Design Ripper Excavator Back Hoe

On Overburde Stripping For Coal

Mine
Small-Scale
Sumar Hadi1, Muhammad Nur Irfan2
Department of Mechanical Engineering, Diponegoro University, Indonesia
sumarhs.undip@gmail.com

ABSTRACT: Bulldozer Ripper is a tool that serves to rake rock hard. The use of a ripper on
the stripping of overburden to increase production, minimize operating costs, especially for
fossil fuel use, and maintenance costs and unloading digging tools. Stripping of overburden
without carded first cause "cycle time" digging tools fit larger load capacity "bucket" (Fill
Factor) is very small, ie between 75% - 85%, "tooth bucket" more rapid wear and tear, and
the use of fuel oil more. Using a "ripper" on stripping overburden to increase production,
reduce the use of fuel oil, and directly minimizing operational costs.

KEYWORDS: Ripper, Bulldozer, overburden, Cycle Time.

I. PRELIMINARY Demolition by means of explosives,

Region of East Kalimantan has the
potential of coal is quite large and evenly
distributed almost all areas, so in the spirit of
regional autonomy and supported by the
demand of coal for various industries, both
domestically and abroad that encourages
local entrepreneurs to turn to coal mining
activities with small scale up medium.
Mining companies are small to
medium bersekala have difficulty in
achieving production targets, due to
overburden material is very compact, solid,
and keras.Kekerasan material can be
classified as follows: soft or easy digging,
medium hard digging, digging hard, very
hard digging or rock. Classification of rock
types very hard digging before excavated
must first be detonated. The rock types
dominate the overburden in coal mines,
especially in the East Kalimantan region, so
that companies have difficulty in
pembongaran and stripping. Alternative
made in the achievement of production is by
means of explosives.
requires substantial funds and require special
handling, besides causing various effects in
its use as vibration blasting and toxic gases.
To achieve the production target of stripping
of overburden without blasting is by using a
"ripper" that serves as the rake before
excavated and published by Excavator Back
Hoe.
II. THEORETICAL BASIS
Ripper consists of several types that
can be classified as follows:
a. Multi-shank Rippers (Rigid type),
Ripper has three shank rippers are
arranged in parallel. Multi-shank
rippers is very efficient for use in
areas that have a soft material for the
corner digging (digging angel)
ripper can be optimum. Rippers
Multi-Shank image can be seen in
Figure 1.

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Figure 1 Multi-shank Rippers
(Rochmanhadi, 1992)
b. Multi-shank Rippers (Variable
type), Ripper has three ripper point
hydraulically angle can be varied
according to the conditions of
material dug .. Picture Rippers
Multi-shank can be seen in Figure 2.
Figure 2 Multi-shank Rippers
(Rochmanhadi, 1992)
c. Giant Rippers (Variable type)
Giant rippers are designed
specifically to break the rock
material hard enough. Ripper Ripper
has a point that can be set
(adjustable) in order to conform
with the excavated material. Rippers
Giant image can be seen in Figure 3.
Figure 3 Giant Rippers (Rochmanhadi,
1992)
Production equipment is calculated
drngan attention to the factors that affect,
among others:
1. The type and capacity of equipment
The type of equipment used for
small-scale mining activities are: Equipment
digger (excavator Back Hoe PC 200 PC 400),
drag the tool (Bulldozer D85-D375), and
Conveyance (dump truck with 6 wheels - 10
wheels).
2. Working hours
As coal mining company in general,
the number of working days mines
(production) accounted for 300 days per year,
with a planned holiday is Hari Raya ldul Fitr,
the Feast ldul Adha, Christmas, New Year,
and Sunday as well as other big day. While
working hours per day from 7 hours to 15
hours.
3. Hours of operation tool
Based on observations at several
coal mining company, that the tool working
hours is influenced by several factors, among
others: the weather, the willingness of the
tool, and its effectiveness. The value of each
factor is estimated as follows:
a. weather factors
Weather factors affecting the
production of calculators by using the
formula:
𝑇𝑅
𝐹𝑐 = 1 − ( )
𝑊
Where:
Fc = Factors weather
TR = Hours lost per year
W = Hours
Total hours lost are calculated using
rusumus:
𝑇𝑅 = 𝑅 𝑥 (𝑅ℎ + 𝑇ℎ)
Where:
TR = Hours lost per year
R = Average days of rain per
year
rh = Hours hujan every day
th = Clock every day cleaning
mud rain
b. Factors willingness tool
(Mechanical Availability, MA)
The availability of tools is a factor
that is used to indicate the readiness of a
device to work, where ketidaksiapannya is a
result of the repair and maintenance (repair
and maintenance). The availability of tools is
determined from the ratio between the
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working hours of effective and effective Table 2 Job efficiency ripping
hours plus hours of maintenance / repair.
Operating conditions job Efficiency
𝑊 Good (Good) 0.75
𝑀𝐴 = 𝑥 100%
𝑊+𝑅 A verage (average) 0:58
Rather poor (rather ugly) 0:50
Where: Poor (ugly) 0:40
MA = mechanical availability
W = Working Hours
Actual production tool rake is
R = Repair
calculated using the following formula:
c. The effectiveness factor (Use of 𝑃𝑎 = 𝑃𝑠 𝑥 𝐽𝑒
Availibility, UA)
Effectiveness factors used to Where:
demonstrate the effectiveness of an operation, Pa = Actual production
in which the tools do not effectively work due ps = Standard production
to lack of coordination and adjustment. Je = job efficiency
Factors equipment effectiveness is
determined by the ratio between the hours of Figure 4 to Figure 7 Ripper in design
operation with total available working hours. using Solidworks.
𝑊
𝑈𝐴 = 𝑥 100%
𝑊+𝑅+𝑆
Where:
UA = Use of availability
W = Working hours
R = Repair
S = standby

