Benefits of Modern Gearless Hydraulic Direct Drive Systems in Mining

By Ashok Amin, North America Mining Segment Manager, Hägglunds Drive Systems (Bosch Rexroth USA)

In the mining industry, high-power density drive systems with a compact size and weight are essential when operating heavy, load-bearing machines. Modern gearless hydraulic direct drive systems have unique, attractive features that allow mining operators to exert more operational control, allowing for improved reliability and energy efficiency. Electro-mechanical drive systems, which have been used in mining for many years, have proven to be less reliable at times. As a result, operators are now exploring innovative, energy-saving choices with hydraulic direct drives that represent a clear return on investment (ROI).

The large, powerful machines in the mining industry are known for their lower speeds and high torque with continual movement. Some in the industry are hesitant to consider newer technology, which can prevent them from improving system operations. Assessing the benefits of change can offer operators insight into how to improve a mine’s overall efficiency while educating the industry on the benefits of gearless direct hydraulic drive systems with variable speed.

Reaping the Benefits of Fluid Power

In harsh environments that are elemental to mining, durable and reliable equipment and applications are essential to maintain longevity and consistency. While electro-mechanical drive systems have been the status quo for decades, modern gearless hydraulic drives offer sturdy, improved solutions that incorporate standard components for efficiency.

Ongoing research and development in recent years has led to better performance of gearless hydraulic drives, making them more reliable with reduced losses and a longer equipment lifespan. Productivity increases and the guaranteed ROI stemming from an extended lifespan and heightened reliability are all incentives for mining companies and their end-users to consider. Many companies that transitioned at one location have moved swiftly to streamline applications across all of their locations due to the tangible benefits of hydraulic applications.

Not only are hydraulic direct drive systems more efficient, but the application is compact and user-friendly. This is due to its modern control systems that use microprocessors and programmable logic controllers (PLC). The shift toward automation has helped produce a precise amount of control for machine operators, a task that has proven difficult with large machines and a need for hyper-specific movements. The electronic, remote operation of modern gearless hydraulic drive systems provides operators and mine managers real-time access to data and predictive maintenance capabilities, along with notable financial savings.

Environmental and Financial Impacts

Change can be difficult for more conventional industries such as mining with deeply ingrained traditions. As these machines consistently work, move, and carry heavy loads, the amount of energy it takes to power them is remarkable. With that being the case, there are consistent developments in policies and industry standards regarding carbon footprint and global emissions.

The Environmental Protection Agency (EPA) and other government agencies continue to ask major operators to prioritize energy savings, specifically promoting the transition to environmentally acceptable lubricants (EAL). The mining industry is responsible for 28% of total global emissions, emphasizing the importance of more sustainable practices that can be adopted using a shifted approach.

Mine operators can affect change through simple equipment swaps that can enhance operations. Mining equipment’s efficiency, energy savings, and carbon footprint can be significantly lowered when using servo motors with variable speed control for precise adjustment of the hydraulic systems’ pump flow. From there, smaller pumps and tandem pumps can be used to reduce energy, improve efficiency, and optimize the duty cycle of a complex mining application. Using servo motors in tandem with hydraulic drive systems also increases equipment responsiveness.

Promising energy savings, financial benefits, and a compelling ROI are all potential impacts seen when hydraulic applications are implemented with the right equipment. Upfront cost savings may be the most important initial factor, but identifying a solution with long-term benefits is a more functional, efficient decision. For example, EALs provide opportunities for operators to ensure EPA compliance and avoid regulatory fines, but they often cost more to use. Although these sustainable oil alternatives may be more costly upfront, avoiding these fines can impact ROI and total cost savings over time.

Promoting Education for Industry Adoption

There is a substantial opportunity for mining managers to serve as industry advocates to facilitate and maintain this shift. Properly managing hydraulic drives requires training and education to improve the full adoption and reap all benefits of the shift. Hiring qualified experts, facilitating ongoing training modules, and offering other on-site educational opportunities can improve the workforce and ensure successful solution application.

Additionally, industry collaboration through thoughtful conversation and continued learning can help overcome these challenges. This includes connecting engineering schools with industry entities to drive recruiting efforts within the areas of mining and hydraulic applications. Once operators learn about these key benefits, they can retrofit their machines with hydraulic direct drive systems to get started.

Mining remains a vital global industry with an immense impact on society and the environment. Discovering customized solutions requires a genuine team effort, involving the right individual contributors willing to make tough decisions, promote continued education, and demonstrate a willingness to embrace change.