Pneumatic starting auxiliary device for optimising the start-up of mining machines with heavy rotors

Introduction. This article addresses the optimization of start-up modes for technological machines with heavy rotors, relevant across industries, including mining and metallurgy. It proposes a pneumatic starting and auxiliary device (PSAD) using bellows pneumatic cylinders and a ratchet mechanism to facilitate start-up and reduce inrush currents in such machines. Materials and methods. An experimental setup simulating a ball mill’s operation was designed. The methodology involved investigating the impact of the limit switch position, which controls the main engine, on the inrush current value. The experiment then fixed this position and altered the pneumatic system pressure in 0.1 MPa increments, from 0.1 MPa to 0.4 MPa, recording the resulting inrush current changes. Results. The study shows the impact from pulse and follow-up current to motor terminals, and the pre-work of PSAD in step-by-step mode. The result showed significant reduction in the initial current peaks due to the starting process of the main engine. The optimal limit switch position was at the beginning of the stroke of one cylinder, providing maximum force at minimal deformation. Increasing pressure led to inrush current decreases. Discussion. These results affirm pneumatic power systems and implementation in starting equipment, but there are complexities with precise adjustment and the requirement for good manufacturing and assembling qualities. These additional findings provide a more detailed evaluation of factors influencing PSAD performance. In particular, selecting the ideal diameter for supply piping is crucial. Conclusion. PSAD using bellows pneumatic cylinders and a ratchet mechanism is a promising approach for heavy rotor machines. Tests displayed efficiency in reducing inrush currents. Pre-work in step-by-step mode, combined with pressure increase, lowers starter loads on the drive. Precise adjustment is critical, otherwise, system performance and reverse drum rotation will result. Resume. This research establishes optimal PSAD parameters (limit switch placement, pneumatic pressure) for minimal inrush current. Results aid PSAD implementation in mining/metallurgy, enhancing reliability, energy efficiency, and decreasing costs. Still, deployment should consider adjusting difficulties and needs of producing and meeting components.