The mining scheme of rope sawing machine and the use method of diamond rope sawing machine are adopt

Foreword: mining stone diamond wire saw abroad application already has a history of more than 30 years, early wire saw is only used to cut soft stone, wire saw worldwide mining marble mining technology has been very mature. For granite and other hard stone, after the rope saw, beaded wire manufacturers and mining enterprises long-term unremitting efforts, with a rope sawing granite mining technology is more and more mature, the wire saw can be widely used in granite, sandstone, etc on the hardness of stone mining, product quality is higher and higher, more and more low cost, has become a worldwide trend.
The scheme of rope sawing machine is adopted in stone mine
1. Basic information of mine
1.1 basic information of mining stone :(provided by the customer)
1.2 current basic mining conditions of the mine (provided by the customer)
2. Analysis on the advantages of diamond beaded rope saw in stone mining;
Compared with the traditional mining method, the application of rope saw mining has the following advantages:
(1) wide adaptability. The rope saw is suitable for all types of mines.
(2) strong function and high efficiency. First, the mining depth is deep, which can reach l0 ~ 20m or even deeper. Secondly, the cutting speed is fast, generally reaching 4 ~ 5m2 / h, which is 2 ~ 3 times of the conventional cutting.
(3) the rope saw can cut in vertical, horizontal, inclined plane and other directions, and can also perform blind cutting.
(4) high material yield and low comprehensive cost. First, the cut surface of the rope saw is very smooth and will not cause any internal damage to the raw materials. Second, the saw seam is small, only about 11mm, which will not waste resources.
(5) safe and environment-friendly, no noise and no dust in rope saw mining, high degree of automation, separated control, low labor intensity and high safety of workers; Conventional cutting noise and dust are very large, and the labor intensity of workers is large, the safety is relatively low.
3. Brief description of diamond string saw mining process
3.1 basic facilities requirements for chainsaw mining
The power supply
Electricity equipment mainly includes: rope saw machine, air compressor, multifunctional drilling, DTH drill, etc., all equipment of the voltage is 380 v, depending on the input of the machine electricity consumption for sure, with a 37 kw rope saw machine and the supplementary equipment, the total power should be around 60 kw, after considering the large-scale mining, can consider to add a 100 kva transformer, such as the early can save investment mining is realized by using diesel generator power supply;
Water and water supply capacity
Wire saw cutting, must through the cooling water, and in order to protect the wire saw sawing machine, cooling water amount depending on the number of machines, a rope saw machine cooling water consumption is 0.5 1 tons/hour, so must ensure that sufficient water and water supply capacity, conditions permit, can be used in a circulating water supply mode, establish circular pool, with continuous uninterrupted water supply ability;
Simple and easy road
There must be a simple road to the mine and a guarantee that all kinds of mining equipment and stone materials can be transported through trucks of more than 20 tons.
3.2 cutting and mining process of rope saw
3.2.1 preparation
(1) the mountain stripping: stripping work is mainly peel off the cover soil on the marble ore body, weathering, peel off layers, surrounding rock and joint fracture without broken marble mining value, make the marble ore body are exposed, to be prepared for the mining work. Special attention should be paid to the protection of the ore body. Blasting vibration is not allowed to affect the integrity and fragmentation of the stone. (2) the construction work platform: after exposure of the marble to digging out the rope saw machine work platform, generally width in 6 m, length according to landform, stope steps in 5 to 10 meters high. In general, drilling and expansive agent are adopted for excavation. Blasting method can be adopted for granite, and matting soil layer can be adopted for the relatively gentle slope.
3.2.2 preparation before mining
(1) drilling
Drilling is a key preparation work. If the hole drilling is not good, it will directly affect the string penetration and affect the service life and cutting efficiency of the string. Therefore, drilling is of particular importance. You must drill three holes, one vertical hole and two horizontal holes, to cut a large piece of waste material. The three holes intersect at one point. If the three holes do not intersect at one point, the perforation of diamond string string is troublesome, and even cannot be worn, so it needs to be redrilled, which reduces the production efficiency. Therefore, drilling must be carried out according to the actual situation and the operating rules. The equipment used for drilling can be used as multi-function rock drill, underground hole drill, manual rock drill, etc.
(2) ropes
Using artificial lacing method, will be fixed at the end of the rope on the thin wire rope, the other end of the cord by multi-strand cord (usually a hammer hung thread), from a hole, vertical plane can use water to rush out the soft line, horizontal wire from the another hole, and then out of the steel cord lead wire saw.
