SPECIALIST EQUIPMENT
BETTER CONNECTED
Nico van Loey explains how an intelligent coupling solution is proving popular for longwall mining applications
C
ircumstances in longwall mines are harsh on miners and equipment alike. T e mining process involves roof shields operating at working pressures
of 350 bar, putting 81KNm of force against the fi tting of the hydraulic connection. Factoring in pressure spikes from pumping equipment, impulses from self-advancing shields and corrosion, the component conditions are extremely tough. Traditional staple-lock couplings become deformed and corroded, making it challenging to replace damaged hose assemblies or to disconnect roof shields. T is often results in workers mistreating equipment, leading to numerous incidents and triggering the need for extreme caution. Gates designed its iLok coupling to improve safety and productivity, and exclude the limits of the staple-lock design. T e iLok is simple to understand as well as
Gates iLok couplings make longwall connections simpler, faster and safer
to use. To connect the fi tting, the male nut is hand-tightened onto the female, drawing the sealing surface under the seal in the female and protecting it from potential damage. A secure cable distributes forces along the full length of the fl ange area, preventing uneven staple stress or deformation. When disconnecting, the cable is cut, removed and the nut can be loosened by hand. T e back of the swivel nut has slots, so a spanner wrench can be used in case an extra tool is needed to loosen the coupling. Ease of connection and disconnection is key for improving safety and productivity. Gates claims that the average disconnect time per coupling can be reduced by up to 90% compared to the staple-lock. T erefore iLok can potentially save hundreds of man-hours
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on every longwall move. If the cable lock is removed while the line is still under pressure, the nut continues to hold the fi tting together, dissipating the pressure away from the worker’s face. Unlike a staple lock, the iLok uses a nut that contacts the entire fl ange surface, helping to distribute forces evenly and prevent the fl ange from deforming. No tools are needed to engage or disengage the coupling, so workers are not tempted to use hammers or chisels.
Improved durability To further increase the lifetime of iLok assemblies in the highly corrosive mining environment, they are plated with Gates Tuff Coat Xtreme. T is coating goes beyond ISO 9227 standard requirements, off ering 840 hours of red rust protection. T e coupling has not only been tested at 420 bar pressure for 300,000 impulse cycles (as applicable in mining ratings for static applications), it has also been tested to one million impulse cycles at 133% of 350 bar working pressure for hydraulic application standards. T e connectors can be used on original equipment, as well as in replacement projects, using the appropriate iLok adapter to connect to staple-lock or fl ange. Several mining companies, including
Wyoming’s Bridger Coal and Bowie Resources, have switched over to iLok couplings. T e key drivers for them are the new solution’s simplicity, improved safety and time and labour savings. ●
For more information ✔ at
www.engineerlive.com/ime
Nico van Loey is product manager, Hydraulic Hose, Couplings & Equipment at Gates Europe.
www.gates.com/europe
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