Jones, Daniel M. (2024) Design, Detail, Manufacture, & Testing of Prototype Telescopic Hydraulic Cylinder for S1000 Drill Rig Feed Frame. [USQ Project]
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Abstract
CH4 Drilling Pty Ltd owns and operates a fleet of S1000 inseam directional drill rigs in the underground coal market throughout the East Coast of Australia. A recognised limitation of the S1000 drill rig is the feed frame’s inability to tilt at an angle to the horizontal plane, resulting in operational difficulties due to undertaken workarounds, & in some instances lost revenue due to the inability to achieve the desired angle of tilt for certain directional drilling contracts.
To remove this limitation, an R&D project was created to develop a detailed design for a prototype feed frame assembly capable of tilting at an angle range of ±10° from the horizontal plane. A telescopic hydraulic cylinder (THC) has been proposed for the feed frame tilt functionality. To further progress the detailed design of the feed frame assembly, a detailed THC design must be developed in conjunction with the feed frame assembly design.
A thorough review was completed of all relevant Mining Design Guidelines, Recognised Standards, Australian & International Standards, currently available THCs, & emerging hydraulic cylinder technologies to understand the legislative requirements, availability of THCs, & potential technologies which could be incorporated into the THC design. A thorough review of current “off-theshelf” THCs identified a lack of available solutions which meet the requirements of the feed frame assembly design, & as such, the need to develop a custom designed THC was clear.
Based on the thorough review, required dimensional specifications & operational specifications, a set of design parameters & non-negotiables were developed for the THC design. Using the defined design parameters & non-negotiables, a detailed THC design was developed using Autodesk Inventor 2024 3D CAD software. During this design process, an analytical stress & operational parameter calculation template was developed & undertaken in Mathcad Prime 10 software. Designed components were then validated with finite element analysis (FEA) using Autodesk Inventor Nastran 2024 software. Once validated, 2D manufacturing drawings were then completed in Autodesk Inventor 2024 3D CAD software to allow subsequent THC manufacture.
The resulting THC design meets all defined design parameters & non-negotiables outlined within the project. Due to more pressing work priorities & subsequent project time constraints, the THC design testing procedure is yet to be developed, with the prototype THC manufacture yet to commence. As such, this delay will allow future work to be conducted prior to THC manufacture. Future work will include detailed fatigue analysis of all key THC components to ensure adequate fatigue life is achieved, along with development of the THC testing procedure.
Once manufactured, the THC design will then be tested as per the developed testing procedure as originally planned for this project, allowing further completion of the prototype feed frame assembly design.
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| Item Type: | USQ Project |
|---|---|
| Item Status: | Live Archive |
| Faculty/School / Institute/Centre: | Current – Faculty of Health, Engineering and Sciences - School of Engineering (1 Jan 2022 -) |
| Supervisors: | Epaarachchi, Jayantha |
| Qualification: | Bachelor of Engineering (Honours) (Mechanical) |
| Date Deposited: | 08 Oct 2025 04:08 |
| Last Modified: | 08 Oct 2025 04:08 |
| Uncontrolled Keywords: | mining; telescopic hydraulic cylinder (THC) |
| URI: | https://sear.unisq.edu.au/id/eprint/53056 |
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