The production capability of the tool

rake (ripper) to the specifications of each
instrument whose value is determined based
on the material hardness in wave velocity
Figure 4 design Rippers
values format (seismic wave velocity). The
ability of a standard production tool rake
Komatsu D 155 and 0375 in various
conditions of the material hardness is shown
in Table 1.

Table 1 Standard production tool rake (bcm /

hour)

Type Seismic Wave Velocitv (m / s)

Tool 500 750 1000 1250 1500 1750 2000
D155 705 520 388 286 203 133 72
D375 1383 1059 828 650 504 380 272
Figure 5 Rippers design looks aside
And based on Job Efficiency
Ripping who constitute the actual operation
penggaruan are affected by the conditions in
which the operating efficiency of the
appliance is not operating at full capacity in
one hour. Value Job Efficiency Ripping is
dlihat in Table 2.

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Figure 6 Dimensional Rippers looks ahead
Figure 7 Dimensional Rippers looks aside
4. METHODOLOGY
This research workmanship step as
illustrated in Figure 8. Research methodology
The research methodology is a step or
sequence and used as a researcher in
conducting research.
Figure 8 Research Flow Chart
In Figure 8 is a processing flow
chart of this research. The first step is
determining the dimensions do Ripper. In this
case the connection with data retrieval. Then
the survey material. Do overburde stripping
process that divided two, with and without the
Ripper Ripper. After the stripping process
overburde stripping and profit results
obtained between the two processes, select
the process more profitable results between
the two methods is seen from the time, money
and fuel.
5. RESULTS AND DISCUSSION
1. Production Ripper
Referring to the general conditions
of the overburden material in the region of
East Kalimantan which has fast propagation>
1000 m / s, then the existence of the tool rake
in principle is needed. Assuming a hard
material having a hardness value of
propagation of 1250 rn seconds, then the
production tool in the Job Efficiency rakes
0375 averages, are:
𝑃 = 650 𝑥 0,58 = 377 𝑏𝑐𝑚/𝑗𝑎𝑚
Of the large number of production
shows that 377 bcm / hour uncovered
overburden material without blown up,
making it easier Excavator Back Hoe in
digging and loading.
2. Demolition without Ripper
Stripping of overburden without
raked in advance using ripper cause a "cycle
time" digging tools fit more especially when
digging and loading capacity "bucket" (Fill
Factor) is very small, ie between 75% - 85%
due excavated material in the form of chunks
large ,
Based on the observation of the
production target of between 245,000 bcm
overburden stripping - 350,000 bcm per
month using 3 units Excavator Back Hoe
Komatsu PC 300 as digging tools fit with the
conditions of the willingness of the tool 90%
indicated that the production target has never
been reached. This is due to a hard and tough
material uncovered, on the other hand use
more fuel and "tooth bucket" faster wear out.
From the calculation of production
stripping overburden at. Gema Coal Abadi is
a mining contractor PT. Insani Bara Perkasa
seen in Table 3.
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Table 3 Production stripping overburden
2005

No. Month Production (bcm)

