Feeder breakerppt

1. Feeder Breaker ( jhanjra ) Submitted By: Harshit Mishra Abhik Chatterjee

2. Introduction The belt feeder breaker is a single piece machine which is installed before the belt conveyor to receive the material and size it before being carried to another location for operation. The Stamler Belt Feeder is a mobile conveyor system, which incorporates a pick up breaker to reduce the size of the material being conveyed through the machine.

3. Design The design of the feeder breaker is such that the material is placed onto the conveyor at the intake end of the machine, which has been built with a hopper that is adequately sized to receive the incoming material. The pick breaker breaks the material by striking the material with sharp pointed picks. Once the material is reduced to the required size, the material is moved through the machine and is discharged on to a belt conveyor at the discharge end.

4. Parts of Feeder Breaker Drag conveyor Pick breaker Hydraulic crawler drives Electric system Hydraulic system Programmable sensor controller

5. Drag Conveyor The conveyor consists of two strands of engineering chain with flights attached at regular intervals, to move the material. The chain ad flights are wrapped around and engage the sprocket attached to the head shaft located at the discharge end. The head shaft is mounted at the discharge end and driven by a hydraulic motor and chain arrangement. A relief valve is provided in the hydraulic system to protect the conveyor in the event of stall.

6. The tail shaft is mounted at the intake end as an idler to maintain the correct tension of the conveyor chains. The conveyor deck is lined with abrasion resistant plate to resist wear.

7. Pick Breaker The breaker is constructed of a solid steel shaft that has several steel rings welded to it. Pick holders are welded to the rings and replaceable picks are inserted into the holders. The breaker is suspended at each end by large roller bearings mounted in housings.

8. The breaker rotates with the material flow allowing the picks to strike the material as it flows towards the discharge end of the machine. Breaker shaft is driven by chain and sprocket arrangement that is connected to a gearbox. A shear pin is positioned at the breaker drive to provide protection in case of stall .

9. Hydraulic Crawler Drives Crawler drives operate independently. The hydraulic valves control valves, mounted on the side of the machines control the speed and direction of motion of the crawlers. Hydraulic cylinders are used to level the machine.

10. Electric System The electrical system is designed and built to operate on AC supply, from the trailing cables connected to the power supply. The supply of 3.3 KV AC supply is received from the Air Circuit Breaker (ACB) and stepped down to 1.1 KV. The electrical system is used to control the following- Breaker Drive Conveyor Drive Hydraulics

11. Safety Devices eg : horns, lights etc Sensing Devices (breaker speed, oil level, oil temperature, voltage, etc.) Heating/Cooling

12. Hydraulic System The hydraulic system consists of a piston motor, oil tank, several cylinders , pressure gauges and other auxiliary parts. The hydraulic system is used to control the following : Conveyor Drive Crawler Drives Levelling Cylinders Auxiliary Functions (PTO, winches, cylinders, etc.)

13. Hydraulic Motor (piston type) Hydraulic Cylinder-piston assembly

14. The hydraulic system is designed with maintenance features to provide safe and reliable operation of the feeder breaker Component test fittings Oil level indicator Hand pump (reservoir fill) Hydraulic pressure gauges are fitted for the visual monitoring Pump operating pressures Conveyor drives system pressures Tram and levelling pressures

15. Programmable Sensor Controller The controller monitors signals received from the sensors and processes, and then uses the information to ensure the feeder breaker is working within its normal operating requirements. If the controller unit’s programming becomes lost or corrupted in such a way, by operator error, damage, malfunction, etc. the unit will no longer allow the feeder breaker to operate and the controller must be re-programmed.

16. The controller must be programmed in accordance to the machinery it is to be used with. In the feeder breaker, it is configured for 8 channels Water flow Water pressure Oil temperature Oil level Sequence/water Sequence/Time out Stop Breaker Run

17. Technical Specification of F.B. used in JHANJRA Conveyor Hydraulic Motor Headshaft rpm : 43.65 Sprocket Ratio : 15T & 30T Conveyor RPM : 101.84 Relief Valve Setting : 2000

18. Electrical Motor(Induction Motor) Serial no:050596 Power(KW):112 RPM:1175 Potential Difference(K.V.):111 Current(Amp.):71 Ambient Temperature(˚C):40˚ Weight(kg):1000 Phase:3 Frequency(Hz):50 Lubricant: ALBIDA RL2 Temperature Rise(K):80

19. Additional Data Heat exchanger type : water/oil & air/oil Breaker reducer ratio : 10:1 Breaker diameter : 28.00 Breaker sprocket ratio : 12T & 46T Mounting : tracks Track width : 120.75 Maximum tram width : 132.26 Hopper width : 120.00 Machine height : 45 Conveyor width : 50.00

20. Hopper Slope : 35 Dust suppression : water spraying system 110KW, 1.1KV AC FLP electrics 2 speed conveyor Speed reducer emulsion 60:40 oil/water

21. Maintenance Head shaft assembly installation – The feeder breaker is installed with a head shaft assembly which is used to transfer power from the conveyor to the conveyor chain and flight. While the head shaft is disassembled it is a good time to visually and mechanically inspect all of the components, for excessive wear, cracks and other mechanical malfunctions.

22. Tail shaft assembly installation – The same maintenance schedule is developed as that of head shaft assembly installation. Breaker shaft assembly installation If in the breaker shaft assembly, one of the component be damaged, then the whole set of the assembly is to be repaired, monitored, or replaced if need be.

23. Breaker pick holder installation – The breaker is designed to use replaceable pick mounted in a holder that is welded to the rings on the breaker shaft. Worn out picks need to be replaced immediately as worn out picks cause sparking when striking material and causes reduction in production.

24. Shear pin replacement – The breaker has a shear hub keyed to the driven end of the shaft. Mounted on the hub and free to turn is the drive shear sprocket. Shear pin is installed connecting the hub and the sprocket the breaker can now operate the pick breaker. With this design should the breaker picks strike something and stall causing the breaker drive to overload, the shear pin will break causing the drive to be disconnected from the shaft. A lubricated surface exists between the shear hub and the sprocket that must be lubricated each time the shear pin is replaced.

25. Conveyor chain wear – Most of the wear causes between the inside of the bushing and the chain pin, this wear causes elongation in the chain. The chain manufacturer has established that when the elongation reaches 3%, the chain is considered to be worn out and it needs to be replaced. The wear percentage is found out by [(X-4.75)/7]*100 where X = distance between one bushing to the next on the outside edge.

26. Cone Drive(Reducer) Cone drive is a assembly of standard worm gear speed reducers and gear sets. It consists of 2 output ends in which the speed reduction ranges from 10:1 up to 70:1 is obtained. Also both of the output ends are perpendicular to each other. Range of operation is 2000-3600 R.P.M. The contact of the gear teeth and the one thread of the reducer is normally through a contact paste or grease.

27. In cone drive there are shims inserted between the bearing cap and housing of bore face to properly position the worm and gear within the gear housing and to set desired bearing end play. Shims also serve as gaskets for the bearing caps and carriers.

28. THANK YOU