Improving energy efficiency and reliability of starting rotary equipment at mining enterprises using pneumatic auxiliary drives
Повышение энергоэффективности и надёжности пуска роторного оборудования горных предприятий с использованием пневматически хвспомогательных приводов
Sarybayev Y.Ye. Beisenov B.S. Balgayev D.E. Tkachenko D.E.
2025North Caucasian Institute of Mining and Metallurgy, State Technological University
Sustainable Development of Mountain Territories
2025#17Issue 2998 - 1009 pp.
Introduction. In the mining industry, the safe and stable start-up of technological machines with heavy rotors, such as drum mills, is a critical factor for enhancing reliability and reducing operating costs. High inrush currents during start-up can lead to motor failures, overloads of drive components, and increased wear. This study addresses these challenges by proposing an auxiliary pneumatic drive system that optimizes start-up modes, lowers inrush currents, and improves the overall energy efficiency of heavy rotor equipment. Methods. A rack-type auxiliary start-up device (AUSD) was designed based on three-chamber bellows pneumatic actuators with an extension stroke of 280–320 mm and operating pressure of 0.35– 0.40 MPa. A test stand was developed to evaluate the effect of actuator stroke length, pressure, and limit switch positioning on dynamic system characteristics. Experimental procedures included systematic variation of pressure (0.1–0.4 MPa) and stroke length (270–350 mm), as well as the use of a receiver to investigate booster (explosive) compressed air supply. Measurements of start-up currents, pushing forces, and pressure oscillograms were recorded to assess system performance. Results. The experiments showed that optimal reduction of starting current occurs when the actuator stroke is within 290–310 mm, with the most favorable range being 300–320 mm. The use of booster compressed air supply significantly increased pushing force– nearly doubling it compared to standard pneumatic feed–and reduced inrush currents to nominal levels. These findings demonstrate that the device effectively decreases peak loads on main drive elements, prolongs equipment lifespan, and enhances energy efficiency. Conclusions. The proposed pneumatic auxiliary drive offers a simple yet effective solution for improving the start-up of heavy rotor equipment. Its design allows for application in remote mining areas, even in the absence of stationary pneumatic mains. By optimizing stroke length, pressure, and air supply mode, the system can significantly reduce inrush currents, ensure stable operation, and contribute to the sustainable functioning of mining enterprises.
energy efficiency , equipment reliability , mining industry , pneumatic drive , rotor equipment , start-up systems , starting current
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Department of Technological Machines and Equipment, Institute of Energy and Mechanical Engineering named after A. Burkitbayev, K.I. Satbayev Kazakh National Research Technical University, 22, Satpayeva str., Almaty, 050000, Kazakhstan
Department of Mechanical Engineering, Institute of Energy and Mechanical Engineering named after A. Burkitbayev, K.I. Satbayev Kazakh National Research Technical University, 22, Satpayeva str., Almaty, 050000, Kazakhstan
Department of Technological Machines and Equipment
Department of Mechanical Engineering
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