1 January 107,000
2 February 115,000
3 March 110,000
4 April 101,000
5 May 105.000 Figure 9 Ripping method of cross-maze
6 June 110,000
7 July 125 600 With this method, the rock would be
8 August 130.000 easily detached from the parent rock, making
9 September 125.000 excavation by Excavator Back Hoe easier and
10 October 109,000 use the time to dig a smaller (small cycle
11 November 110 200 time).
12 December 102,000
Based on observations at the same
location and different pit mine using a
And from data on the use of fuel oil "ripper" for demolition excavator overburden
for loading the third excavator is shown in and unloading by Cat 330 Excavator Back
Table 4. Hoe 2 units with the production condition of
80% is obtained as follows seen in Table 5.
Table 4 The use of fuel
Table 5 Production stripping overburden
material Hour
No. Month roasted Productive No. Month Production (Bcm)
(liter) (1am) 1 January 141 600
1 January 13125 477.50 2 February 148 000
2 February 12000 450.00 3 March 145 200
3 March 13275 425.00
4 April 143000
4 April 12 825 475.00
5 May 156 000
5 May 13050 492.50
6 June 160 100
6 June 12750 500.00
7 July 14850 507.50 7 July 192 500
8 August 15000 550,00 8 August 198000
9 September 14 925 475.00 9 September 193000
10 October 13200 495.00 10 October 151 000
11 November 13650 492.50 11 November -
12 December 13500 450.00 12 December -
3.Demolition of the Ripper From the production data show that
In general, the type used on the job using the Excavator Back Hoe two units with
Bulldozer ripping is Komatsu D 155 - the same capacity and aided by bulldozers to
Caterpillar D9N D378 or given area of Pit rip before excavation, production is greater
Mine to the production target of stripping than using Excavator Back Hoe 3 units
245,000 bcm - 350,000 bcm per month is not without ripping done first. And search data on
too large. the use of fuel oil both Excavator Back Hoe
unit and one unit Bulldozer show a decline in
Ripping methods that do are a cross- the use of fuel (see Table 6. This is due to the
cutting maze coating field rock or 45 ° see strength of the machine tool does not work
Figure 5. hard.

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Table 6 The use of fuel oil in 2006 the most red-colored area, and the parts that
have the smallest deformation is the most
Exacavator Bulldozer D375 ' blue (Hong-Kyu, 2018). Deformation
Month Hour Hour simulation results can be seen in the figure
BBM Productiv BBM Productiv below.
January 8531 358.13 e 75000 170.00e
February 7800 337.50 78000 165.00
March 8628 318.75 79600 182.00
April 8336 356.25 73200 175.00
May 8482 369.38 75200 186.00
June 8287 375.00 77400 183.00
July 9652 380.63 84000 204.00
August 9750 412.50 83000 210.40
September 9701 356.25 81000 191.20
October 8580 371.25 79 166.80
November - - -
800 -
December - - - -

Figure 11 The results of deformation

For the analysis of the storage tank
2016. Analysis using Anysy analysis Ripper
style 1000 N when given as in the following
explanation.
a. Stress Analysis (Von Mises)
Voltage is set force (force) on an
object surface. The narrower area of the
surface but the style remains, the greater the
stress. The voltage is indicated on the red
shades, the smallest is the most blue. While
the area with medium voltage areas are green-
yellow-blue. (Indarniati and Frida, 2008)
analysis
Based on the above simulation
results, defromation greatest value is in the
red
c. Strain analysis
The strain is part of the deformation,
which is described as a relative change of the
particles in the body that is not a rigid body.
Another definition of strain may vary
depending on the field of what term is used,
or from and to the point where the strain
occurred. (Hasbi, 2014).

Figure 10 The results of stress analysis Figure 12 Results strain analysis

Based on the above simulation
results, Ripper declared safe because there
are no red gradation.
b. AnalysisChanges Shape
(Deformasion)
deformationis the change in shape
on the body is subjected to force. Parts that
have the greatest deformation of this order is
In the above simulation,Ripper
declared safe because there are no red
gradation.
6. CONCLUSION
Production ripper on the overburden
material that has a value of propagation of
1250 m / sec at 377 bcm / hour, thereby

6
extracting and loading using the Excavator
Back Hoe Can more easily without detonated.
Stripping of overburden without
raked first cause "cycle tirne" digging tools fit
larger load capacity "bucket" (Fill Factor) is
very small, ie between 75% - 85%, "tooth
bucket" more rapid wear and tear, and the use
of fuel oil more.
Using a "ripper" on stripping
overburden to increase production, reduce the
use of fuel oil, and directly minimizing
operational costs.
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Using Instrumented Bulldozers to
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Relationship of Compressive Stress-
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