Komatsu Mining during a special virtual livestream event today unveiled three new drilling and bolting products that resulted from a new type of approach, working with its customers who said that safety, productivity and reliability are their highest priorities. A collaborative journey began by rethinking the working end of drilling machines.
Two of these products are in the smaller-class line, which Komatsu calls the Z2 category. One is from the medium-class line, or the Z3 category. This is a new battery jumbo drill, the two boom ZJ32Bi, which will also be available as a diesel ZJ32i machine. In the new product line overall plan, which includes yet to be launched models, a one boom ZJ31 jumbo and ZB31 bolter are also listed, which are expected to come in both battery and diesel versions, which using the new nomenclature would be the ZJ31Bi/ZJ31i plus ZB31Bi/ZB31i. The ZJ31 replaces the old one boom DR-1SB and the ZJ32 the old two boom DR-2SB. As with the new LHDs, in branding terms colours will now be Komatsu yellow instead of Joy orange.
These products it says were built to help transform hard rock mining operations in need of both small and medium classes of machines. “All of these workhorses are founded on proven drilling technology developed over more than a hundred years in the mining industry,” says Komatsu.
But it is the common platform approach that really stands out. “What’s truly different and unique about this product line is a common platform design. In fact, you might say that the common platform approach is like the multi-tool of mining of hard rock bolting and drilling. The platform offers 100% design commonality between bolter and jumbo from the rear skirt to the outer boom structure.” Komatsu says this common platform between bolter and jumbo is an industry first. Everything up to the outer boom is identical, making for a seamless conversion from bolter to jumbo, or vice versa.
The inner boom of the ZB21 small-class bolter for example can be swapped out for a drilling feed system, effectively converting it to a jumbo. The same with the ZJ21. This inner boom can be changed out for bolting. And the common platform approach goes beyond the drill attachment. Even the controls are the same. The universality of the controls was intentionally designed to help benefit mining operations from a training and maintenance perspective. Komatsu said the diesel version of both the ZB21 bolter and the ZJ21 jumbo are available to order now, with a battery option rolling out next year though it is unclear as yet if these will be referred to as ZJ21B/ZB21B or ZJ21Bi/ZB21Bi. The ZJ21 replaces the old VRII machine.
Komatsu stated on the Z2 class machine controls: “The hydraulic pilot control system comes with universal bolting and drilling controls. The universal control platform allows for simplified user training and adoption across both drilling and bolting models. We’ve heard from many customers that their operator and maintenance skillsets are declining due to an aging workforce, remote sites and a cyclical industry. This common platform approach may be part of the solution and the way forward. Plus, this universality provides advantages in job site efficiency and — with the common parts, service, and maintenance — could help reduce costs.”
Komatsu says it also listened to customer input that helped it totally redesign the operator cabin. The input devices and zone of comfort used for enclosure design are driven by ISO 6682. A few key points were given about the common platform approach as it relates to the operator environment:
In terms of other features on the ZJ21 drill, despite being 1 m longer on average than its competitors in the class, this machine can effectively navigate a 90-degree intersection in a 3 m by 3 m heading. Plus, a 16 ft drill steel “allows for the longest round and highest productivity in the class.” This longer boom provides the machine with a significant usable face coverage of up to 66 square metres, making this machine easily capable of backing up a two-boom jumbo in larger drives. With an overall operating height of 2.8 m and maximum width with levelling jack extended to 2.7 m, operators can efficiently use this machine in small headings.
The ZB21 is a bolter on this new common platform. The ZB21 boasts the same operating dimensions and is capable of handling up to an 8 ft bolting head. Its bolting fan pattern offers 7 m on the walls, 7.5 m on the backs and a 50 square metre face coverage. The bolter can bolt in any direction. Plus, the bolting head technology enables mines to perform 100% of the bolting cycle from the operator’s enclosure using a patented screen handler design and innovative chemical injection system. The bolting head also leverages many uniquely-designed polyurethane-casted components that decrease weight and reduce parts count.
The ZJ21 jumbo has a unique and versatile boom design, intentionally engineered to help protect the crew, control costs and boost productivity. The underslung boom configuration limits the impact of feed length on the outside turning radius, allowing drilling teams to drill up to a 15.5 ft hole in a 3 m by 3 m heading, while still effectively navigating a 90-degree turn or intersection.
The boom design also ensures zero contact with the operator’s station or the carrier or levelling jacks when drilling anywhere on the face, including the lifters — even in the longest feed configuration and fully retracted. Komatsu states: “This helps protect the operator and reduces the possibility of damage and the resulting increased repair costs. This boom design also provides a profile that matches the typical mining tunnel while delivering up to 66 square metres of coverage. This makes it easier for your operator to perform vital tasks — drilling lifters, perimeter holes, up and down ramps, truck loading bays, and service bay, cross cuts and even backing up two boom jumbos in larger drifts.”
An updated bolting head design leverages the legacy of Timberock (acquired June 2019) while ensuring 100% of the cycle is completed from the protection of the operator’s compartment. Again, the bolting head leverages cast polymer components to reduce weight and improve durability, which helps in controlling operating and rebuild costs. “We’ve used polymer components to provide additional forgiveness in many areas such as the bolt centralisers, bolt carousel, bolt driver, stinger pad and rear feed plate. These components also reduce the need for adjustment and the overall number of moving parts, ensuring optimal alignment for bolt installation — all factors that may help you avoid downtime.”
Another notable feature of the bolting head is that it handles and installs all four major types of bolts and features a 9-bolt magazine in its base configuration. It can handle two various types of bolts with minimal carousel adjustment needed to modify the bolt diameter. The bolting head for the ZB21 is available in 5- to 8-ft bolt lengths. The 8-ft configuration offers simple adjustability to a 7- and 6-ft overall length to maximise its versatility and accommodate most ground support programs.
The feed system has been reengineered to enhance maintainability and productivity. “The feeds are lightweight, durable, and cost-effective and are built to deliver exceptional drill performance and reduced maintenance. Here you have more lightweight polyurethane components that also offer flexibility.” The stinger pad, backplate and centraliser have an all-purpose design providing maximum forgiveness and reducing misalignment. The timing ropes are identical lengths with common part numbers and come with a standard ‘quick attach’ feature that Komatsu says ensures anyone can change these ropes with ease in an underground setting.
The hose drum has no bearings and is also made of polyurethane, which increases longevity because it’s a material that is far less brittle than traditional plastics. The hose drum is graphite-impregnated, which means that it’s essentially self-lubricating. Komatsu stated: “Even the guide strips have been designed with the maintenance team in mind. They are common from left to right and twice as thick as the competitors, but are made of a slightly softer material to reduce cracking. They are also a breeze to change out, requiring only simple hand tools and one technician.” The feeds are available in up to 16-ft fixed lengths or in a double telescopic configuration that is ideal for bolting.
Finally there is also a new drifter made by Komatsu company Montabert which came up with hydraulic drifter technology back in the 1970s. The components are the result of years of experience in hydraulic rock breakers and drifter design and manufacturing. “In-depth knowledge of shockwave transmission and percussion mechanism theory has translated into new concepts for hard rock mining, such as hydraulic dampening and progressive blow energy.”
Working closely with Montabert and its sophisticated manufacturing plant with ultra-modern machining tools at it Saint-Priest, France plant, the new hydraulic drifters have been designed to deliver high performance, longevity, long maintenance intervals and low tool consumption. These are described as the “Komatsu JZD12 and JZD21, manufactured by Montabert.”
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