mining machinery nit rourkela

8/17/2019 Mining Machinery Nit Rourkela

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WIRE ROPESWIRE ROPES

Presented by

Prof. Devidas S. Nimaje

Assistant Professor

Department of Mining Engineering

National Institute of Technology

our!ela"#$%&&'( INDIA


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Wire ropes are made from steel wires of plain carbon steel having

high tensile strength.

Typical analysis of steel is as follo)s *+y )eight percentage,-

Carbon – 0.5

Silicon – 0.11

Manganese – 0.!

S"lph"r – 0.0##Phosphoro"s – 0.01 and

$ron – rest

%ccording to $.S. Specification no. 1!#5 of 1&'1( neither s"lph"r

nor phosphoro"s content in the steel for wire rope sho"ld e)ceed

0.0!0 *.

+ltimate tensile strength ,brea-ing strength of the wires "sed for

ha"lage/winding ropes is generally between 10 – 10 -gf/mm 2


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4opes of stainless steel are not "sed as the material has less tensile

strength.

$f the wire rope is to be "sed in a wet shaft( the wires aregalvanied( i.e. coated with molten inc.

6he wire is s"b7ected to the following tests carried o"t according

to the standards provided by $.S. specifications8

1.6ensile test

.6orsion test

#.9ending test

.Wrapping test

5.:ooping test


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Types and construction of )ire ropes-

;n the basis of "se( wire ropes are classified as8

Standing opes

4e


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;n the basis of constr"ction( wire ropes are classified as8

Stranded ropes-

are made of strands and each strand consists of n"mber ofconcentrically twisted wires laid in the form of heli) ro"nd a

central steel wire.

Non-stranded ropes8

6hey incl"de loc-ed coil ropes.


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ross"section of different )ire ropes


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6he fle/i+ility of a strand depends "pon8

0.Type of core= a strand with a fle)ible core is more fle)ible than

one with steel core at the centre.

1.Thic!ness of individual )ires – 6hinner the wires( more is the

fle)ibility. and

2.Num+er of )ires= :arger the n"mber of wires( more is the

fle)ibility.


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3ay of )ire rope-

6he lay of a wire rope describes the manner in which either the wires

in a strand( or the strands in the rope( are laid in a heli).

3eft and right hand lay-

:eft hand lay or right hand lay describe the manner in which the

strands are laid to form the rope. 6o determine the lay of strands in

the rope( a viewer loo-s at the rope as it points away from them. $f

the strands appear to t"rn in a cloc-wise direction( or li-e a right=

hand thread( as the strands progress away from the viewer( the ropehas a right hand lay. $f the strands appear to t"rn in an anti=cloc-wise

direction( or li-e a left=hand thread( as the strands progress away

from the viewer( the rope has a left hand lay.


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4rdinary lay

6he lay of wires in each strand is in the opposite

direction to the lay of the strands that form the

rope.

3ang5s lay

6he lay of wires in each strand is in the same

direction as the lay of the strands that form the

rope.

Alternate layStrands alternate between :ang>s lay andordinary lay? e.g.8 in a '=strand wire( # strands

are ordinary lay( and # are :ang>s lay.

egular lay %lternate term for ordinary lay.

everse lay %lternate term for alternate lay.


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6he specification of a wire rope type – incl"ding the n"mberof wires per strand( the n"mber of strands( and the lay of the rope

– is doc"mented "sing a commonly accepted coding system(consisting of a n"mber of abbreviations.

6he rope $/0% 6 7 43 6S8 @where '" 3"mber of strands

that ma-e "p the rope( 1& = 3"mber of wires that ma-e "p eachstrand( AC= Aibre core( 4B ;: ASW4 = 4ight hand ;rdinary lay

Ale)ible steel wire rope.


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onstruction of )ire rope


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Warrington differs from the other types ,Ailler Wire and Seale

constr"ction in that the o"tside layer of wires in each strand of thewire rope is composed of wires alternately large and small. 6he

o"tside wires of both the Ailler Wire and Seale constr"ction ropes

are "niform in sie.

6he f"ndamental difference between these types is that the layer of

wires "nderneath the o"tside layer in the Seale type is made "p of

wires all of the same sie. 6he wires "nder the o"tside layer of the

Ailler Wire rope are made "p of a combination of main wires( each

of the same sie( and smaller filler wires( each of the same sie(nested between the main wires. 6he o"tside layer of wires(

therefore( is s"pported partly by the main inside wires and partly

by the filler wires.


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Some ropes have shaped or formed ,triang"lar wires to improve

the wear and bearing properties of the o"ter layers ,rather thancirc"lar drawn wire.

9y having different lay directions of the strands and wire ,left

and right = also -nown as S and D? it is possible to balance the

tor


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6lat ope-

6hese are "sed for winding and are made with a flat constr"ction. $t

consists of a n"mber of small ropes or strands laid side by side andlaced or stitched together with soft iron wire. 6he individ"al wires

are laid "p in opposite direction so that those of ad7oining ropes test

closely together. Aor "se with the flat rope( a special winder( -nown

as the reel winder is designed. 6his is arranged so that the flat rope

winds "pon itself in concentric layers which are retained all the

sides by radial arms or by side plates on the reel. 9y mo"nting two

reels "pon the common shaft( a partly balanced system of winding

co"ld be arranged. 6he effect is similar to that of a conical dr"m

with which the cage at greater depth i.e. the greater s"spended load,incl"ding rope is at smaller diameter. 6he development of circ"lar

stranded ropes( which are cheaper to man"fact"rer( more reliable in

"se and easier to operate ca"se them to s"perside the flat rope and

lead to the development of reel winders by dr"m


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Advantages-

1.Compared to the ro"nd stranded ropes( they are more fle)ible.

.6hey have been preferred as balancing ropes on the -oepe

system of winding.

Disadvantages-

1.Wear in the rope lacing or stitching which holds the individ"al

rope section together ca"ses diffic"lty in operating flat ropes

while repairs are slow and e)pensive.

.6heir life is m"ch shorter compared to the ro"nd stranded

ropes.


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ound 8ire ope-

6he most important attrib"te for a winding rope is the ability to

withstand( witho"t permanent deformation( repeated bending "nder

stress s"ch as when the rope is wo"nd over the head sheave or on

the dr"m.

6his re


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Advantages-

1. %bility to withstand witho"t permanent deformationrepeated bending "nder stress.

. Ale)ible

#. $t ret"rns to its original form when the load is removed.

1. Compared to the flat rope they are less fle)ible.

. Compared to the flat rope they have less strength.

Disadvantages-

3 ! d il


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3oc!ed oil ope-

6hey differ from standard ropes in constr"ction and are made by

spinning concentric layers of single wire aro"nd a core and finishing

with one or more s"rro"nding layer of shaped wires which are interloc-ed to restrain( the centre layers and to ma-e a smooth cover.

Each layer of wires is sp"n in a heli) abo"t the centre core. Fepending

"pon the design one or more of the inner layers are made "p ofalternate ro"nd and shaped or half loc-ed wires

6he o"ter layers of f"lly inter loc-ed wires is laid on in the opposite

directions to the inner layers with the res"lt that the rope is almost

non=spinning. 6he cross section of the loc-ed coil rope shows that the

central portion consists of strands of thic- ro"nd wires only the o"ter

layer ,or two layers consists of ro"nd wires placed between specially

shaped wires of $ section( rail section or trapeoidal so that the wires

loc- with one another and the rope s"rfaces is smooth and plain as


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ross"section of different )ire ropes

*6irst ro)- 6lattened strand rope( Middle ro)- 3oc!ed coil

rope and 9ottom ro)- Spiral strands,


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Advantages-

1.$t has a ma7or advantage in sin-ing shafts where g"ide ropes

are not available.

.Aor winding and hoisting p"rposes a loc-ed coil rope is

sometimes preferred.

#.$t has capacity factor which permits a high factor of safety.

.6heir smooth e)terior ca"ses less abrasion and wear of the

s"rface in contact. Bence it gives more d"rability.5.$t has more space factor ,5*. Bence greater strength.

'.$t has more tendencies to twist or rotate. $t red"ces wear on the

cage g"ide.

.6hey are greater strength than the ro"nd rope beca"se the wiresare more completely arranged.

!.6hey are greater resistance to cr"shing.

&.6hey have fewer tendencies to twist and stretch in wor-ing.


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1.Constr"ction is somewhat diffic"lt.

.$ts interior cannot be l"bricated from o"tside.#.$t is not so fle)ible.

.$t is somewhat diffic"lt to cap as compared to the standard ropes.

