Authors: K.Yu.. Zerschikov

Title of the article: Cable crossovers made of polymer composite materials to reduce the cost of operating excavator-vehicle complexes

Year: 2026, Issue: 4, Pages: 62-72

Branch of knowledge: 2.8.8. Geotechnology, Mining machines (engineering)

Index UDK: 622.271

DOI: 10.26730/1816-4528-2026-4-62-72

Abstract: The article presents an innovative solution for reducing costs during the operation of excavator-vehicle complexes – cable crossovers made of polymer composite materials. The relevance of the study is due to the need to optimize production processes in the mining industry and reduce the cost of extracting minerals. Cable lines that supply electricity to mining complexes must be reliable and cost-effective to operate. Existing cable line supply options are technologically complex, require significant safety measures, and are costly. Proposed cable crossover for a power cable made of a polymer-based wear-resistant composite ensures long-term operation, is highly mobile, and does not require the use of special equipment. As a result, total costs are reduced. However, the use of new technology requires confirmation of its performance characteristics. To achieve this, a finite element analysis was performed using the Abaqus software package to assess the impact of a 630-ton dump truck on the cable crossing. The calculation showed that the strength is ensured. Given the cyclic nature of loading, the strength was also calculated based on the condition of 100,000 overpasses. Since this number of cycles corresponds to approximately 10 years of operation, it was concluded that the crossovers can be used for a long time. The economic efficiency of using cable crossovers was calculated in comparison with the traditional cable routing scheme. Consequently, the technical and economic advantages of cable crossovers make their implementation highly effective. The scientific novelty of the work lies in the development and justification of the effectiveness of using mobile cable crossovers made of polymer composites instead of traditional metal structures.

Key words: Excavator-vehicle complexes cable gates mobile cable crossover composite material strength calculation finite element method economic efficiency

Receiving date: 05.02.2026

Approval date: 01.09.2026

Publication date: 27.08.2026

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