CM445 Continuous Miner

CM445 Continuous Miner

The Cat® CM445 Continuous Miner is designed for mining applications ranging from 1626 mm (64 in) up to 3810 mm (150 in) where increased weight to horsepower ratios are required for performance in hard cutting type mining conditions. The hard head-style cutter head makes the CM445 the preferred miner for hard-cutting coal, trona, and potash.

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Mainframe

Heavy Duty Mainframe

To ensure maximum rigidity and stability, the high-strength one-piece mainframe is constructed from steel plate ranging in thickness from 1.9 to 7.6 mm (0.75 to 3 in). Large diameter, robust hinge points with replaceable hardened steel pins and bushings for the cutting head, gathering head and conveyor. The main support rails are 50.8 mm (2 in) thick, and the large 114.3 mm (4.5 in) diameter pivots have replaceable 12.7 mm (0.5 in) wall bushings. The mainframe has been shortened by 762 mm (2 ft 6 in) to improve maneuverability.

Traction

Traction

Like all Cat continuous miners, the CM445 features independent tramming for greater maneuverability and wide crawlers for maximum penetration and low ground pressure.

Maximum Torque

The traction system is controlled by Variable Frequency Drives (VFDs), which give smooth zero-to-full speed transition. The drives can develop 100% torque at zero RPM.

Crawlers

Forged, heat-treated alloy steel pads with a minimum hardness of 340 BHN with a width of 558.8 mm (22 in) ensure high strength and wear resistance, and low ground pressure.

Enhanced Productivity

Variable Frequency Drive (VFD) traction control means more tonnes (tons) produced per shift due to improved sumping and relocation times and a faster tram speed of up to 26 m/min (85 ft/min) (governed).

Cutter Head

Cutter Head

The cutter head on a continuous miner uses up to dual 250 kW (335 hp) 2 × 209 kW (280 hp) motors to cut material. The head typically consists of three pieces: the right drum, left drum, and center drum. Drum diameter is optional (1066-1168 mm/42-46 in), as is drum speed (42-52 rpm).

Motor Protection

The cutter motors are protected by torque-limiting clutches designed to respond within 1/10th of a second. Massive 152 mm (6 in) boom legs on the cutter support the frame and ensure minimal deflection and fatigue. The cutter drums are 50.8 mm (2 in) thick, allowing maximum bit-tip standoff.

Split Gear Case

The cutter gear case is split. Each side is independent and only connected by the center cutting drum. This allows one gear case - with half the number of components - to be replaced.

Gathering Head and Conveyor

Gathering Head

The CM400 Series offers a variety of 3-finger centrifugal loading arms (CLAs) to meet customer requirements as well as a choice of three chain and CLA speeds. 6-finger CLAs - found to be 40% more effective in low seams - are also available. The gathering head assembly has a chromium-carbide overlay (CCO) wear protection package.

Conveyor

The CM445 has 965 mm (38 in) or 762 mm (30 in) wide conveyor for fast loading. The high-strength 69.85 mm (2.75 in) Cincinnati conveyor chain is driven by an 8-tooth dual sprocket with universal joint for smooth, low-wear operation. An automatic hydraulic chain tensioning system reduces noise and further improves chain service life.

Wear Protection

The top decking of the conveyor is CCO-plated (chromium-carbide overlay) and the return deck is plated with 450 BHN wear plate for greater wear protection. The conveyor has a 45-degree swing capability each way.

Control Systems

Ease of Operation

The Cat Machine Control Unit (MCU) is designed to operate the entire Cat CM445. Based on a mine-duty PLC, this drive and control system combines maximized coal production and operator safety with minimum downtime. Traction motors are controlled by a microprocessor-based system, minimizing the connection points that are the major cause of downtime. The MCU provides data logging, fast diagnostics and enhanced troubleshooting capability.

Machine Management

A comprehensive machine management and diagnostics system is used to manage the continuous miner’s health and aid in the quick diagnosis and repair of the problem.

Remote Control

A Super Simpson radio remote with self-diagnostics is available. Features include:

  • Graphic display shows the condition of all motors, VFD components, and the condition and position of all hydraulic control valves and solenoids.
  • Tito remote control console or new compact remote control console
  • Motor Mate AC current sensor

VFD Technology

Enhanced Performance with VFD

Variable Frequency Drive (VFD) traction control means greater tonnage produced per shift due to improved sumping and relocation times and a faster tram speed of up to 26 m/min (85 ft/min) (governed). VFD also means

  • Greater system efficiency
  • Reduced cost of motors
  • Ease of troubleshooting

More Torque

VFD provides more motor torque across the entire traction speed range.

Brushless Motor Design

This translates into less maintenance and longer motor service life.

Pays for Itself

VFD pays for itself through higher extraction and lower maintenance costs over its 1.79 million tonne (2 million ton) service life.