5.6hey do not stretch as m"ch as the standard ropes and their

smooth e)terior ca"se less abrasion and wear of the s"rface incontact.

'.6hey are not preferred for -oepe winders beca"se of smooth

s"rface and low coefficient of friction.

Disadvantages-


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Precautions-

1.%void "se of the rope with fiber core( when the rope is s"b7ected to

heat flames and e)treme press"re..9"y right constr"ction of rope s"itable for the 7ob.

#.Corrosion can be delayed by "sing galvanied rope.

.Fo not load the rope beyond its safe wor-ing load.

5.Ens"re that the rope is strongly seied before it is c"t.

'.Ale)ibility of rope sho"ld be s"itable to the sie of the dr"ms and

p"lleys and diameter of the rope grooves.

.Grease the rope and cover properly before storing in a dry

ventilated shed.

!.Bandle the rope caref"lly while transporting and "ncoiling to avoid-in-s.

&.$nspect the rope periodically and l"bricate with acid free l"bricant.

10.H"dge the safe life of the rope for the conditions "nder which it has

to wor- and replace it in proper time.

S l ti f i


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Selection of )ire ropes-

% wire rope is to be selected on the following considerations8

0.8atery place and corrosive atmosphere " to prevent r"sting and

effect of corrosive f"mes( a galvanied wire rope sho"ld be "sed in

s"ch places.

1.7igh temperature : ropes with fibre core sho"ld be avoided andin s"ch places steel core sho"ld be "sed i.e. in fo"ndries( steel

melting shops( etc.

2.Stationary or running ;coiling rope : stationary ropes can be oflarger diameter rods or strands e.g. g"ide ropes in a shaft. 4"nning or

coiling ropes re


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'. 9ending fatigue" 9ending fatig"e of a wire rope over sheaves or

dr"ms ca"ses fatig"e fail"re of the wires. 6he rope sho"ld be

fle)ible which is possible in a rope having large n"mber ofsmaller wires.

%. ?roove si@e : the rope sho"ld not be loose or too tight in the

groove of the p"lley or dr"m.

0&. rushing and distortion : a flattened strand rope and loc-ed coil

rope is better able to withstand cr"shing than a ro"nd strand rope.

6he core sho"ld be of steel wire.

;nce the constr"ction lay and other characteristics of the rope are

decided "pon( one has to decide its sie after calc"lating the

stresses that the rope may have to withstand.


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opes used for different purposes-

0.8inding ropes-

' ) :ang lay AC

' ) 1& Seale reg"lar or :ang lay AC

' ) 1 Ailler wire reg"lar or :ang lay AC

' ) 5 Ailler wire reg"lar or :ang lay AC

' ) Alattened strand :ang lay AC' ) #0 Alattened strand :ang lay AC

:oc-ed coil hoist rope

1.?uide ropes-#.Balf loc-ed coil g"ide rope

2 8i di f h ft i !i


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2. 8inding rope for shaft sin!ing-

1& ) 3on=rotating 4eg"lar lay or loc-ed coil hoist rope.


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#. Dragline 7oist ropes-

Aor # mm to 5! mm sie( ' ) 5 Ailler wire :ang lay with $W4C or

' ) 1 Seale Ailler :ang lay with $W4C

'. Do@ers-

' ) 5 Ailler wire 4eg"lar lay with $W4C ,9lade hoist ropes

%. ?uy opes *ship masts" sta+ility-

Galvanised strand 1 ) ( 1) 1&( 1 ) # etc or ) or ) 1&

0&. Aerial rope)ays-

J 9i"ca+le rope)ay-

Trac! ca+le- :oc-ed coil ,A"ll or Balf loc-Traction ropes- mm and larger( ' ) 1& seale :ang :ay AC or ' )

5 Ailler wire :ang lay with $W4CJ Monoca+le rope)ay-

' ) :ang lay AC

' ) 1 Ailler wire :ang lay AC


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00. Mo+ile ranes-

J Main 7oist rope-

' ) 5 Ailler wire 4eg"lar lay with AC ,"se $W4C ropes to ta-e

care of cr"shing of the rope on the dr"mJ 9oom hoist rope-

' ) 5 Ailler wire 4eg"lar lay with $W4C


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Mass and strength of )ire ropes-

6he mass of a rope depends "pon the


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Type of rope ! s

4o"nd strand with fibre core 0.#5 5

4o"nd strand with wire core 0.0 5'

Alattened strand with fibre core 0.1 55

Alattened strand with wire core 0.5 5!

:oc-ed coil 0.5' !5

S ! ti i d


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Soc!eting or apping a rope end-

6he end of a rope where the load is to be attached sho"ld be a good

portion of the rope( free from worn( r"sted( bent or bro-en wires

and free from the effects of bending and corrosion.

6he simplest and easiest way to ma-e the rope end s"itable for

attachment of load is to "se a grooved thimble and bend bac- the

rope end on it and part of the rope before finally tightening ='rope clips at intervals on it. $t needs less s-ill and s"ch attachment

is permissible for ha"lage and s-ip ha"ling on inclined planes b"t

not permitted for winding ropes. 4ope length "nder clips is nearly

#0 times the rope diameter.

6here are different ways of attaching capels or soc-ets

1.Split capel with rivets

.Coned soc-et type capel

#.$nterloc-ing wedge type capel ,4eliance capel


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Interloc!ing )edge type capel *eliance capel,


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TRANSPORT SYSTEMTRANSPORT SYSTEM

Presented by

Devidas S. Nimaje




Presented by


Assistant Professor


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6he main methods of transport are as follows8

%. 4ope Ba"lage

1. Firect rope ha"lage

a. 6ail rope ha"lage

. Endless rope ha"lagea. ;ver=rope

b. +nder=rope

#. Main and tail rope ha"lage

. Gravity ha"lage

9. Conveyor system of ha"lage

1. 9elt conveyor

. Cable belt conveyor

# Chain conveyor


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a. Scraper chain conveyor

b. %rmo"red chain conveyor

c. Gate end loader

d. Mobile stage loader

e. Pic-=abac- conveyor

. Plate conveyor

5. Fisc conveyor

C. :ocomotive ha"lage

a. Fiesel locomotive

b. Electric battery locomotive

c. 6rolley wire locomotived. Cable reel locomotive

e. Compressed air locomotive

f. Electro=gyro locomotive

F. Sh"ttle cars

#. Chain conveyor

+ndergro"nd transport arrangements are divided into two


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+ndergro"nd transport arrangements are divided into two

categories8

1.Main Ba"lage

.Gathering ha"lage

6he main ha"lage arrangement is that which operates between

winding shaft/incline and the main "ndergro"nd loading points. %tthe main loading point( the loads are collected from one( two or

more districts.

6he gathering ha"lage arrangement is that which operates between

the wor-ing faces and the main loading points.

$n a large mine( where the wor-ing faces are far from the main

loading point( an intermediate transport arrangement operates and it

is -nown as secondary ha"lage.


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ROPE HAULAGEROPE HAULAGE

Presented by

Devidas S. Nimaje




Presented by


Assistant Professor

Direct ope 7aulage


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Direct ope 7aulage

Simplest system employing in the mine.

consist of one p"lling rope and one ha"lage dr"m for ha"lingminerals in t"bs or mine cars "p a gradient which is generally

steeper than 1 in 10.

6he ha"lage engine is sit"ated at the top of an inclined roadway.

6he train of t"bs is attached to one end of the rope( the other end

being fi)ed to the ha"lage dr"m.

6he empty t"bs attached to the end of the ha"lage rope travel on

the down gradient by their own weight and do not re


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Advantages-

1.6he rope speed is generally !=1 -m/h and the system can operate

between any point of the ha"lage plane and the ha"lage engine.

.$t can( therefore( cope with the ha"lage re


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Disadvantages-

1.Bigh pea- power demand as load starts its 7o"rney "p thegradient.

.Severe bra-ing d"ty on the downward r"n.

#.Bigh ha"lage speed demanding high standard of trac-

maintenance.

.3ot s"itable for mild inclination of roads.

5.% derailment is associated with heavy damage beca"se of high

speed.

Direct rope dou+le drum +alanced haulage


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$t is the modification of direct rope ha"lage( two dr"ms are

provided so that when a train of f"ll t"bs is being ha"led

o"tbye( a set of empty t"bs is lowered inbye.

9oth the dr"ms are fitted with cl"tches and are mo"nted on

the same shaft.

Weights of the rope and the t"bs are balanced and only the"nbalanced load for the engine is mineral.

6his res"lts in a red"ced pea- power demand and easier

bra-ing.

6he system gives higher o"tp"t in each trip of the rope brings

the loads and there is reg"lar delivery of the loaded t"bs.