(3) the rope sawing machine is installed in place
After lacing, first laying equipment of orbit, orbit should be parallel to the horizontal hole, and clean measurement orbit plane levelness and make it meet the requirements, the lifting rope saw machine to orbit, hang up the rope saw, connected to the power supply. Due to the heavy equipment, after cutting a plane, the equipment needs to be moved again. Any one of the equipment such as mast crane, forklift truck, loader, excavator can be used to move the sawing machine.
(4) turn on the water, cooling water pipe installation, generally need to configure the two pipe, a set up at the entrances to the rope hole location and another in the export of rope position, and as the cutting progress need to constantly adjust the position and the water outlet direction.
3.2.3 stone cutting
In order to ensure the smooth cutting, it is necessary to cut the horizontal plane before cutting the vertical plane. If the vertical plane is cut first and then the horizontal plane is cut, it is easy to break the stone material and press the string of beads, thus causing the motor to slide in idling and damage the rubber of flywheel. More serious will cause the rope saw scrap.
The cutting method commonly used in mining is primary cutting - pull - over (off) - secondary cutting and shaping. Is the main purpose of a cut in the mountains to cut out of stone, stone depends on the size of the ore body, carrying capacity, the size of the stone material utilization factors determine, usually in 30 to 60 m3, after the stone cutting, the stone away from the ore body with winch or loader overturned and pull over the gravel, second cutting and shaping, cutting out the shortage of commercial value.
The cutting methods commonly used in rope sawing machines are as follows:
A vertical cutting method (figure omitted)
B horizontal cutting method (figure omitted)
C 90 degree cutting method (figure omitted)
D blind cutting method (figure omitted)
4. Capacity estimation, equipment and personnel allocation
Equipment and personnel shall be allocated according to the set capacity. Since the mine does not provide a clear production capacity target, we can only use a rope sawing machine as the main equipment, considering the most reasonable auxiliary equipment configuration and personnel configuration, and calculating the production capacity. If the mine needs to expand its production capacity, the required configuration can be copied accordingly.
The usage of Diamond rope sawing machine
A beaded diamond rope sawing machine is used to extract stone materials. The machines, tools, conditions and processes used in these two methods are different.
(1) circular sawing
This method is also called lasso saw cutting method. The essence of which is: a string of beads that form a ring type diamond wire wrapped around by the cutting rocks, with the aid of diamond sawing machine move rope wheel rotation with two kinds of sports, warping beads type diamond wire cutting rock. The length of cutting curve and radius of curvature change from large to small.
This method is applicable to both mining and cutting of working face and plastic cutting of stone after stone segmentation. This method is only used for beaded diamond rope saw.
Vertical and horizontal cutting can be made when mining and cutting working face. In vertical cutting, both vertical cutting and vertical cutting can be carried out for the machine to stand horizontally above the front cutting, or machine standing horizontally below the front cutting.
The process of circular saw cutting is: perforation, lasso and saw cutting.
Perforation: first perforation is made at the position of the sawing face design. If the vertical saw is cut, a vertical hole and a horizontal hole are right angles to each other. The aperture is 40-70mm. Vertical holes can be made by drilling rig, while horizontal holes should be made by horizontal guide groove drill, which can Pierce holes slightly higher than the ground & '%. The benchmarking on the equipment can be used to ensure the correct connection with vertical holes.
Lasso: when two lacing hole through, will wear beads type diamond wire into the vertical hole, from horizontal hole in the metal hook is pulled out, will dock beads type diamond wire ChengWuJi ring, set on the driving wheel diamond sawing machine. The diamond rope is supported so that the two guide wheels and the holes through the two guide wheels should be on the same plane, with correct direction and no deviation. Saw cutting: saw cutting according to the operation requirements and procedures.
(2) under pressure sawing
This method is also called compression cable saw cutting method. The essence of the diamond string is that the beaded diamond rope is driven by the driving rope wheel of the sawing machine. The cutting curve is limited by the working face length. The length and radius of curvature are not very different, and the cut rock is below the beaded diamond rope. This method is only applicable to the mining and cutting of the working face, not to the plastic cutting after stone segmentation.
This method must be used in conjunction with multi-purpose drilling rig or cutting working pillar. And only vertical cutting.
According to the different equipment used, there are several ways as follows:
1. Cut with a multi-purpose drill or cutting working pillar
When the field in front of the cutting step is open, it is suitable to install the diamond sawing machine. Only one hole should be drilled on the working step, and the cutting can be carried out in cooperation with the drill. See figure 1-37. This method is more suitable when the ore body has a natural bedding surface.
