizontal
drilling is not normally carried out in opencast mining
due to the difficulties associated with drilling and
charging.
The Difficult geological conditions and more
intense mining processes taking place today in many
building sites lead to a high mechanization level of
building works. Because of this, specialized selfpropelled Drilling machines are constructed, which
enable a sufficient progress in the mining works.
Among the machines most frequent l used in the
mining and building sites, there are those directly used
in the preliminary works. There are various systems
used in drilling pit mining machine are:
•
Feed assembly
•
Rotation assembly
•
Boom assembly
•
Track Assembly.
tracks. The up gradation of roller for track therefore
required identifying the worst loading conditions
using simple force analysis. Machines used in surface
mining such as derricks, roof bolting machines,
loaders, transportation vehicles as well as their subcomponents are subject to requirements radically
different from machines operating on the surface.
Considering their specific applications, these
machines are subject to adverse and variable operating
conditions and are often subject to percussive loads.
The exploitation conditions are much heavier and
severe in general. Design of mining machines should,
therefore, result in a reliable construction that
withstands the required loads on track frame whilst
also being economical.
A. Problem Identification
The up gradation of roller in existing track is
required to maintain the ground pressure as per Drilling
Rig safety standard. Existing machine consist of 6 Nos
of roller per track Hence total No. of roller becomes 12
nos including both track. As per Company field report
analysis there was wear in roller after few working of
hours of machine. There are several drawback they
found during the inspection. Out of draw bags it is
suggested to change the roller size including Nos of
Roller pre track system.
Load distribution is not equal in sprocket
mechanism of track vehicle due to less number of
rollers. Hence more chances of failure due to uneven
loads. More wear and tear of rollers. Less life of roller.
The purpose of up gradation of roller for track frame
was to overcome the failure problem at various worst
load conditions and to develop a universal track
assembly that would sustain the maximum weight with
higher capacity.
So the need of project is to upgrade the roller for
track frame to sustain the increased weight of new
upgraded technologies onthe machine. And by
maintaining minimum cost of manufacturing of
machine so making it compatible to all surface drilling
machine. Thus to validate the part as per specifications
some design modification needs to be done.
B. Expected Outcomes


It was noted that it is essential to increase the load
carrying capacity of track frame by reducing the wear
of roller in track assembly. The company has desired
that entire machine be made out of standardize
components and machine parts and units for
interchangeability reasons. The company desires to
upgrade a universal track with the up gradation of
roller which could be mounted on various types of
ISSN: 2231-5381


Cost effective solution for the highly under
stressed Track
Solutions for the Weakest part of the machine
which must be very strong
Track frame design & selection of roller to
sustain the load without fracture and wear at
its extreme downward position of drilling.
Newly design track will also be applicable for
the machine which will going to use for 6‖
drilling Hole Applications.
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International Conference on Global Trends in Engineering, Technology and Management (ICGTETM-2016)
One of the aims of FEM computations is to
identify the stress field generated by the tramming
operation to determine its effect on the life of the track
and roller. Most of the structural members will model
using standard plate‘selements. As compared with
other track frame models, shell models yield more
precise results since they take into account the ways in
which the structural members are joined together and
their influence on the stress field (e.g. in the vicinity
of welded joints). The effort will calculate for the
loads specified as per specified extreme condition.
Static and changing loads, will be define as given in
the standard, and will be analyse as per the condition.
The source of changing loads are dynamic interactions,
body forces produced by operating motions, tilts,
output loads, digging forces, etc.
II. BACKGROUND
Earlier investigations were focused at increasing
performance of track frame for surface drilling
machine. The difficult geological conditions and more
intense mining processes taking place today in many
building sites lead to a high mechanization level of
building works. Because of this, specialized selfpropelled drilling machines are constructed, which
support for sufficient progress in the mining works.
These are the vehicles used for stabbing, drill rigs and
bolt setters. The common feature of these machines is
the fact that the whole load of various system are
placed on a track assembly. The roller mounted on
track. Track should have a sufficient variable load
carrying capacity.
(Mohamed A Omar1, 2014) presented a
formulation and procedure for incorporating the
multibody dynamics analysis capability of tracked
vehicles in large-scale multibody system. The
proposed self-contained modular approach could be
interfaced to any existing multibody simulation code
without need to alter the existing solver architecture.