6he system re


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Trac! layout of Direct rope

*E" Trac! of empties and 6 : Trac! of loads,


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Endless rope haulage

$n this system there are two parallel trac-s side by side.

;ne for loaded t"bs and another for empty t"bs and the endless

rope passing from the driving dr"m located at o"t bye end of the

ha"lage road to the in bye end and bac- again via a tension bogey.

6he t"bs loaded as well as empties are attached to the rope with

reg"lar interval with the help of clips so that the entire rope length

has t"bs on it at intervals.


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;nly one end of the t"b is attached to the rope at a time. 9"t

where lashing chain is "sed for attachment the normal practice is

to attach a set of t"bs and the attachment or detachment is

performed by stopping the rope if however clips are "sed for

single t"bs they can be attached or detached when the rope is in

motion.

6he gradient of ha"lage road is mild and rarely e)ceeds 1 in '.

6he rope speed ranges between # -m/h and -m/h and the

ha"lage is slow moving.

6he rope moves in one direction only.


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Endless rope haulage


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Tension +ogey

Types-


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Types-

6here are two types of endless rope ha"lage.

1.Over Rope type- $n over rope type the ha"lage rope passesover the t"b or set of t"bs.

2.Under Rope type8 $n "nder rope type it passes beneath the t"b

or set of t"bs.

Advantages-

1.9eca"se of slow speed( less wear and tear..%ccident from derailed t"bs does not ca"se m"ch damage d"e to

slow speed.

#.Motor of less power re


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Disadvantages-

1.$t re


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ope clips used in Endless haulage

6he t"bs( loaded as well as empties( are attached to the rope at

reg"lar intervals with the help of clips( so that the entire rope

length has t"bs on it at intervals. When the clips are "sed for

single t"bs they can be attached or detached when the rope is in

motion.

Types of rope clips-

6he design of endless ha"lage rope clips depends on whether the

ha"lage is of over rope type or of "nder rope type. Some of the

clips "sed in the endless ha"lage are as follows8=

1.Screw Clip

.Smallman Clip

#.Cam Clip and

.:ashing Chain


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Scre) lip-

6his clip is tightened on the rope by a handle and screw and the

handle is co"pled to the draw bar of the t"b by a long steel rodhinged to the clip.

Smallman lip-

consists of a pair of steel chee-s or side plates( loosely held

together by the ad7"stable central bolt which has a spring

s"rro"nding it to -eep the plates apart and -ept in position by

pins s"pporting the lever and the co"pling hoo-.

6he clip can be detached a"tomatically from the rope by fi)ing

a bridge=piece or trip bar to a sleeper at s"ch a tight and in

s"ch a way that the rope passes "nderneath while the lever of

the clip stri-es against it.


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am lip-

6his consists of a plate and a cam=shaped lever which is pivoted

and is connected by a small chain to the t"b to be ha"led. 6he p"ll

of the t"b t"rns the lever aro"nd the pivot so that the grip of the clip

on the rope is proportional to the load. ;n "nd"lating roadways( a

clip m"st be provided at each end of the t"b .

3ashing hain-

6he lashing chain is "s"ally .5 to # m long with a hoo- at each

end. ;ne hoo- is attached to the draw bar of the t"b and the otherend of the chain is coiled # to times aro"nd the ha"lage rope and

is lin-ed to the chain. $t slows down the speed of t"bs ca"sing less

wear and tear. $t helps to prevent accidents by derailing the t"bs.

When the lashing chains are "sed to 7oin t"bs( it helps to attach t"bs

at different level easily .


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Scre) clip

3ashin chain

am clip

Smallman cli


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Main and Tail rope haulage

6he ha"ling engine is provided with two separate dr"ms one for

the main rope( which ha"l the f"ll train o"t and one for the tail

which ha"l for the empty train in.

When one dr"m is in gear( the other revolves freely on the shaft

b"t controlled when necessary( by the bra-e to -eep the rope ta"t.

6he main rope is appro)imately e


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;nly one trac- is re


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Main and tail rope haulage


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Advantages-

1.6his system of ha"lage is s"itable for "nd"lating roadways(where it is impossible or "ndesirable to maintain the do"ble

trac-.

.+nli-e endless rope ha"lage( this system re


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g

1.%s it operates at fairly high speed( more wear and tear.

.Ferailment can ca"se more harms to man and machine.

#.:ong length of rope is re


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?ravity haulage or Self acting incline

6his ha"lage operates witho"t any motor or e)ternal so"rce of power and consists of a cast iron p"lley of 1.# m to m

diameter having a bra-e path on the side and a strap bra-e.

$t is located at the top of the inclined roadway and is employedto lower by gravity the loads attached to one end of the rope

which passes ro"nd the vertical 7ig p"lley.

;nly single trac- is re


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ig pulley of gravity haulage

Plan and section of la out of ravit haula e


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Safety Devices in 7aulage

6he vario"s safety devices "sed on ha"lage roadways are asfollows8

0.Stop"+loc!s-

% stop=bloc- is a common arrangement placed near the top of

inclines. $t consists of a sto"t beam or bloc-s lying across the rails(

pivoted at one end and held against a pivoted side=bloc- at the

other. 6he side=bloc- may be straight or bent. When it is desired toopen the bloc-s( side bloc- is first opened and then the stop=bloc-

is t"rned.

1 9uffers-


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1. 9uffers-

When any roadways or face is in direct line with a ha"lage trac-

and persons may be e)posed to danger from r"naway t"bs( strong b"ffer is provided and maintained on ha"lage road to prevent s"ch

danger? 9"ffers may be horiontal or vertical.

2. 9ac! catches-

$t may consist of a pivoted piece of steel rail placed between the

two rails as shown in the fig"re ,mon-ey catch. 6"bs can move

over it only in one direction. $n case of bac-ward r"nway it will

catch the t"b a)le th"s arresting the t"bs. % sto"t wooden bloc- is pivoted at one end and passed over the rail by a strong spring

allows the t"be in one direction only and prevents r"nway

,bac-ward in case of spring catch.


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p

6his is fitted on the main ha"lage trac- to deflect a bac-ward

r"nway into the prepared side of the roadway. 6he derailed t"bs

may be a"tomatically re=railed when drawn forward.

>. Drop )ar)ic!-

$t consists of a girder ,heavy type hinged at one end to a speciallyset roof girder and held "p at the other by an eye=bolt and pin. 6he

warwic- is released when re


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%n obvio"s disadvantage that e)cessive impact into the warwic-

may displace the roof s"pport( th"s ca"sing a roof fall( if thewarwic- post ,drop girder is hinged to a roof bar. $t is essential

therefore to anchor the warwic- to a girder not forming part of the

roof s"pport b"t firmly set into the side of the roadway. 6ho"ght

m"st also be given to the sitting of the warwic- between ref"ge

holes( avoiding possibility of accidents to persons sheltering

therein. 6he a"tomatic closing type of warwic-s are "sed which

are balanced by weights. 6he drop girder is slightly heavier than

the weight rod attachment in this case. 6he moving t"b itself

stri-es the weight rod attachment in this case. 6he moving t"bitself stri-es the weight rod to ca"se dropping of the girder at some

distance.


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S"ch warwic-s may be operated by means of8

1.a weight rod s"spended from the roof

.a side warwic- in which a side arm is balanced to ret"rn to the

closed position either by gravity or by a set of weights after a last

tram has passed( the type has the swinging movement controlled

by balance weights and p"lleys.


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Where( it is desirable to have the roadway closed that is against

r"nways when t"bs are passing "nder warwic-. $t is possible to

connect two warwic-s in series so that when one tram opens and

the other is a"tomatically closed. 6his system can only be installed

where the trams r"n in one direction.

Warwic-s can be arranged to have an a"tomatic tripping device

incorporated whith comes in to operation when the normal speed ise)ceeded. 6his wor- on the principles that the trams travelling at

normal speed move a pend"l"m witho"t disconnecting the slip lin-

which is holding a drop girder by means of a chain and cable. $f a

certain speed is e)ceeded the pend"l"m is str"c- a harder blow ands"fficient to release the slip lin- and th"s ca"sing the girder to drop

to the closed position.


68/343

$. Agecroft device-

6his is designed to arrest forward r"nways a"tomatically. 6hesewor-s on the principle that the first a)le of the t"bs depresses the

higher end of a catch raising the for-ed end to a)le height. $f the

t"b is passing at normal speed( the for-ed end drops before the

bac- a)le reaches it. $f the t"b is moving too fast the bac- a)le isheld by for- and the t"b is stopped.