Health and Safety

Safety

Cat mining machines and systems are designed with safety as their first priority. The control system is proximity detection ready (details below). The intuitive human machine interface gives the operator and maintenance supervisor an unprecedented level of understanding of their machine. The dual-sprocket conveyor chain drive results in lower ambient noise, while the hydraulic temperature and spool position monitoring (via CAN bus) herald a new level of safety as the machine can identify points of failure and recognize valve malfunction.

Proximity Detection

Caterpillar has developed a Personnel Proximity Detection System with the aim of clearly identifying the presence or absence of personnel reliably and with high repetition accuracy, and of transmitting this information in real time to the local control system to allow appropriate action to be taken to prevent injury. The machine controls can be configured to give different responses to encroachment into the various zones, such as warning, reduced speed and shutdown. A silent zone can overlay the red zone, allowing the operator to see the cutter while staying out of the turning radius of CM. The fields can be customized to provide different-shaped fields.

Other Safety Features

These include a dust collector, scrubber, dust ignition protection, water solenoid valve to minimize water use and spillage, methane monitoring and noise reduction.

Serviceability

Service-Friendly

In addition to long overhaul intervals and wear-resistance features, the CM445 has a number of features to simplify maintenance and repair:

Preventive Maintenance

Caterpillar’s thorough preventive maintenance program ensures that the integrity of the machine is not compromised. When properly maintained, Cat continuous miners perform for years at lower maintenance costs, thus lowering the total cost of ownership.

Easy Access

  • Centralized location of grease points and fill ports for ease of maintenance
  • Ease of access to cutter head gear oil checks and replacement
  • Cutter head motor mounting location allows easier access for replacement

Resistant to Wear

  • Astralloy-V crawler frame wear liners
  • Chromium-carbide overlay (CCO) wear protection package for cutting head gear case struts
  • 3- or 6-finger centrifugal loading arms (CLA) with replaceable bolt-on wear tips
  • Chromium-carbide overlay (CCO) wear protection package for gathering head assembly
  • The top decking of the conveyor is CCO plated and the return deck is plated with 450 BHN wear plate
  • Heat treated alloy steel crawler pads for wear resistance and 100% increase in pivot wear area material

Split Gear Case

The cutter gear case is split. Each side is independent and only connected by the center cutting drum. This allows one gear case - with half the number of components - to be replaced, as opposed to standard designs that require replacement of the entire assembly. The gear case has three independent oil compartments, allowing convenient viewing of oil levels through site gauges.

Slide from the Side

The traction units are complete assemblies that slide in from the side. VFD motors are brushless motor design, requiring less maintenance and ensuring longer motor life.

Specifications

Mining Range
1651-3480 mm (65-137 in)
Weight
85.7 tonnes (189,000 lb)
Total Power
1185.0hp

Power

Cutter Head Power
670.0hp
Total Power
1185.0hp

Operating Dimensions

Maximum Reach
12.42ft
Ground Clearance
9.0in
Length Rear Bumper to Face
28.32ft
Minimum Height
59.0in
Mining Range (recommended)
1651-3480 mm (65-137 in)

Machine Weight

Weight (total)
85.7 tonnes (189,000 lb)

Loading Unit

Conveyor Depth
12.0in
Conveyor Power - Motors (one-hour rating)
2 × 48 kW (2 × 65 hp)
Conveyor Width
38.0in
Loading Capacity
14-35 tonnes/min (15-39 tons/min)
Loading Method
3 finger CLA

Optional Dust Suppression

Fan Power - Motor
1 × 30 kW (1 × 40 hp)
Scrubber Assembly
Top mounted
Scrubber Capacity
4.7 m3/sec (10,000 ft3/min)
Scrubber Type
Wet bed

Cutting Unit

Cutting Drum Diameter
44.0in
Cutting Drum Width
11.75ft
Cutting Power - Motors (one-hour rating)
2 × 209 kW (2 × 280 hp)

Total Installed Power

One-hour Rating without Scrubber
975.0hp

Transport Dimensions

Frame Width (over rub rails)
11.23ft
Height (over cover line)
55.0in
Overall Length
37.83ft

Traction Unit

Crawler Assembly Length
11.65ft
Crawler Chain Width
22.0in
Crawler Speed
0-23 m/min (0-75 ft/min)
Ground Pressure
30.7psi
Traction Power - AC/VFD (one-hour rating)
2 × 82 kW (2 × 110 hp)

Pump Unit

Pump Power - Motor (one-hour rating)
1 × 48 kW (1 × 65 hp)

Electrical System

Control System
Processor based/radio remote control
Machine Voltage (International voltages available)
995V AC 60 Hz

Cutting

0 to Maximum Cut
1492-3989 mm (58.75-157 in)