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In the field of mining machinery, equipment maintenance and parts processing have always faced many challenges. Traditional processes are inefficient, unstable in quality, and harmful to workers’ health. With advanced water jet cutting technology, forplus provided a customized solution for a mining company and successfully solved its difficulties in the repair process of the cutting drum of the coal mining machine.
A mining company has long relied on full manual repair methods in the repair of coal mining machine cutting drums, and needs to repair more than 120 pairs of drums every year. The traditional repair process requires the use of air planers to cut the old tooth seats, which not only produces a large amount of smoke and arc radiation, seriously affecting the health of employees, but also leads to low repair efficiency and difficulty in meeting production needs. In addition, the various specifications of the drums, different degrees of wear, complex distribution angles of the tooth seats, and lack of accurate 3D model data further increase the difficulty and complexity of the repair work.
To address these challenges, forplus waterjet conducted in-depth research on advanced water jet cutting technology and developed a set of automated solutions based on ultra-high pressure water jet cutting technology and 3D visual recognition.
1.Cutting technology selection:
Ultra-high pressure water jet cutting technology is used. This technology uses high pressure water flow mixed with abrasive to generate strong cutting force. it is a cold cutting process with advantages such as no thermal deformation, smooth incision, high precision,and adaptability to cutting of various materials. Compared with the traditional “hot” cutting process, it can avoid physical and chemical changes of materials, and the cutting seam is narrow, which can save materials. There is no dust in the processing process, which is environmentally friendly and greatly reduces occupational health risks.
2.Core Equipment Configuration :
(1)High-pressure Pump System:
Adopts l+N series 6L/min ultra-high-pressure pump as the core high-pressure water generator.
(2)Robot Actuator :
An industrial robot is selected as the main actuator, including a vision module and a cutting head module. The vision module is installed in a closed manner, and the cutting head module is optimized in design, with a reduced end size and longer arm length to adapt to cutting operations in narrow spaces.
(3)3D Binocular Face Scanning Vision Sensor:
Using binocular face scanning grating 3D vision camera , high-precision scanning andmodel matching, to provide accurate positioning for cutting.
(4)Customized Control Software:
The software integrates 3D drive engine and digital twin technology, and displays the drum angle, gear seat position and simulated cutting status in real time. It has perfect permission control, automatic saving and power-off memory functions, and can coordinate various functional modules and multi-sensor data to realize process control, exception handling and alarm prompts.
1.The Cutting Efficiency is Greatly Improved:
The cutting time of a single tooth seat is <10 minutes, which is significantly improved compared with traditional manual cutting, effectively shortening the repair cycle of the coal mining machine cutting drum and meeting the production needs of mining companies.
2.The Cutting Quality is significantly Improved:
The cutting accuracy is high, the cutting surface is smooth and flat, which reduces the subsequent grinding process, improves the repair quality, and ensures the quality and stability of the new gear seat welding.
3.Improved Environmental Protection and Safety Performance:
The water jet cutting process does not generate dust, which reduces environment at pollution. The waterjet cutting is carried out in a relatively closed, silent and safe room,which effectively blocks noise and reduces health hazards to operators. At the same time,the waterjet is equipped with complete safety protection devices, such as electronic fences,emergency stop buttons, etc., to ensure the safety of the operation process.
4.The Comprehensive Benefits are Significant:
Through water jet automated cutting, the reliability and stability of the equipment are improved, which not only reduces labor costs, but also reduces the number of equipment maintenance and downtime, thus bringing significant economic and social benefits to mining enterprises.
The successful application of ultra-high pressure water jet cutting in the field of mining machinery fully demonstrates Forplus waterjet’s professional strength and innovation ability in waterjet cutter technology. In the future, we will continue to conduct in-depth research on the application of water jet cutting technology in the field of mining machinery, continuously optimize solutions, provide more customers with efficient, high-quality and environmentally friendly water jet cutting services, and help mining enterprises achieve intelligent upgrades.
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Copyright © 2025 Forplus Intelligent Equipment (Chongqing) Co., Ltd.