#. 9ac!stays-

%ny train of t"bs ascending an incline ,e)cept endless rope shall

have a drag or bac-stay attached to the rear t"b so as to prevent

the train from r"nning bac-. 6hese may be attached to the t"b

a)le or to the t"b drawbar according to their types.

'. un)ay s)itches-


69/343

6he basic principle of these is that the t"bs brea-ing loose from

a rope are diverted by means of an open trac- switch.

6he r"nway points are closed by the t"b wheels as the train

ascends the incline b"t they are immediately opened again

a"tomatically by the action of a spring.

4"nway t"bs are then g"ided into the side to a place prepared to

receive them.

6he points are held in the closed position for t"bs descending

the incline( by a light rope attached to a specially designed catch

&=#0 m "p the incline( which is released by a ha"lage hand when

the train has gone over the point leaving them in safety position

with the light rope slac-.


70/343

% form of interconnected stop bloc- and r"nway switch is "sed

at the brow of the direct rope ha"lage plane.

$t is so constr"cted that at one time either the stop bloc- or the

r"nway switch is effective in the event of a bac-ward r"nway of a

set of t"bs.

$t is man"ally operated by the ha"lage attendant when the set of

t"bs has to pass clear of the stop bloc-.

6he distance between the stop bloc- and the safety switch is

s"fficient to accommodate the f"ll length of the train.


71/343

%. a@@ rails-

6he principle of this device is that t"bs travelling at normal

speeds pass over a section of the 7a trac- negotiating the bend

readily.

$f the t"bs travel at an e)cessive speed as in the case of r"nway

they will fail to get ro"nd the bend and a derailment occ"rs.

4ails sho"ld be bent to correct radi"s.

0& etarders-


72/343

0&. etarders-

Slowing down and stopping t"bs are integral parts of ha"lage

operations.

% hand operated retarder consists of two plan-s( lined on the top

with belting and mo"nted on cams. %n end cover plan- fastened to

the inside faces of plan-s serves to hold the plan- in position.

6hey are operated by a single lever. When the cams are f"lly raised

the t"b wheels are lifted clear to the rails and a bra-ing action is

provided on the a)le. 6he t"b retarders represent waste of energy and

sho"ld be avoided in planning. Bowever the speedy movement oft"bs re


73/343

cylinders( are widely "sed.

6he device consists of two pairs of hinged bars faced with

renewable s-id plates and brea-ing action effected bymovements of two opposing pistons in a cylinder containing air.

6he bars are raised above rail level and grip the wheels. When

no bra-ing is desired( the valve releasing to the atmosphere isopened after c"tting off compressed air s"pply. % spring draws

bac- the bra-ing bars to normal position.

%"tomatic hydra"lic t"b retarder is s"itable for locomotive

ha"lage or ordinary rope ha"lages. 6he hydra"lic press"re iss"pplied from a 1= KW electrically driven p"mp. 6he

oncoming tram is retarded by the tread of the leading wheels

r"nning between fi)ed s-ids and an inclined hinged platform

which acts as wedges.


74/343

0&. Approach )arning device-

$t is sometimes necessary to warn men wor-ing or travelling in a

ha"lage roadway.

% simple way of operating a warning device in rope ha"lage

roads is an arm protr"ding into the path of oncoming trams whichwhen deflects closes an electric circ"its connected to a signal lamp

or bell.

6he device is operated by a lever depressed by tram a)le.


75/343

A +ac! catch

Dro )ar)ic!

una)ay s)itch

Si nalin s stem )ith rela


76/343

LOCOMOTIVE HAULAGELOCOMOTIVE HAULAGE

Presented by

Devidas S. Nimaje




Presented by


Assistant Professor

1 Where the gradient of the roadway is mild 3early flat gradient


77/343

1. Where the gradient of the roadway is mild. 3early flat gradient

is preferred. % gradient of 1 in 15 against the loads is considered

to be limit tho"gh locos are generally employed on gradients

milder than 1 in 5.

. Where the loco trac- is in settled gro"nd not s"b7ected to

movement by mining operations.

#. $n the inta-e airways where the velocity is ade


78/343

Types-

1.Fiesel :ocomotive

.Electric battery locomotive and

#.;verhead wire locomotive ,6rolley wire locomotive

Diesel 3ocomotive


79/343

$t is commonly "sed. 6heir weight ranges from # to 15 te and

the power from 15 to 5 KW.

6he power "nit is a diesel engine with (# or cylinders of

stro-e cycle( compression ignition type. Beavy d"ty locos are

of ' cylinders.

:ocos "sed in an "ndergro"nd coal mines have the power "nit

in a flameproof enclos"re as a safeg"ard against ignition of

firedamp.

6he inta-e air going to the engine passes first thro"gh a filter

and then thro"gh a flame trap. Similar flame trap is fitted on

the e)ha"st side of the diesel engine @E)ha"st conditioner.


80/343

6he e)ha"st gases from the engine ,very low C;*( ;( 3

( C;

and small


81/343

6he filtering material and the flame grids ,n"mber of stainless

steel plates 50 mm wide and L mm apart welded between

ad7acent plates in stainless steel ho"sing are readily

removable and m"st be replaced by a clean set every ho"rs.

6he e)ha"st smell may mar- the odo"r of spontaneo"s

comb"stion and in mines where the coal is liable to

spontaneo"s heating? the diesel locomotive sho"ld be avoided.

$t is not permitted in "ndergro"nd coal mines when the

percentage of inflammable gases more than 1.5 * in the

general body of air.

$f the water is allowed to fall below a certain level in e)ha"st

conditioner( the f"el is a"tomatically c"t off from the engine

and the bra-es are applied.


82/343

E/haust conditioner


83/343

Electric +attery locomotive

6he power "nit is a FC electric motor receiving its c"rrent froma storage battery carried in a casing on the "pper part of the chasis.

$t is for light and medi"m d"ties as they are less powerf"l(

tho"gh battery locos of 1# te weight available in o"r co"ntry.

4ange is from – 0 KW contin"o"s rating.

$t is


84/343

6here are batteries on a loco and it constit"tes nearly '0*

weight of the weight of the locomotive.

6he batteries are of lead acid type and each battery consists of a

0=0 n"mbers of volts cell.

6he battery cannot be made flameproof and its container has to

be well ventilated.

$t gives service of ! ho"rs of reg"lar traction d"ty. %t the end of a

shift( the battery has to be placed on a charging rac- and it ta-es

nearly ! ho"rs to f"lly charge.

9y a lifting tac-le( the nearly discharged battery of a loco is

removed and placed on charging bays at the end of a shift and

f"lly charged battery from the charging station replaces it.


85/343

6he direct c"rrent for charging at the station may be available

from the motor generator set or by the "se of a merc"ry arc

rectifier ,no moving or rotating parts. 6he battery charging

station sho"ld be close to the inta-e airway.


86/343

9attery charging room layout

4verhead )ire locomotive *Trolley )ire locomotive,


87/343

$t is e


88/343

6he bare overhead cond"ctors are of hard drawn copper wire

s"spended centrally over the trac- at a height of more than m.

the cond"ctors are s"spended thro"gh ins"lators from short cross

wire of mild steel.

%n earth lea-age wire is connected to cross wire. 6he rail trac-forms the ret"rn path for the electric s"pply circ"it and therefore

the former m"st be s"itably bridge at each rail 7oint by copper

cond"ctors.

Section isolation switches for isolating parts of the roadways

have to be "sed in easily accessible position to the roadsides.

6he roadways sho"ld be s"fficiently high and wide to providesafe clearance and the gro"nd free from any movement arising

f i i i


89/343

o"t of mining operations.

6he roadways have to be e


90/343

Trolley )ire for trolley )ire loco


91/343

AERIAL ROPEWAYAERIAL ROPEWAY


92/343

AERIAL ROPEWAYAERIAL ROPEWAY

Presented by

Devidas S. Nimaje




Presented by


Assistant Professor

%n aerial ropeway is an installation in which transportation ofmaterial or men is effected by moving carriers p"lled by ropes


93/343

s"spended above the gro"nd.

Types-

;n the basis of n"mber of ropes and the mode of transportation( the

ropeways are classified as8

1.Mono=cable 4opeway – the ropeway has a single r"nning endless

rope which both s"pport and moves the carriers.

.9i=cable 4opeway= the ropeway has two fi)ed trac- ropes along

which the carriers are ha"led by an endless traction rope.

#.6win=cable 4opeway= the ropeway has two pairs of trac- ropes to

s"pport the carriers and one endless traction rope.

Applica+ility


94/343

%erial ropeway provides the only economic means of long distance

transport over ro"gh co"ntry( hilly and diffic"lt terrain( even it can

pass thro"gh the congested areas( marshy lands( nallahs( rivers( forestsand important agric"lt"ral land.

