Cable reel system design for underground mining.
Case study: ASTCAD designed a motorised cable reel system for an underground coal mining contractor — handling 800m of high-voltage trailing cable for continuous miner operations to AS/NZS 4871 for electrical equipment in coal mines.
Project overview
ASTCAD designed a fully motorised cable reel system for a NSW-based underground coal mining contractor. The reel handles 800m of high-voltage trailing cable for a continuous miner, with automatic level-wind, slack-cable detection and overload protection. The design complies with AS/NZS 4871 for electrical equipment in coal mines and AS 4024 for safety of machinery.
The challenge
The existing manual reels were causing cable damage at the slip-ring assembly and required two operators to manage during retreat mining. The client needed a self-managing reel with automated speed control synced to the miner’s tramming speed, plus intrinsically safe sensors for methane-rated environments.
Our approach
- Hydraulic motor sizing for 18 kN constant pull with cable on full and empty reel
- Level-wind mechanism with optical cable position feedback
- Slip-ring assembly redesign with replaceable carbon brushes accessible without dismantling
- FEA validation of drum shaft and side flanges for fatigue at 50 reversals per shift
- Ex-rated enclosure design for control panel to AS/NZS 60079
Deliverables
- Full mechanical assembly drawings (162 sheets)
- Hydraulic schematic and component schedule
- Electrical schematic and control logic narrative
- Manufacturing dossier including FEA reports
- Operator manual and maintenance schedule
Outcome
Three units were built and deployed to a Hunter Valley coal mine. Cable damage incidents dropped to zero in the first 12 months. The single-operator design freed up one crew member per shift, with measurable productivity gains during retreat-mining cycles. The client commissioned a second batch of five reels in 2024.