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Key Technologies and Applications of Large-Tonnage Breaker-Type Hydraulic Excavators

  For large-scale mining operations, traditional explosive blasting methods present significant issues including high pollution, excessive noise, and substantial safety risks. In recent years, with the tightening of national regulations on mining safety and environmental protection, the industry has gradually shifted from traditional explosives to using large excavators equipped with hydraulic breakers for rock fragmentation. As market competition intensifies, the profitability of excavator-based breaking operations has declined, equipment payback periods have lengthened, and customers have raised their requirements for excavator operational efficiency, fuel consumption, and reliability. Consequently, developing large-tonnage, high-efficiency, low-consumption, and long-operation-cycle specialized excavators for rock breaking has become an inevitable trend.

  In response to market demand and pain points for large-tonnage rock-breaking excavators, and keeping pace with technological advances and market shifts, this project focused on tackling key technical challenges such as low breaking efficiency, high fuel consumption, and poor structural reliability. The following innovative outcomes were achieved:

  A pioneering self-optimizing control technology for variable-load breaking was developed. Through the innovative design of a three-stage frequency conversion hydraulic breaker and its self-optimizing control system, the technology enables automatic identification of rock hardness under breaking conditions and automatic adjustment of breaking power according to operational demands. This allows the new breaker to rapidly adapt impact force and frequency based on varying rock hardness, improving operational efficiency and reducing energy consumption.

  A full-range working condition control strategy for breaking operations was created. By adopting a self-matching control strategy for segmented actions during breaking and a constant-flow control under full-pressure breaking, two energy-saving control strategies were implemented. This reduces energy loss during low-pressure breaking, balances breaking and auxiliary actions, and lowers fuel consumption.

  An accurate assessment method for ultra-long fatigue reliability life of the working device was invented. Based on the concept of damage equivalence, the method reconstructs the random load spectrum under full breaking conditions. It incorporates welding residual stress in the equivalence process between welded joint samples and the fatigue life of the full-machine large-scale structure. Through anti-fatigue design, the fatigue life of the working device has been effectively enhanced.

  The project has filed a total of 27 patents, of which 16 have been granted (11 invention patents and 5 utility model patents). The relevant technologies have been implemented in Zoomlion’s large-tonnage excavator models such as the ZE550EK-10, ZE385GK, and ZE650GK. Over the past three years, these models have achieved cumulative sales of 1,675 units, generating additional revenue of RMB 2.81 billion and added profit of RMB 772 million. The project has effectively addressed customer pain points in the mining market, including low breaking efficiency, high fuel consumption, and insufficient structural reliability of rock-breaking excavators, delivering significant social, economic, and environmental benefits.