%erial ropeways have fo"nd wide application in8

1.6ransporting and conveying b"l- materials between two fi)ed pts.

.%erial d"mping of load at any point along the line of ro"te

#.Stoc-ing of materials

.F"mping of waste materials

5.6ransporting of persons in mo"ntaino"s regions

Advantages-


95/343

1.% relatively high transport capacity ,"pto 500 t/hr

.4eg"larity of service and imm"nity to all weathers

#.%bility to overcome nat"ral obstr"ctions ,rivers( marshy gro"nd etc.

.$nherent ability to -eep the gro"nd free for other p"rposes

5.%bility of negotiating steep gradient ,0* and over

'.Possibility of "sing a"tomation

.Minim"m time lost in transportation

!.:ow initial and operating cost and short time for ret"rn on capital


96/343

Disadvantages-

1.Ai)ed location of loading station

.S"sceptibility to damage by string winds.

#.6he length of the line and transport capacity is limited byeconomic and technical consideration.

9i +l


97/343

9i"ca+le ope)ay

$t has following components8

1.6wo trac- ropes or cables stretched at re


98/343

9i"ca+le aerial rope)ay


99/343

Scope of applica+ility and 3imitations

9i=cable ropeways are s"itable for capacities 100 to 00 t/hrand

lengths "p to ' -m in one section of traction rope.

Aor capacities less than 100 t/hr and distances less than #00

m( bi=cable ropeway cannot provide the desirable economy.

Different parts


100/343

Different parts

opes-

Trac! ropes-

6rac- ropes are "s"ally loc-ed coil ropes made of large sie wires

in order to have longer life.

:oc-ed coil ropes provide a smooth s"rface for the movement of

carrier wheel and the s"rface wear of it is relatively "niform.

6he factor of safety for trac- rope d"ring installation sho"ld be #

and m"st be withdrawn from service when it red"ces to .5.

%verage life of the rope is 5 to years.


101/343

Traction rope-

6raction ropes are Si)=strand langIs lay with fibre core.

6he rope diameter varies from 1 to ' mm.

6he factor of safety sho"ld be 5 d"ring installation and ropes

sho"ld be withdrawn when it comes down to .

arriers-


102/343

% carrier has the carriage( hanger( b"c-et and grip for traction

rope.

Carriage r"ns on trac- rope with wheels( and it r"ns on the trac-

rope( with the help of wheels ,0 – #0 cm/diameter mo"nted on it.

6he n"mber of wheel is for light loads and for medi"m orheavy loads .

6he hanger is s"spended from carriage to ma-e its a)is vertical.

6he b"c-et is s"pported by the hanger and grip on carriage.

6hree types of carriers are commonly "sed namely rotating

carrier( bottom discharge carrier and f"lly enclosed b"c-et .


103/343

arriers of a 9i"ca+le rope)ay


104/343

Standard car *T)o )heeled and 6our )heeled, of a 9i"

ca+le ro e)a for the trans ort of +ul! materials

Trestles-


105/343

6he trestles for bi=cable ropeways provide s"pport to both the

trac- and traction ropes. as well as giving necessary profile to the

ropeway.

6he trac- ropes rest on the saddles at the top crossbeam and the

traction rope on the sheaves at the cross beam below.

6restles are constr"cted either in steel( reinforced concrete /

timber.

6he height of the trestles is "s"ally in the shape of a tr"ncated

pyramid. 6he ht. of the trestles is "s"ally ! to 1 m on levelgro"nd and spaced at intervals of 100=50 m. 9"t in a

mo"ntaino"s region( they m"st be as high as 100 m and spaced at

500 m or more. 6he trestles sho"ld be erected on firm gro"nd.


106/343

Steel trestles of a 9i"ca+le aerial rope)ay

Saddles-


107/343

6hese are rolled steel section bent along their longit"dinal

central line to allow rope c"rvat"re on the s"pport.

6he "pper part of the saddle is grooved to accommodate and

s"pport the trac- rope.

Aor safety against "nloading of the rope( the groove dia. sho"ld

be 1.5 d and the depth of the groove 0.!d( where d is the diameter

of the rope.

Stations-


108/343

Stations-

3oading station-

Station where carriers are loaded are called loading station and in

bi=cable ropeway it is more complicated than monocable ropeway.

%t the loading stations( the trac- rope tensioning device is

avoided and the end of it is anchored instead. Bowever the

tensioning of the traction rope may be incorporated.

h i h i l h - d id


109/343

%t the entry to station( the carrier leaves the trac- rope and rides

on the station rail and while leaving it( rides bac- on the rope. 6o

facilitate those( rope deflecting saddles are p"t at the transition point.

6he carriers passes thro"gh the arrangement of releasing and

gripping of the traction rope movement of the carrier is controlled

man"ally or by r"nning chain at a"tomatic station.

Bnloading station-

$t is the discharged end of the rope way.

6he "nloading station sho"ld be s"fficiently high eno"gh above

the gro"nd level to ma-e possible "nloading by gravity.

Intermediate station-


110/343

Intermediate station-

When a bi=cable ropeway has more than one section(

intermediate stations are provided where it passes from one

section to another.

%rrangements are there for tensioning.

Angle station-

When it is not possible to ta-e a straight line ro"te( angle

station are provided to change the direction of ro"te.

Bere the trac- ropes of ad7acent arms terminate by means of

anchorage or tensioning arrangement.

E/amples-

6h f ll i h i l f h diff


111/343

6he following are the partic"lars of the different ropeways

operating in 7haria coalfield( $ndia. 6hese are only meant for

transportation of sand in the different collieries8=

:oyabad ropeway= its starting point is river damodar ,villages

Hat"dih( Ganeshadih( Harma and Petia( district Fhanbad . 6he

length of the ropeway is 1( m.

6erminating and serving points are

1.9adrooch"c- colliery

.M"dihih colliery#.M"dihih=6ent"lmari colliery

.:oyabad colliery

Si7"a=Mal-era ropeway= its starting point is river

d d , ill b d di i Fh b d 6h l h f h


112/343

damodar, village tangabad( district Fhanbad. 6he length of the

ropeway is 1(#' metres.

6erminating and serving points are=

1. Si7"a colliery

. Malera colliery

Pot-ee=-an-anee ropeway= its starting point is river damodar

,village Fhawardah( district Fhanbad. 6he length of the

ropeway is ('5 metres.

6erminating and serving point are=

1. Kan-anee colliery

. Pot-ee colliery

BELT CONVEYORBELT CONVEYOR


113/343

BELT CONVEYORBELT CONVEYOR

Presented by

Devidas S. Nimaje




Presented by


Assistant Professor


114/343

6he belt conveyor is basically an endless belt in a straight line

stretched between two dr"ms( one driving the system and theother acting as a ret"rn dr"m.

$n coal mines and other mines of stratified deposits( where the

"ndergro"nd mineral if won by longwall method( the transport

media which often consists of conveyor .


115/343

3ayout of face( gate and trun! conveyors in a coal mine

6he system of transport by belt conveyor consists of the

following8


116/343

g

1.% flat endless belt which moves contin"o"sly and carries at its

top s"rface the material to be conveyed.

.6he idlers which s"pport the belt.

#.6he str"ct"re of channel iron on which the idlers are mo"nted.

.6he tensioning arrangement for -eeping the belt in proper

tension.

5.6he dr"ms at the discharge and tail end over which the belt

passes.

'.6he drive head which comprises the electric motor( co"pling(

gearing and sn"b p"lleys


117/343

Arrangement of a +elt conveyor

ross"section of +elt for conve or s stem

Selection of +elt conveyor-

1 % f i l b d


118/343

1.%mo"nt of material to be conveyed

.Contin"ity of operation needed

#.Sie of l"mps

.Fistance of transportation

5.Environmental allowance

'.Gradient

.Method of coal winning( i.e. :ongwall or 9ord and Pillar

•Capital %vailable

Advantages-


119/343

g

1.% contin"o"s s"pply of material.

.:ow operating cost than road transportation system.

#.Bigh rate and speed of s"pply.

.9"nding can be done to get fair grade.

5.More efficiency and low cost.

3i it ti


120/343

3imitations-

9elt conveyor8

1.Cannot be "sed for long distances

.4e


121/343

1.6he average tonnage ,t/h( pea- rate ,t/min and fre


122/343

6ensioning of the belt is necessary to prevent e)cessive sagging of

the belt or belt in good contact with the driving dr"m.

1.%"tomatic ta-e "ps

.Gravity ta-e "ps.