2. Cooperate with two multi-purpose drilling RIGS or cutting work pillars for cutting
When the step length is sufficient and the cutting surface parallel to the top line of the step should be sawed, two drilling RIGS can be used to work. The drill and the saw are arranged in a straight line. If there is no trench, two holes should be drilled and two RIGS installed to work together. See figure 1-38. If there is a trench, the drilling rig (or cutting work pillar) can be placed in the trench to work together.
Under - pressure saw cutting process: drilling - saw cutting. Because this method only needs vertical hole, does not need to wear horizontal hole, therefore does not have cable technology.
Operation technology
(1) control of curve radian of cutting curve
When circular cutting is adopted, the length of the cutting curve and the radius of curvature change from large to small, and the bending stress of the rope changes accordingly. In conclusion, the bending stress of steel rope is related to the ratio of drum diameter to rope diameter. When the ratio of drum diameter D to steel rope diameter D is used, i.e., D/ D <=60, the decrease of D/ D will lead to a sharp increase in bending stress of steel rope.
For beaded diamond rope, its diameter is 4-5mm, although in the design of diamond sawing machine, the maximum flexibility and bending stress of the rope have been taken into account. But the sharp edges of the rock, in the process of sawing hard inclusions when in contact with the rope will inevitably produce bigger impact stress, especially in cutting curve radian is large, the rope is too large bending will make bending stress has increased dramatically. This will lead to a broken rope accident. After breaking the rope, five beads will be scattered and lost, increasing the cost of mining. Therefore, the reasonable control of the curve radian is of great significance.

The following measures may normally be taken:
When cutting large rock mass vertically, the sharp edges and angles of rock should be treated first. After the rope wheel is driven by the sawing machine, it naturally opens to the top of the rock body. The upper guide wheel cutting in front of the sawing machine is not needed. In the early stage of horizontal sawing, the rope is surrounded by four edges and corners, which can increase an auxiliary guide wheel to open the rope and reduce the increase of bending stress of steel rope.
When the sawing surface is about 30cm from the rock edge, the sawing should be stopped, so as to avoid the increase of bending stress and shortening service life of the rope due to too small bending radius.
The initial distance between the sawing machine and the working face can be measured by tensioning the saw rope, but it should not be over-tensioned to avoid difficulties and damage of beads when starting.
(2) feed speed control
The feed speed has a great relationship with the sawing efficiency and the wear amount of beads. The feed speed is related to the linear speed of the rope wheel driven by the sawing machine and its backward speed on the guide rail. The tension degree of the rope ensures the necessary pressure during sawing. Under the premise of sawing pressure, the increase of the stress of the steel rope should also be considered. Because the increase of saw cutting pressure must increase the traction of steel rope. When the cutting pressure is constant, increasing the traction speed of steel rope can improve the cutting efficiency and increase the stress of steel rope. On the contrary, the cutting pressure is too small, the cutting efficiency is also small, is not desirable. The wire speed of the rope has a great influence on the cutting efficiency of the saw. However, excessive cooling makes the cooling condition not good, but makes the power consumption increase, the diamond wear too fast, the temperature rise. So we have a reasonable velocity. This is related to the sawing machine performance, rope quality, stone hardness and other factors. And the speed is different at different sawing stages. Usually, the feeding speed is 3/4 of the normal feeding speed at the beginning of sawing and cutting stage. When the saws are more than 100mm deep and the sawing curve is relatively smooth, the feeding speed can be increased to reach the normal value. The speed should be reduced at the end of sawing. Monitor the control instrument closely during operation. The pressure value is in the optimal state of saw cutting. For electronic controlled diamond sawing machine, automatic control can be realized and the work is reliable.
(3) feed water control
In the process of sawing, water should be supplied continuously, which not only plays the role of scouring and removing mud from saw joints, but also plays the role of cooling diamond rope to improve the service life. Because of the diamond is composed of carbon element, heat will make its physical performance, when the temperature of 950 degrees Celsius, it is oxidation diamond combustion produces carbon dioxide (powder), losing the ability to sawing. Therefore, enough cooling water and its correct supply are important guarantee to improve the quality of sawing and reduce the wear of rope.
Cooling water is generally no less than 15L per minute, and the quality of water is also important. It is better to use soft water without sediment, especially for stone materials that can produce adhesive abrasion mud when sawing. When adding water, the water should be injected from the direction of the rope into the saw seam.
3. Maintenance and safety
(1) regularly check the intact condition of the joint and other parts of the saw rope. The guide rail of the drive rope wheel should be kept clean and cleaned with gasoline in time. No lubricating oil is needed to avoid the adhesion of rock powder.
(2) change the oil every four months.
(3) regular maintenance, semi-annual minor repair, and biennial major repair.