Walking Dragline Excavators in Mining and Construction

Walking dragline excavators are a type of heavy equipment used in mining and construction, offering a unique combination of mobility and digging power.

They can be used in a variety of settings, including open-pit mining and heavy construction projects.

These machines are designed to move around on their own, allowing them to access different areas of a site without the need for additional transportation equipment.

Their ability to walk also enables them to work in areas with limited access.

Draglines fall into two broad categories: those based on standard, lifting cranes, and the heavy units built on-site. These smaller crane-based draglines are used for road, port construction, and dredging.

Most crawler cranes can act as a dragline with an added winch drum on the front. They are designed to be temporarily dismantled and transported over the road on flatbed trailers.

The larger type of dragline, built on-site, is commonly used in strip-mining operations to remove overburden above coal and oil sands. These units can weigh up to 13,500 tons.

A dragline bucket system consists of a large bucket suspended from a truss-like boom with wire ropes. The bucket is maneuvered by ropes and chains.

The hoist rope, powered by large diesel or electric motors, supports the bucket and hoist-coupler assembly from the boom.

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A walking dragline excavator is a powerful machine used for digging and excavation work. It's a massive piece of equipment that's designed to handle tough jobs.

The boom on a walking dragline excavator is its long arm, which extends the reach and depth of the machine. This allows it to dig and excavate in areas that would be difficult or impossible for smaller machines.

The bucket is a critical component of the machine, collecting material as it digs. It's designed for large capacity and features sharp teeth to help break up tough material.

The crawler tracks provide mobility and stability on various terrains, allowing the machine to move around the work site with ease. This is especially important for walking dragline excavators, which can be massive and heavy.

The cab is the operator's control center, where they manage the various functions of the machine. From the cab, the operator can control the boom, bucket, and other components of the machine.

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Here are the key components of a walking dragline excavator:

In a typical cycle of excavation, the bucket is positioned above the material to be excavated, then lowered and dragged along the surface of the material. The bucket is then lifted and swung to the place where the material is to be dumped, before being tilted and emptied.

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A dragline system used in open pit mining can cost anywhere from $50 to $100 million.

Their massive buckets can hold up to 80 cubic yards of material, and some draglines have even larger buckets that can hold up to 220 cubic yards.

These machines are not like other mining equipment, they require a direct connection to the high-voltage grid to power them, using up to 6 megawatts of electricity during normal operations.

Draglines are so powerful that they can move up to 450 tons of material in a single cycle.

Draglines in mining can cost anywhere from $50 to $100 million, with some extremely large buckets reaching up to 220 cubic yards in volume.

A typical dragline boom can range from 45 to 100 meters in length, allowing it to move up to 450 tons of material in a single cycle.

Most mining draglines are not diesel-powered and instead have a direct connection to the high-voltage grid, consuming up to 6 megawatts of power during normal digging operations.

Draglines can be quite heavy, weighing between 4000 and 6000 tons, with some stories suggesting that even small power outages could occur if multiple draglines were to turn on at the same time.

However, these stories are likely apocryphal, and draglines are actually restarted one at a time due to their immense power requirements.

Draglines are able to move across the ground by "walking" using feet or pontoons, as caterpillar tracks place too much pressure on the ground.

Their maximum speed is only a few meters per minute, since the feet must be repositioned for each step.

For longer distances, a special dragline carrier can be brought in to transport the dragline, or disassembly is required.

Despite their limited mobility, draglines can work a large area from one position, making them valuable in surface mining operations.

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Dragline excavators are incredibly versatile machines that have revolutionized the way we excavate and move materials. They can move large amounts of material in one pass.

One of the most impressive features of dragline excavators is their ability to excavate to great heights and depths. This makes them perfect for projects that require precision and control.

Dragline excavators are also adaptable for various tasks and environments. Whether you're working on a construction site or a mining project, they can handle it.

Their ability to minimize pollution and soil disruption is a major advantage, especially in environmentally sensitive areas. This is a significant benefit, as it reduces the impact on the surrounding ecosystem.

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Dragline excavators can be remotely operated for safety, which reduces the risk of accidents and injuries. This is a huge plus, especially in high-risk environments.

Some of the key advantages of dragline excavators include:

Draglines have a primary limitation in their boom height and boom length, which restricts where they can dump waste material.

Their dig depth is also limited by the length of rope they can use, making them less efficient at digging above a certain level.

A dragline is most efficient excavating material below the level of its base, but can dig above itself, albeit inefficiently.

Draglines are not suitable for loading piled-up material, unlike rope shovels or wheel loaders.

Their high capital cost is another significant limitation, but their reliability and low waste removal cost make them popular with many mines.

The technological advancements in walking dragline excavators have been relatively slow compared to other earth-moving equipment. The basic mechanical technology of draglines has remained unchanged in design and control functions for almost 100 years.

Some advances have been made, such as the introduction of hydraulic controls, which have improved the efficiency of these machines. These controls have also been upgraded to electro-hydraulic systems, making them even more effective.

Using simulation software to train new operators is another notable advancement, allowing for more efficient and effective training processes. This technology has been widely adopted in the industry.