#.6a-e "p p"lley with co"nter weight.

.Co"nter weighted loop ta-e.5.Co"nterweighted wheel mo"nted tail end p"lley

'.Power ta-e "ps

.Electric motoried winch and load cell loop ta-e "p.

!.Pne"matically operated ta-e "p

&.Bydra"lically loop ta-es "p.

10.4igid or man"al ta-e "ps

11.Screw ta-e "p

1.Hac- ta-e "p

1#.Winch ta-e "p


123/343

Automatic gravity ta!e"up arrangement


124/343

Arrangement of a drive motor( loop ta!e"up and

tensioning )eights on a +elt conveyor discharging

do)nhill


125/343

Arrangement of a driving gear and loop ta!e" up for

a +elt conveyor on level or uphill

9elt conveyor Trou+leshooting

Trou+le auses orrections


126/343

1. Conve

yor

belt

r"ns to

one

side at

a

partic"

lar

pointon the

convey

or

;ne or more idlers inbye of the

tro"ble not at right angles tolongit"dinal centre line of belt.

%dvance the end of idler to which

belt has shifted in the direction of belt travel

Conveyor frame not lined "p

properly or idler boards not

centred on belt.

Stretch line along edge to determine

how m"ch o"t of line and correct

Stic-ing idlers 4eplace or free idlers

Str"ct"re not level and belt

tends to float to low side:evel str"ct"re

9"ild "p of materials on idlers.$mprove maintenance. $nstall belt

and p"lley scrapers

. ;ne section of

belting r"ns off to

Hoint not s


127/343

belting r"ns off to

one side all along

the conveyor

Croo-ed belt

ca"sed by bad

storage

after being r"n in( if not try and re=c"t 7oint

to co"nteract otherwise replace with new

length.

#. Conveyor belt r"ns

to one side of

str"ct"re alongconveyor line

$mproper loading

of belt

Mostly receiving hoppers or ch"te to load

material centrally

. Conveyor belt has

erratic actionfollowing no

partic"lar position.

9elt too stiff

May be d"e to newness. $f it so( allow time

to settle down. $t will shorten the time( if

belt is left loaded not in "se. 6ilt tro"ghingidlers forward a ma)im"m of #0.+se self=

aligning idlers. +se more fle)ible belt or

less steep tro"ghing idlers.

Bead p"lley o"t of

alignment

Chec- alignment of p"lley

and ad7"st if necessary


128/343

5. 9elt r"nning off at head

p"lley

alignment and ad7"st if necessary

6ro"ghing idlers

approaching head p"lley

o"t of alignment.

Chec- alignment of

tro"ghing idlers and ad7"st

if necessary

'. 9elt r"nning off at tail

p"lley

9"ild "p of materials on

ret"rn idlers

Clean idlers and provide

more maintenance and

better belt cleaners.

4et"rn idlers o"t of

alignment

Chec- and ad7"st as

necessary.

+ne


129/343

. E)cessive wear

on bac- cover

of belt

Slippage between belt and

drive p"lley

device.

$ncrease angle of wrap of the belt on

the drive p"lley with sn"b p"lley.:ag drive p"lley or renew worn=o"t

lagging.

Stitching or seied

tro"ghing idlers

4eplace or free

Material spillage between

p"lley and belt.

$nstall scrapers in front of tail p"lley

on ret"rn belt or sn"b and bend

p"lley

E)cessive pitch of

tro"ghing idlers

6oo large a pitch ca"ses belt tro"gh

to flatten and belt slip between belt

and wing idlers rolls rema-ing

tro"gh. 4ed"ce pitch of idlers.

$nstall belt cleaners( sn"b


130/343

!. E)cessive wear on top cover

of belt

Firty( froen or misaligned

ret"rn idlers.

p"lley scrapers and plo"gh at

tail end p"lley. Clean( ad7"st

and replace where necessary.

E)cessive sag between

tro"ghing idlers ca"sing

load to 7og as it passes over

idlers.

$ncrease belt tension if too

little. 4ed"ce idler pitch.

%brasive S-irt board+se soft r"bber s-irt material(

never "se old belting.

Poor loading

Engineer loading ch"te to load

material centrally( in the same

direction and as near belt

speed as possible.

4ed"ce friction by cleaning "p conveyor(

l t - t idl


131/343

&. E)cessiv

e stretchin belt

6oo m"ch tension d"e to

improper maintenance of

tro"ghing and ret"rn idlers

replace st"c- or worn o"t idlers.

Provide better maintenance. 4ed"ce belt

tension by lagging drive p"lley or

increasing angle of wrap of belt on drive

p"lley. $ncrease belt speed -eeping

tonnage same.

4ed"ce tonnage -eeping the same beltspeed.

Slac-en tensioning device "ntil the

tension is 7"st eno"gh to -eep belt from

slipping.

9elt too tight for the horse

power to be transmitted

4eplace with proper belt of lower

elongation or higher strength.

$mpact of large

l"mps felling on+se impact idlers. Engineer the loading ch"te so

the impact hits the bac- plate :oad in line with the


132/343

10. Short

brea-s in

the cercass

of the belt

belt at loading

station

the impact hits the bac- plate. :oad in line with the

belt at a speed e


133/343

11. Aasteners p"ll o"tof belt

6ension too high

Provide better maintenance. 4ed"ce belt tension

by lagging drive p"lley or increasing angle ofwrap of belt on drive p"lley. $ncrease belt speed

-eeping tonnage same.

4ed"ce tonnage -eeping the same belt speed.

Slac-en tensioning device "ntil the tension is

7"st eno"gh to -eep belt from slipping.

Mildew +se mildew inhibited belt.

Wrong type of

fasteners andimproper 7ointing

4eplace belt 7oint with correct fasteners.

$mproper starting

,Firect=on=line=

starting

+se fl"id co"pling on tor


134/343

1. E)cessive noise or

s


135/343

Presented by

Devidas S. Nimaje




Presented by


Assistant Professor

$t is mostly "sed in the longwall face.

6he capacity of a commonly "sed scraper chain conveyor is #0


136/343

to 0 tph on a level roadway( nearly 50 m long and the drive

motor is of 1= 15 KW.

6he main application of scraper chain conveyors in

"ndergro"nd is transportation at the face and ad7oining short

wor-ings( where they are ready to withstand mining condition.

6hey are also "sed to ha"l the coal along gate roads over short

distances before it is feed to gate belt conveyor.

6hey are also "sed for transporting on inclines having an angleof inclination e)ceeding 1!0 where belt conveyors are not "sed.

6hey are also "sed on the s"rface for conveying coal from shaft

to b"n-er as well as in screening and washing plants.


137/343

Scraper chain conveyor

Different parts-

0.Trough-


138/343

g

6hese are stationary things "s"ally m long( and consisting ofdetachable section bolted together or 7oined by hoo-s(

1.6lights-

%n endless chain with flights moving in the tro"ghs( which are

nearly 50 mm wide at top and #00 mm at bottom.

2.hain *endless,-

6he chain of endless character is installed there. 6he chain consists

of lin-s and after #= lin-s a flight is provided so( that the flights

are =.5m apart.

< Tensioning head-


139/343


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4n the +asis of fle/i+ility

1.4igid chain conveyor

.Ale)ible / %rmo"red chain conveyor

4n the +asis of num+er of chains usedC

1.Single chain conveyor

.Fo"ble centered chain conveyor

#.Fo"ble o"tboard chain conveyor

.6riple chain conveyor

igid chain conveyor-

1.% rigid chain conveyor essentially consists of stationary steel

h h ll l d h d d d


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tro"ghs( each "s"ally m long( connected together end to end( and

an endless chain with flights moving in the tro"ghs.

.6ro"ghs s"pported on angle iron frame wor-( slightly dished at

one end. So( that the ne)t one fi)ed in to form a fl"sh point.

#.%d7acent tro"ghs are sec"red together and to the frame "nderway by both.

.6his gives rigidity to conveyor.

5.6he ret"rn end is provided with a tensioning arrangement.

'.6he capacity is #0= 0 tph on a level roadway( nearly 50m long

and 15KW motor.

Armoured chain conveyor-

1 + d ll l ll f it b d d ith t


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1.+sed generally on long wall faces( it can be advanced witho"t

dismantling( with hydra"lic rams.

.6hey can wor- with lateral or( vertical "nd"lations( and coal

c"tting machine and shearers can be mo"nted on them.

#.Motor power varies between #0 to 1!5 KW.

.Pan width at top varies from 50 to !50 mm and pan length from

1.# to 1.! m. the vertical fle)ibility of pans is #=0 and horiontal

fle)ibility is =#

0.

