In a large open-pit coal mine, Master Zhao was operating the Liugong CLG856 bulldozer for coal seam stripping. One morning, when the bulldozer lifted a shovel of thick coal seam, the oil cylinder suddenly made a dull abnormal sound, and then the bucket could not be lifted normally. Master Zhao immediately stopped the machine for inspection, and through the simple detection function of the equipment, he found that the pressure value of the lifting cylinder dropped sharply, which was obviously abnormal.
He contacted the maintenance personnel in the mine. After the maintenance personnel removed the oil cylinder cover, they found a slight leakage near the bottom of the cylinder barrel. After testing with a special instrument, it was confirmed that there was a hidden crack in the cylinder barrel. Further checking the operation records of the equipment, this bulldozer has been working in the coal mine under high intensity for nearly two years, exposed to coal dust and moisture for a long time, and the coal seam in the recent operation area is relatively hard, so the oil cylinder frequently bears high pressure. The maintenance personnel speculated that the cylinder barrel material was fatigued under the long-term harsh environment and frequent high pressure, and coupled with possible tiny defects during manufacturing, which eventually led to the occurrence of cracks. Since there was no spare cylinder barrel in the mine and the delivery of original parts would take a week, the mine's production plan was in a dilemma.
Solution:
KICAN Team's Online Customized Solution
After the person in charge of the mine contacted the KICAN team, the team quickly started the online service process. They first asked the maintenance personnel in the mine to send the oil cylinder design drawings of the Liugong CLG856 bulldozer, detailed operating parameters of the equipment (including working hours, load changes, pressure curves, etc.), as well as high-definition photos and detection data of cylinder barrel cracks via email.
After receiving these materials, the engineers of the KICAN team immediately carried out analysis. They used professional software to simulate the stress situation of the cylinder barrel, and combined with the characteristics of the coal mine's operating environment, quickly formulated a customized plan. In the plan, the cylinder barrel material is 27SiMn alloy steel, which has stronger wear resistance and corrosion resistance. This material has much better stability than ordinary steel in coal dust and humid environments; in view of the frequent high pressure on the oil cylinder, the wall thickness of the cylinder barrel is increased by 1.5mm to improve its pressure resistance; at the same time, the inner wall of the cylinder barrel is specially chrome-plated to enhance its wear resistance and prolong its service life.
The team showed the 3D model and detailed parameters of the plan to the person in charge of the mine through an online meeting, and explained the design ideas and advantages of the plan in detail. After confirmation, the KICAN team immediately arranged production. During the production process, they showed the mine the processing progress and quality inspection links of the cylinder barrel in real-time through video. After three days of urgent production, the customized cylinder barrel was sent by express logistics and arrived at the mine in only two days.
User Feedback and Machinery Usage Experience
The maintenance personnel in the mine successfully completed the replacement of the cylinder barrel according to the online installation instruction video provided by the KICAN team, and the whole process took less than 3 hours. When Master Zhao started the bulldozer again, he obviously felt that the lifting of the bucket was more stable and powerful, and the previous abnormal sound disappeared.
After using it for a week, the person in charge of the mine reported that the operation efficiency of this Liugong CLG856 bulldozer was much higher than before, and it could strip nearly 200 cubic meters more coal seam every day. Moreover, the new cylinder barrel has good sealing performance, and no leakage has occurred. Master Zhao also said that it is easier to operate than before, the response speed of the oil cylinder is faster, and even when pushing harder coal seams, there is no obvious stuck feeling.
From the cost perspective, the online customization plan of the KICAN team not only saved the time of waiting for the original parts, avoiding the shutdown loss of nearly 5 days (about 15,000 yuan per day), but also the price of the customized cylinder barrel is about 10% lower than that of the original parts, which has saved a lot of costs for the mine. The mine is very satisfied with this online service, believing that this mode is efficient and convenient, providing a strong guarantee for mine production.