Improved automation systems are being pursued, with the goal of further increasing efficiency and reducing operator error.

A walking dragline excavator is a powerful machine that can move around on its own, making it perfect for digging and hauling heavy materials on various terrains. The components of a walking dragline excavator are designed to work together seamlessly, allowing for efficient operation.

The boom is a long arm that extends the reach and depth of the digging process, giving the operator more flexibility and control. The bucket is designed for large capacity and sharp teeth, making it perfect for collecting and hauling heavy materials.

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Crawler tracks provide the necessary mobility and stability on various terrains, allowing the machine to move around easily and safely. The cab is the operator's control center, where they can manage all the functions of the dragline excavator.

Counterweights are used to balance the dragline excavator, preventing it from tipping over and ensuring safe operation. The winch system raises and lowers the bucket, allowing for controlled movement and precise material handling.

Here are the main components of a walking dragline excavator:

The hydraulic system powers the movements of the boom and bucket, allowing for smooth and efficient operation. The control system integrates all the controls for easy and efficient operation.

The largest dragline excavators are truly massive machines, with the British firm Ransomes & Rapier producing a few large excavators that weighed between 1400-1800 tons. One of these machines, named SUNDEW, was used in a Iron stone quarry from 1957 to 1974.

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Smaller draglines were also commonly used before hydraulic excavators became widespread. Firms such as Priestman, Ruston and Bucyrus made models like the RB10, which were popular for small building works and drainage work.

Some of these smaller draglines can still be seen in the English Fens of Cambridgeshire, Lincolnshire and parts of Norfolk. They're a testament to the ingenuity of the engineers who designed them.

The coal mining dragline known as Big Muskie was the world's largest mobile earth-moving machine, weighing nearly 13,000 metric tons and standing nearly 22 stories tall. It operated in Guernsey County, Ohio, from 1969 to 1991, and was powered by 13,800 volts of electricity.

The walking dragline excavator has a rich history that spans over a century. It was invented in 1904 by John W. Page for use in digging the Chicago Canal.

The first walking dragline was developed a few years later, providing draglines with mobility. This innovation revolutionized the industry and paved the way for the development of more advanced dragline models.

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In 1911, Bucyrus introduced the "Class 14" dragline, the first crawler-mounted dragline. This marked a significant milestone in the history of walking draglines.

Bucyrus also helped pioneer the use of electricity as a power source for large stripping shovels and draglines in 1912. This shift towards electric power was a major breakthrough in the industry.

In 1914, Harnischfeger Corporation introduced the world's first gasoline engine-powered dragline. This innovation further expanded the capabilities of walking draglines.

The Marion Steam Shovel Dredge Company built its first walking dragline in 1939. This marked another important milestone in the development of walking draglines.

By the 1960s, dragline manufacturers had begun to adopt archless bucket designs, pioneered by Page. This design change improved the efficiency and performance of walking draglines.

In 1988, Page was acquired by the Harnischfeger Co., which later became known as P&H. This marked the end of an era for Page, but the legacy of its innovative dragline designs lived on.

Heavy Engineering Corporation Limited (HEC) was the first Indian company to manufacture a walking dragline of 31-yard bucket capacity.

HEC makes draglines with bucket capacities up to 44 yards, which is comparable to Caterpillar's Small Draglines 8000 series with a 42-yard bucket.

Some notable manufacturers of draglines include Bucyrus International, Priestman, Marion Power Shovel, NCK, NCK Rapier, P&H, Ransomes & Rapier, Ruston-Bucyrus, and Thomas Smith & Sons (Rodley) Ltd.

The UDD (universal dig-dump) is a fundamental change to draglines, using four ropes instead of two to manipulate the bucket, allowing for greater selectivity in picking up and dumping the bucket.

Manufacturers play a crucial role in the dragline industry, and there are several notable companies that have made significant contributions.

Heavy Engineering Corporation Limited, an Indian company, was the first to manufacture a walking dragline with a 31-yard bucket capacity. They have since improved their design to accommodate up to 44-yard buckets.

Bucyrus International, a well-known manufacturer, has been producing draglines for a long time. They are one of the many companies listed as dragline manufacturers.

Some notable manufacturers include Bucyrus International, Priestman, Marion Power Shovel, NCK, NCK Rapier, P&H, Ransomes & Rapier, Ruston-Bucyrus, and Thomas Smith & Sons (Rodley) Ltd.

These companies have been involved in the production of draglines, with some notable achievements including Heavy Engineering Corporation Limited's 44-yard bucket capacity.

UDD, or universal dig-dump, represents the first fundamental change to draglines in almost a century.

It's a significant upgrade that uses four ropes, two hoist and two drag, allowing for greater selectivity in picking up the bucket and dumping it.

This design generally leads to higher productivity compared to standard draglines.

However, UDD machines often have greater mechanical issues, which can be a trade-off for their increased efficiency.

The mining industry is still debating whether the benefits of UDD justify its costs.

The use of four ropes instead of two can be a game-changer for dragline operators, giving them more control over the bucket's movement.