5. :imiting gradient with flights 1 in 1.5 and witho"t flights 1 in #.

'. :ength may be "pto #'0 m and capacity is "pto 100 tph.

Advantages-


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1.Can convey "phill against relatively steep ,1 in # or more

gradient as well as of downhill gradient.

.M"ch stronger and can be ro"ghly handled.

#.Ale)ible so( as to dismantle( e)tended or shortened.

Disadvantages-

1.Bigh initial cost.

.Bigh power cons"mption

#.Wear and tear more.Bighly noisy

5.Prod"cing high percentage of fine d"st

SCRAPER HAULAGESCRAPER HAULAGE


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Presented by

Devidas S. Nimaje




Presented by


Assistant Professor

Scraper ha"lage is the simplest method of transportation of

bro-en materials where a scraper b"c-et digs into materials and


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bro-en materials where a scraper b"c-et digs into materials and

transports it by dragging it over nat"ral or specially=prepared

floor.

Types-

Scraper ha"lage is classified as8

1.6wo dr"m hoist

.6hree dr"m hoistaWitho"t obstacle

bWith obstacle

0. T)o drum Scraper hoist-


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6here may be different arrangements of scraper ha"lage

depending on wor-ing conditions and type of scraper hoist"sed.

6he arrangement is generally "sed where load has to be

transported along a straight line.

6he main rope is attached to the front end of the scraper

b"c-et( while the tail rope passes ro"nd a tail bloc- sheave

sec"red at the face and is fastened to the rear end of the b"c-et.


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Arrangements of t)o drum Scraper haulage

T)o drum Scraper hoist

onstruction-


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$t consists of an electric or compressed=air motor 1( main and

tail dr"ms ! and &( gears( and two operating handles for

controlling the band bra-es 1 and 1#.

6he motor drives the main shaft thro"gh gears 1= and #=.

6he main shaft carries two s"n wheels 5 which rotate the planet

wheels ' mo"nted freely ,on ball bearings on the shafts 10 and 11

which are rigidly connected to the dr"ms.

6he planet wheels in t"rn rotate the wheels ,mo"nted on ball

bearings by meshing with its inner teeth( when the bra-es are off.

;n applying the bra-e( the rotation of wheel is prevented( as a

res"lt of which the planet wheel revolves ro"nd the s"n wheel th"s


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res"lt of which the planet wheel revolves ro"nd the s"n wheel th"s

setting the dr"m in motion.

6he dr"ms are th"s driven by gears of force of friction between

the bands of the bra-es and the o"ter s"rface of wheels .

6his prevents overloading of the motor as well as brea-age ofropes and damage to other parts when the scraper b"c-et

enco"nters obstacles d"e to the bands slipping on the wheel .

6wo=dr"m scraper hoists with s"n=and=planet gearing are


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6wo dr"m scraper hoists with s"n and planet gearing are

simple and reliable.

9"t they have the disadvantage that the tail blac- has to be

shifted along face for proper cleaning if the latter is wide

,otherwise hand=shoveling becomes necessary.

6he more complicated three=dr"m scraper hoists do not s"ffer

from this disadvantage.

6hey have similar constr"ction and are fitted with three band

bra-es and conse


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$n this case three ropes ,two tail and one main are attached to

the b"c-et and two tail bloc-s are installed one at each end of the

face so that the scraper b"c-et may be ha"led bac- to any point

along the face by s"itable manip"lation of the tail ropes.

6he main rope only hails the loaded b"c-et.

%ny modification of this method may be "sed where the scraper

b"c-et has to be manip"lated aro"nd obstacles ,for e)ample(

aro"nd the pillar.

$n this case( two main and one tail ropes are "sed.

;ne of the main ropes is g"ided by a g"ide bloc- while the


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;ne of the main ropes is g"ided by a g"ide bloc- while the

other is g"ided aro"nd the obstacle by a g"ide roller.

6he loaded b"c-et is first ha"led by the rope passing ro"nd

one g"ide bloc- sheave to a point clearing one obstacle and

ones ha"led by one( second main rope to one "nloading

point after emptying.

6he b"c-et is ha"led bac- with the aid of the first main rope

and the tail rope.

% similar arrangement may be adopted where the load has

to be transported along two roadways meeting at an angle.


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Method of Scrapping )ith three drum hoist :

a, )ithout o+stacle +, )ith o+stacle

Types of Scraper +uc!ets

9uc!ets


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ario"s types of scraper b"c-ets are "sed in practice( depending

on wor-ing conditions and properties of materials to be handled. 6

he bo)=type b"c-ets are s"itable for relatively light and well=

fragmented materials. 6hey have a slanting bac- for easy digging

into the interior and vertical sides for co"nting the materials d"ring

its transport.

Aor hard=digging and large=sie materials( hoe=type b"c-ets are

"sed. 6hese dispense with side walls and are often fitted with

detachable manganese=steel digging teeth.

6he main factors governing the performance of a scraper b"c-et


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6he main factors governing the performance of a scraper b"c-et

are its weight G and the angle of digging , the angle between the

slanting bac- or teeth and the horiontal.

6he tare weight of a b"c-et is "s"ally e


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0.5 m deep hole.

$t sho"ld be light in weight for easy removal and refi)ing at face.

6he bloc- sheave is "s"ally 00 to #50 mm in diameter.

opes

6he ropes for scraper ha"lage sho"ld be fle)ible and resistant to

abrasion.

6he parallel=lay rope of Seale=strand constr"ction( in which an

inner layer of thinner wires is covered with thic-er o"ter wires( is

most s"itable for scraper ha"lage.

WINDINGWINDING


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Presented by

Devidas S. Nimaje




Presented by


Assistant Professor

Winding system are classified into two gro"ps based on

the device employed to hoist the cage or s-ip to the

f


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s"rface8

1.Fr"m winding

.Koepe winding ,Ariction winding

i.Gro"nd mo"nted -oepe system

ii.6ower mo"nted -oepe system

$n the dr"m winding system( cylindrical dr"m with tail rope or

bi=cylindro=conical dr"m are commonly "sed in most of the mines beca"se it gives balanced system and red"ced the pea- power

demand and negative tor


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friction between the winding rope and the lining of the sheaves.

$n gro"nd mo"nted -oepe system( the winding engine is installed

at the gro"nd level and the headgear sheaves are sit"ated one above

the other or side=by=side on the headgear. 6he rope operates in the

plane of -oepe driving wheel witho"t any angle of fleet.

$n tower mo"nted -oepe system( the winding engine is installed

on the headgear. $t also re


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To)er mounted !oepe )inder

Selection of 8inding system-


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$t is based on the following factors8

0.Depth- Aor deeper shaft( -oepe winding system is s"itable as

compare to dr"m winding system which is s"itable for shallow

shaft.

1.Dec!ing system8Aor m"ltidec- winding system( the dr"m

winding is s"itable.

2.Space- Aor less space( -oepe winding is s"itable and for largerspace( dr"m winding is more s"itable.

< Multilevel- Winding from different levels dr"m winding is


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7eadgear and Pulley-

6he head gear is a steel or concrete framewor- on the shaft mo"th.

$ts p"rpose is8

1.6o s"pport the head gear p"lleys( the weight of the hoisting rope(

cages and rope g"ides.

.6o g"ide the cage to the ban-ing level.

$t sho"ld withstand dead and live loads and wind press"re.

6he dead loads on the headgear are reasonably constant and

calc"lable b"t the live load d"e to winding is a variable one


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calc"lable b"t the live load d"e to winding is a variable one

depending on the length of ropes in the shaft( the contents of

the cages and the rate of acceleration and deceleration.

Bead gear is "sed for tower mo"nted -oepe winders are

designed to carry in addition the load of motors( winding

p"lley and other e


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g y g

to two inclined bac- legs ,towards the winding engine room.

6he top of the headgear has a steel platform or plate and the

b"sh bearings of the winding p"lleys rest on the vertical

members of the headgear frame.

$t is "s"al to design the "pright members of the headgear frame

to carry the dead weights and the wind press"re( leaving the

bac- legs to the ta-e care of the res"ltant of the live loads d"e

to the ropes and cages.

6he height of headgear is decided b considerations of n mber


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6he height of headgear is decided by considerations of n"mber

of dec-s on a cage( ban-ing level or s-ip discharging point( pittop layo"t and depth of the shaft.

6he headgear p"lley sho"ld be at s"ch a height above the

detaching plate that the rope capel is released before it comes in

contact with head gear p"lley. 6he distance is abo"t #m.

