Automated shaft boring machines for underground mining

Underground mining is one of the most demanding sectors in mechanical engineering. Great depths, difficult geological conditions and high safety requirements present operators worldwide with complex challenges.

At the same time, there is growing pressure to make processes more efficient, cut costs and reduce the number of staff in hazardous areas. At bauma, Herrenknecht demonstrates how these requirements can be met through automation and specialised drilling technology. The company is best known for its tunnel boring machines. Experience gained in tunnel construction is now increasingly being incorporated into solutions for mechanised mining. The focus is on systems capable of creating shafts and boreholes of various dimensions whilst automating as many work steps as possible.

Herrenknecht applies tunnelling technology to mining

The basis for many developments stems from tunnelling. For decades, machines have been used there that can create large cavities precisely and safely. Herrenknecht now also utilises this expertise for applications in underground mining. The aim is to create boreholes and shafts of various diameters and in different directions in a cost-effective manner. The spectrum ranges from large-scale bottom-up drilling to fully mechanised shaft drilling processes. The focus is not on individual machines, but on complete system solutions for various requirements in mining.

Shaft boring machine relies on the ‘hands-off’ principle

Safety is a key concern. In mining, many risks arise where people have to work directly alongside heavy machinery. That is why Herrenknecht consistently pursues the “hands-off” approach. The basic idea is simple: the fewer personnel there are directly in the danger zone, the lower the risk of accidents. Modern shaft boring machines therefore automate numerous work steps.

One example of this is the automatic pipe handler. This system transports drill pipes autonomously and inserts them into the machine. Staff no longer need to move the heavy components manually and can remain outside the immediate working area. The key safety features include:

• automated pipe handling via the pipe handler
• reduction in manual intervention within the danger zone
• reduced staffing requirements at the machine
• controlled and reproducible workflows
• remote monitoring of key operating data
• greater process reliability for complex drilling operations

Shaft boring with diameters of up to nine metres

The dimensions of the systems presented are particularly impressive. In so-called raise boring, a pilot borehole is first created. A large drill head is then mounted from below and pulled upwards. During this process, roller bits break up the rock. The material falls downwards and can be removed from there. In this way, a complete shaft is created step by step. Depending on the application, diameters ranging from around 1.5 to 8 or 9 metres can be achieved. The possible depths are also considerable. Under favourable geological conditions, shafts can reach lengths of up to 1,500 or even 2,000 metres. Such dimensions illustrate why mechanised methods are becoming increasingly important in modern mining.

Constructing blind shafts without access from below

Access from the lower level is not always available. For such situations, Herrenknecht offers special shaft boring machines capable of constructing so-called blind shafts. Here, the tunnelling takes place entirely from top to bottom. The excavated material is removed via the shaft. Although workers are still present at various working levels, the principle of reducing direct contact between humans and machines as much as possible also applies to these systems. Automated processes take over the majority of physically demanding and safety-critical tasks. This improves both safety standards and cost-effectiveness.

Remote monitoring and automation shape the future

Development does not stop at automatic pipe changers or mechanised drilling methods. Another key focus is on digital networking and remote monitoring. Even today, operational data from individual systems can be transmitted in real time to central locations. This gives technicians insight into machine status, performance data and potential faults without having to be on site themselves. The long-term trend in mining is clearly evident: more automation, fewer personnel in hazardous areas and greater digitalisation of processes. People will still be needed, but their tasks are increasingly shifting from physical labour towards monitoring, control and analysis. The systems presented at bauma demonstrate how this transformation can already be implemented in practice today. Automated shaft boring machines combine high performance with a safety concept designed to keep people as far away as possible from hazardous work areas. For many mining projects, this very approach could prove decisive in the future.