Load and Energy Consumption Analysis of Rope Winches Used in Mining Rail Transport

Krzysztof Krauze, Ryszard Klempka, Kamil Mucha () and Tomasz Wydro
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Krzysztof Krauze: Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, al. Mickiewicza 30, 30-059 Kraków, Poland
Ryszard Klempka: Faculty of Electrical Engineering, Automatics, Computer Science and Biomedical Engineering, AGH University of Krakow, al. Mickiewicza 30, 30-059 Kraków, Poland
Kamil Mucha: Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, al. Mickiewicza 30, 30-059 Kraków, Poland
Tomasz Wydro: Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, al. Mickiewicza 30, 30-059 Kraków, Poland

Energies, 2025, vol. 18, issue 11, 1-12

Abstract: A central engineering concern in the use of such winches is their energy intensity, which is significantly influenced by operational factors such as the length and gradient of the transport route, the transported weight, and the target hauling velocity. These variables directly affect the drive system’s load and thus the power demand of the motor, which represents the primary component of the system’s energy consumption. While manufacturers typically provide structural, kinematic, and power-related specifications, the user must evaluate whether a given winch can operate efficiently within the energy constraints imposed by specific site conditions. To aid in this assessment, an analytical model, along with a computational software tool, has been developed. This solution enables the continuous determination of essential parameters, with particular attention paid to the energy requirements of the system, supporting informed selection and implementation of winches with appropriately rated motors to optimize energy consumption. For the analyzed case, it was calculated that doubling the transport distance results in an increase in energy consumption of approximately 50%. Moreover, an increase in the velocity of the transported weight by only 0.5 m/s leads to a rise in energy consumption of approximately 25%.

Keywords: underground mining; rail transport; rope winch; drive load; energy consumption (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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