Roadheaders are versatile machines used for excavating tunnels and mines. They have a rotating cutting head equipped with picks, which are essential for breaking rock and other materials. The effectiveness of mining operations largely depends on the proper use and maintenance of these picks.

Understanding Roadheader Picks

Roadheader picks, also known as cutting bits, are made from durable materials like tungsten carbide to withstand the harsh conditions of mining. They are designed to be mounted on the rotating cutting head of the roadheader, which can vary in shape and size depending on the type of material being excavated.

Preparation for Using Roadheader Picks

Selection of Picks:

Choose picks that are appropriate for the type of material being mined. Hard rock requires picks with higher durability and wear resistance.

Ensure that the picks are compatible with the roadheader’s cutting head.

Installation:

Securely attach the picks to the cutting head. Proper installation is crucial to prevent the picks from becoming loose during operation, which can lead to equipment damage or safety hazards.

Follow the manufacturer’s guidelines for installation torque specifications.

Inspection:

Regularly inspect picks for signs of wear and damage. Worn-out picks reduce cutting efficiency and can increase the risk of machine breakdowns.

Replace damaged or excessively worn picks promptly to maintain optimal performance.

Operating the Roadheader with Picks

Machine Setup:

Position the roadheader correctly at the worksite. Ensure that it is stable and properly aligned with the direction of the tunnel or mining face.

Adjust the cutting head to the correct angle and height for the material being excavated.

Cutting Process:

Start the roadheader and allow the cutting head to reach the required speed before engaging with the material.

Gradually advance the cutting head into the material. Sudden or forceful movements can damage the picks and the machine.

Maintain a steady feed rate to optimize cutting efficiency and prolong the life of the picks. Too slow a feed rate can cause excessive wear, while too fast a rate can overload the machine.

Monitoring:

Continuously monitor the performance of the roadheader and the condition of the picks. Listen for unusual noises and watch for signs of excessive vibration, which can indicate problems.

Use sensor systems, if available, to track the wear and temperature of the picks. Some advanced roadheaders are equipped with monitoring systems that provide real-time data.

Adjustments:

Adjust the speed and feed rate as needed based on the type of material and the condition of the picks. Harder materials may require slower cutting speeds and more frequent pick replacements.

Change the cutting pattern if necessary to ensure even wear on the picks and to avoid creating weak spots in the material being excavated.

Maintenance of Roadheader Picks

Regular Maintenance:

Conduct routine maintenance checks on the picks and the cutting head. This includes cleaning, lubricating, and tightening any loose components.

Schedule regular pick replacements based on the manufacturer’s recommendations and the observed wear patterns.

Pick Rotation:

Rotate the picks periodically to ensure even wear. This helps in maximizing the lifespan of each pick and maintaining consistent cutting performance.

Keep a log of pick usage and rotations to track wear rates and schedule replacements accurately.

Storage:

Store spare picks in a clean, dry environment to prevent corrosion and damage. Organize them by type and size for easy access during maintenance operations.

Training:

Ensure that operators and maintenance personnel are trained in the proper use and care of roadheader picks. Training should include safe installation practices, operation techniques, and maintenance procedures.

Using roadheader picks effectively in mining involves proper selection, installation, and regular maintenance. By following best practices in these areas, mining operations can achieve higher efficiency, reduced downtime, and longer-lasting equipment. Continuous monitoring and adjustments based on material conditions and pick performance are key to optimizing the use of roadheader picks.