Each track is modelled as a super-component that can
be treated separate from the main system. The supercomponent can be efficiently used in parallel
processing environment to reduce the simulation time.
In the super-component, each track-link is modelled as
separate body with full 6 degrees of freedom (DoF).To
improve the solution stability and efficiency, the joints
between tracks links are modelled as complaint
connection.
The spatial algebra operator is used to express the
motion quantities and develop the link‘s nonlinear
kinematic and dynamic equations of motion. (Choi,
Lee, & Shabana, 1998) proposed a spatial multibody
model for a full tracked vehicle system. In this model
the links were connected with revolute joints.(Choi,
Lee, & Shabana, 1998) extended their work in 1998 to
develop force modules that can account for the contact
between the track links and other components. The
interaction between the track and terrain was modelled
using simple soil mechanics based forces.(Ryu, Bae,
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Choi, & Shabana, 2000) created a three-dimensional
multibody model similar to that by (Ma & Perkins
2006) and (Madsen 2007), except that the vehicle has
a compliant track chain.
1.Kunsoo Huh and Daegun Hong ,2001, ―Track
Tension Estimation in Tracked Vehicles Under
Various Maneuvering Tasks‖ Hanyang University,
Sungdong-ku, Haengdang-dong 17th,Seoul, Korea
133-791 JUNE 2001, Vol. 123/ 179.
III. INTRODUCTION TO
UNDERCARRIAGEAND ROLLER
A. Undercarriage Basics
Undercarriage Assembly-The total undercarriage
assembly of a dresser crawler is made up of
components that transfer tractive effort from the
tractor to create forward or reverse motion. Front
Idler-It is basically used for making chain in tension.
A large wheel at the front of the track frame that
guides the track chain and absorbs shock loads. It is
adjustable for proper track chain tension.
Fig. 1 Undercarriage Assembly
SprocketAll dresser crawler use a hunting tooth design sprocket,
which consist of an odd number of sprocket teeth. This
design permits each tooth to make contact on every other
revolution. The same sprocket is used for the dry seal and
the lubricated track system.
Top IdlersThese are used for support to the track chain. Metal
wheels at the top of the undercarriage which support and
guide the track chain assembly between the sprocket and
front idler.
Track RollersThe Rollers delivers load from track frame to track
chain. Rollers are mounted in series. Metal wheels mounted
to the bottom of the track frame which supports the tractors
weight and which rolls over the rail portion of the track
chain.
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Fig. 3 Roller Assembly
Fig. 2 Track Roller
Components Of Roller.
1. Rubber Load Ring
2. Roller Shaft
3. Roller Shell
4. ‘O‘Ring
5. Outer Shell
6. Flange
7. Heavy Duty Brackets
B. Roller Wheels
Roller wheels mounted to the undercarriage frame
transfer machine weight to the track. The wheels,
acting as contact points, help distribute machine
weight evenly across the ground through the track. As
a comparison, a skid steer loader concentrates
machine weight on the four points where tires contact
the ground. Roller wheels also help guide the track.
Track lugs travel between or outside the roller wheels
and are kept in alignment when the machine turns or
works on slopes. Roller wheels are constructed of a
high-density plastic core with rubber bonded to the
circumference. The bonded rubber provides a
cushioned surface to minimize track wear where the
rollers contact the rubber track.
The rubber acts as a cushion to help resist track
damage when rocks or debris are caught between the
roller and track. This prevents pushing the debris into
the belt and damaging it. Roller wheels are wear item
and need to be replaced periodically. Operation in
abrasive conditions, as well as improper operating
technique, can cause the rollers to wear faster.
Because of the open design of the undercarriage,
replacement of a worn wheel can be easily
accomplished.
The CAT MTL undercarriage roller wheel hubs
incorporate heavy-duty metal face seals which are
sealed for life. This design helps to avoid
contamination, leaks, and provides a long service life
for the bearings. This proven technology is seen in
other pieces of Caterpillar equipment, including larger
Track-Type Tractors.
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Roller wheels mounted to the crawler frame to
transfer machine weight to the track. The wheels,
acting as contact points, help distribute machine
weight evenly across the ground through the track.
Roller wheels also help guide the track. Roller wheels
are constructed of a high-density plastic core with
rubber bonded to the circumference. The rubber acts
as a cushion. Roller wheels are wear item and need to
be replaced periodically.