6he design of the headgear depends "pon dead and live loads(

the depth of the shaft( the


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7eadgear- measurements in meters

6he head gear p"lley sho"ld have as large a diameter as

possible to minimie bending stresses in the winding rope.

$ts diameter sho"ld be at least 100 times the rope diameter.


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$ts diameter sho"ld be at least 100 times the rope diameter.

P"lleys of over .5 m diameter are generally constr"cted in two

halves and bolted together.

3ormally the diameter of the groove of the headgear p"lley

sho"ld be 110* of the rope diameter for stranded ropes and105* for loc-ed coil ropes.

6his ens"res that 1/#rd of the circ"mference of the rope are in

contact with the groove.

% lesser angle of contact ca"ses e)cessive strain on the rope

and wear on the p"lley.

6he headgear p"lley is -eyed to a mild steel forged shaft( whichrests in plain b"shed 7o"rnal bearings.

6he angle of fleet which is the angle between the vertical plane


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6he angle of fleet( which is the angle between the vertical plane

of the p"lley and the rope( when the cage is at the pit top or pit bottom( sho"ld not e)ceed 1.50. More fleet angle res"lts in wear

of the rope and wear of the p"lley.

6he shafts of the two head gear p"lleys which are placed side

by side are in a horiontal line and their planes of rotation are

vertical and parallel.

$n the case of -oepe winders( gro"nd mo"nted the planes of

rotation of the two headgears p"lleys are one below another.

$f a dr"m winder is "sed for a deep shaft( it may be necessary to

consider do"ble layer coiling of rope in order to accommodate

all the rope on the dr"m and -eep the fleet angle limited to 1 50


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6leet angle

Arrangement of driving sheave and pulleys in !oepe

)inding 3eft- to)er mounted right- ground mounted

age attachment to 8inding ope


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% typical arrangement of attaching cage to winding consists offo"r cage chains in the case of a single cage ,and ' chains in the

case of a tandem cage attach the cage to a triang"lar distrib"tion

plate which is connected to a safety detaching hoo- thro"gh F=

lin-s. 6he detaching hoo- is attached to rope capel.

+nder mining reg"lations all the chains are to be chec-ed in

every ' months and the detaching hoo- is made of 1.5*

manganese steel.


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ope attachment to cage

ages and S!ips

6he cage is a lift s"spended from the winding rope( open at both


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ends where gates can be positioned d"ring man riding and it has

rails fitted to the floor for mine cars or t"bs.

6o prevent the mine cars/ t"bs from falling o"tside the cages(

catches are provided on the floor which act against the a)les of the

mine car / t"bs? in addition( a long bar( t"rned at both ends andhinged at one side of the cage( prevents movement of the t"bs

d"ring travel "p or down the shaft.

Cages "sed for man riding have a hand bar near the roof for the

men to hold and at both ends collapsible gates are provided which

can be closed or opened man"ally or by compressed air.

6he roof has a hinged or removable door for accommodating long

timber or rails whenever necessary.


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% cage which can accommodate only a single t"b is a single cage

and one with two t"bs is called tandem cage.

Cages with more dec-s are "sed in mechanied mines dealing

with large o"tp"t.

6he cage travels in the vertical plane.

Advantages of cage-


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1.6hey are made to travel in vertical plane..Winding coal and mineral from different levels is easy.

#.6hese are best "sed in shallow mines.

.% high head gear is not re


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A single dec! cage and s!ip A s!ip for automatic

tipping in an inclined

shaft at Mosa+ani

S-ip can be filled with minerals thro"gh its top opening s-ipstraveling in a vertical plane have a discharge opening at the

bottom for "nloading the mineral content b"t s-ips traveling a

il l i li d h l l il d d i l


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rail along an inclined ha"lage plane are so tilted( d"ring travel(

near the "nloading end that their contents are discharged fromthe top end.

S-ips moving in a vertical plane are sometimes partitioned for

accommodating men at the "pper half and material/ mineral atthe lower half.

S-ips are provided with cast steel g"ides shoes having

malleable cast iron br"sher( "s"ally fo"r shoes per cage or s-ip.

6he s-ip carries a large payload( "s"ally ! ton or more(

compared to the cage and the ratio payload/ gross weight of

s-ip ,loaded is high for s-ip

Advantages of s!ip-

1.S-ip winding is best s"itable for deeper shafts where high o"tp"t is

desirable


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desirable.

.6he ratio of payload/gross load of loaded s-ip is high nearly 0.'.#.S-ip lends itself to a"tomatic loading( "nloading and dec-ing

operations( and thereby providing


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p pp g y

s"pport to the cage b"t their "se res"lts in proper alignment of the

cage floor and dec-ing level so that the stretch of the winding rope

creates no diffic"lty d"ring dec-ing.

Keps are "sed at the pit top "nder o"r mining reg"lation.

6heir "se is not necessary at the pit bottom as the cages rests on

rigid platform at steel girders and wooden plan-s.

Keps are not re


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p y p y y p p

the -eps are pne"matically operated they are interloc-ed with otherdec-ing e


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6hey are man"ally operated by the ban-sman at the pit top.

6he ascending cage p"shes the -eps bac- and as it is raised

slightly higher than the dec-ing level( the -eps fall bac- in position

by gravity after releasing opening lever.

6he cage( after it has come to a halt( is lowered by the winding

engineman to rest on the -eps.

When the top cage is to start on its downward 7o"rney( the

winding engineman raises the cage only slightly to ma-e it clear of

the -eps? the ban-sman withdraws the latter by man"al operation of

a lever which is held by him till the cage is lowered past the -eps.

Disadvantages of igid !eps-


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g g p

1.%cc"m"lation of slac- rope on the pit bottom cage when the top

cage is raises a little for withdrawal of -eps. %scent of the pit

bottom cage is generally associated with shoc- load on the winding

rope and the stress amo"nts to 00* of the static load.

.:oss of time and power in lifting the top cage before its download

travel.

Davies improved !eps gear-

6he gear consists essentially of the shafts S to which is -eyed


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g y y

the hand lever and a pair of arms % with a steel roller 4 mo"nted

on a pin between the arms.

6he roller presses against a renewable roller path on a swing

lever : which is pivoted at P and carries a QpalletO mo"nted on a

steel pin at its other end.

6he pallet is free to move "pward and aro"nd the pin( and

allows "pward passage of the cage( b"t it is prevented from

moving downwards by a pro7ection on the lever :.

6he cage is th"s sec"rely s"pported on the "pper s"rface of the

pallet


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pallet.

6he gear may be withdrawn( however witho"t first raising the

cage.

$t will be seen that when the hand lever is moved to the left( theroller 4 moves "pward along the roller path on the lever :( th"s

allowing the lever to rotate downwards by gravity aro"nd the pin

P "ntil the pallet is clear of the cage.


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Davies improved !eps gear

igid !eps

Detaching 7oo!

Fetaching hoo- which is 7"st placed below the rope capel( is a


187/343

safety device which acts when an overwind ta-es place.

$ts p"rpose is to s"spend the cage/ s-ip in the headgear if an

overwind occ"rs and at the same time to release the rope to go over

the head gear p"lley.

Types of hoo!s-

1. ;rmerod detaching safety hoo-.

.King detaching safety hoo-.

ing detaching safety hoo!-

$t is generally "sed in most of the winding system.


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$t consists of fo"r wro"ght iron plates i.e.( two being moveable

inner plates and two fi)ed o"ter .

6he two inner plates are placed together in opposite ways so that

the hoo- of one plate and that of the other 7ointly form a sec"re

hole for the reception of the rope capel bolt.

% main bolt or centre pin passes thro"gh the holes and in all fo"r

plates and serves

1. 6o bind the plates together

. 6o transmit the tension of the winding rope from the hoo-s of the

inner plates to the shac-le both of the main F= lin- and

#. 6o provide a pivot on which the two inner plates can move.

6he hoo-s are so c"rved that p"ll of the winding rope has notendency to open o"t the inner plates.

% copper pin is placed thro"gh the holes c in all fo"r plates and

i d i d f h i l


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riveted over to prevent inadvertent movement of the inner plates

when they are not "nder tension.

F"ring an overwind as the ascending cage goes "p the hoo- is partially drawn thro"gh the circ"lar hole in catch plate( sec"rely

attached to a horiontal member of the headgear and the lowerwing d of each plate ,inner is forced inwards.

6he copper pin is th"s sheared and hoo-s in are forcibly separated(

so releasing the F=lin- of winding rope capel.

Sim"ltaneo"sly the catches g on the inner plates are forced

o"twards so that rest on the "pper side of the catch plate and the

cage in thereby safety held.

When the weight of the cage is ta-en by the catches g( the inward


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mining machinery nit rourkela

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