The three key functions of undercarriage roller
wheels are:
1. Distribute weight of machine from the frame to
the track.
2. Guide the track.
3. Provide a cushion between the tracks
IV.EXISTING TRACKFRAME AND ROLLER
Primary level study states that load of machine
sustating per roller is somewhat higher. Hence it is
necessary to increase the no. of roller so that
weight to No roller ratio get improved.
A. Current Track Specifications
According to company‘s internal FSM report and
their pre study it is required to take some
improvement action on crawler.
Fig. 4 Schematic Diagram of track frame
Total weight of m/c is 15.5 ton.
No. of roller is 6
Total Length (L) = 3177 mm
Total Height (H) = 8
70 mm
Total Width (W) = 320 mm
Centre distance between Sprocket and Idler
Gear (C) = 2660 mm
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International Conference on Global Trends in Engineering, Technology and Management (ICGTETM-2016)
B. Design of Existing Roller
Overall Dimensions of Existing RollerDiameter of Roller-135mm
Length of Roller-140mm
No. of Rollers used in track -6
Fig. 5 Schematic Diagram of existing Roller
Fabrication of Model & Radiography for
Fabricated Track frame.
Assembly of roller and track on machine.
Test and validation of actual component on
site.
ACKNOWLEDGMENT
Apart from the efforts of me, the success of
this Seminar depends largely on the encouragement
and guidelines of many others. I take this opportunity
to express my gratitude to the people who have been
instrumental in the successful completion of this
Project.
I take immense pleasure in thanking Prof. Dr.
K.S. Wani, Principal, Shri S.S.B.T‘s College of
Engineering And Technology and Prof. D.S
Deshmukh, H.O.D. Department of Mechanical
Engineering and Prof. P.N. Ulhe, P.G. Coordinator,
for all their valuable assistance in the seminar work
I wish to express my deep sense of gratitude
to my Guide, Prof. P.G. Damle for his valuable
guidance and useful suggestions, which helped me in
completing the seminar work, in time. I would also
mention that he had been a source of inspiration and
for his timely guidance in the conduct of our project
work.
REFERENCES
Fig. 6 Drafting of existing Roller
C. Preliminary Changes suggested:
Increase no. of roller from 6 nos to 7 nos.
Increase the diameter of roller according to size
available in market and feasible to machine.
Modify the track frame accordingly.
Increase in roller size will also help to
improve the ground clearance of machine.
V. METHODOLOGY
To find the solution for identified problem, we
will go through the steps given as below.
Theoretical calculation over roller
Selection of roller based on calculation
Creation of 3D model and drawing using Pro
Engineer software
Verification of proposed design by FEA
analysis using analysis software ANSYS.
Correction of Design Model on the basis of
FEA Analysis.
Updating and Release the Drawing for
Fabrication.
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Compliant Tank Link Model for High-Speed, High-Mobility
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1502.Kar, M. K., 1987, ‗‗Prediction of Track Forces in Skidsteering of Military Tracked Vehicles,‘‘ J. Terramech., 24, No.
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2. Models as a Basis of Test Stand Simulation of the Turning
Resistance of Tracked Vehicles,‘‘ J. Terramech., 29, No. 1, pp.
57–69.
3. Ma, Z.-D., and Perkins, N. C., 1999, ‗‗Modeling of TrackWheel-Terrain Interaction for Dynamic Simulation of Tracked
Vehicle Systems,‘‘ ASME paper DETC99/VIB-8200,
Proceedings of the ASME 17th Biennial Conference of
Mechanical Vibration and Noise, Las Vegas.
4. Nakanishi, T., Yin, X., and Shabana, A. A., 1996, ‗‗Dynamics
of Multibody Tracked Vehicles Using Experimentally Identified
Modal Parameters,‘‘ ASME J. Dyn. Syst., Meas., Control, 118,
pp. 499–507.
5. McCullough, M. K., and Haug, E. J., 1986, ‗‗Dynamics of High
Mobility Track Vehicles,‘‘ ASME Journal of Mechanisms,
Transmissions, and Automation in Design, 108, pp. 189–196.
6. Huh, K., Cho, B. H., and Choi, J. H., 1999, ‗‗Development of a
Track Tension Monitoring System in Tracked Vehicles,‘‘
ASME IMECE Conference, DSCVol. 67, pp. 461–468.
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