PARTS AND MAINTENANCE OF TIPPLER

The place where the wagon is placed , to be tippled , is called table . On to the table the rail is fixed with clamps , it is a detached portion from the ground rail. There is a safe gap of 10 to 12 mm maintained between the table and ground rail , so that when the platform rises for tippling it doesn't collides with the rail on the ground. 


How do one know's the position of wagon on table ?

For positioning of wagon there lies a curved convex portion on rail , on the table , for the wheels of wagon to exactly sit without movement during tippling process. When the wagon is tippled at an angle of 80°  , there lies a structure called ARMS , with rubber pads attached to them. 



The Arms hold the wagon from free fall in to the hopper . The tippler tipples the wagon till an angle of 135° ,in this position the wagon is completly rested on the arms. They are just free moment equipment , they are not rotated by any external means , the arms are connected to a rigid structure with a pin in a journal . As we see the construction of a wagon , the wagon body is mounted on a spring on an axle with wheels attached . so when the wagon is lifted the axle is automatically rotated , so when tippling , at an angle of 135° there is a chance of the axle to get rotated and it doesn't position itself on the table , when the process is completed. To avoid that , a plate of 16mm X 2000mm is welded to support the wheels of the wagon , at exactly the position where the wagon placement takes place.

How tippling takes place ?

So a machine to run , it needed some form of energy , here an Electric motor of power 130 Kw drives the unit with 440 volts. It is coupled to a reducer of ratio 1:30 . The coupling is a drum coupling , where a thruster brake with 8000 Nm spring force for braking the torque is used . The reducer output is coupled with gear coupling to an intermediate shaft with two pinions on each side of the tippler . The tippler consists of a rack assembly bolted to its body with M30 bolts.


The tippler stucture is supported by rollers which are mounted on to the foundation 


So when the motor rotates the electrical energy is converted to mechanical energy with the power transmission line aka coupling,reducer , shaft. So when the shaft rotates the pinion rotates as it is  shrink fitted on the shaft , which in turn rotates the tippler as it is meshing with the rack.

Operational Safety

From the wagon placement to tippling  and again after completion of tippling , the placement of table position to ground level , is an operating cycle. If in case of emergency an operator choses to stop the tippling process at any angle from ground , he operates the stop push button , so the comand via PLC goes to thruster brake and the brake is applied , which avoids the free fall or movement of tippler. All electrical sensors and mechanical limits are placed for safe and smooth operation. Electrical interlocks and software limits are provided and monitored constatantly to avoid failures.

Maintenance of system

After the operation is completed, that is after a rake is handled, Luberication is done at pivotal points  . Pivotal points are the upper structure of of tippler rotating ,plummer blocks ,intermidiate shaft with gear couplings.EP3 at points where wear and tear is more i.e where journal is present and thick film is required.EP2 at plummer blocks where bearings are present.
Compound is applied to rack and pinion for every possible intervals. The intermidiate shaft gear coupling bolts needed to be checked after every rake completion. when the wagon is being tippled it rests on the wall of tippler, where rubber pads were used, need to check regularly and change if damaged, otherwise the main structure would get indentation and damage . Weekly the rollers underneath the table needed to be checked, if damaged needed to be changed. All the bolt and nut assemblies along the tippler need to check for tightness. All the bearings had to be checked physically, any sign of damage , need to escalate and changed. For positioning of ballast tank (It is the counterweight for the wagon when tippling ) there are pendulum's on both sides with a locking wedge , which needed to be inspected for any damages and wear out.

Comments

Post a Comment

Popular posts from this blog

GRAB SHIP UNLOADER - GSU

Image
GSU- Grab Ship Unloader , of all the different equipment's i worked till now , this is my favorite one . Because this is a combination of many equipment's and there is a lot of scope for learning in this equipment. Everyday is a new day and some or the other thing always used to surprise me. Have to say hatsoff to the team that developed or invented this type of machinery. I  had worked in  GSU's of two makes , one is ZPMC and the other is TRF . ZPMC is of Chinese make and TRF is Indian i.e TATA's product , but have to admit that the Chinese equipment i.e ZPMC GSU is top notch , maintenance friendly and operation effective. There wont be any difficult in maintenance even if there is no previous maintenance history . ZPMC Grab Ship Unloader GSU is a machinery which runs on electric power. The bottom portion of the machinery is called gantry and the entire crane that is the structure rests on the four legs , each leg consists of six bogies and each bogie consists of one d
Read more

DIFFERENT TYPES OF FEEDER'S

Image
 There are different types of material conveying systems , in which i will be talking mostly on belt conveyor systems which is my area of expertise. As discussed earlier the cargo is unloaded from different types of machinery namely wagon tippler , Grab ship Unloader , Harbor mobile crane etc . These equipment unloades the different types of cargo with respect to handling methods and the machinery designed to handle the type of cargo with respect to load capabilities. The first step in unloading and storing process is that the unloaders unloades the cargo in to the hopper , this was discussed earlier. From the hopper how will the cargo flow happens? There comes this equipment called feeder . As the term defines itself , the feeder feeds the cargo to the conveyor. The feeder can be a variable speed one or the fixed speed one with respect to the requirement of the feeding and the design of the plant. The various types of feeder can be 1)     Apron feeder 2)     Feeder belt 3)    
Read more

Little say about ports

There are different equipment or machinery in ports used for various purposes . So before jumping of to equipment's, lets first know what happens inside a port. First,what's a port?. If you google it you would find lots of explanations and definitions starting with history, Let's simplify it. Its a place where business happens through imports and exports , OK wait ! , import and export doesn't mean , the business is strictly from or to other countries , it can also happen from one part of the country to other part of the same coast line , we have to understand only one thing , THE MEANS is sea i.e sea transport. Next question that pop's up in our mind is , What does one import or export ? .Ok lets also simplify this . The imports and exports can be RAW MATERIALS like iron ore , coal , bauxite , limestone etc . there are many more , these are just examples . OUR MANUFACTURED PRODUCTS be it any thing from wind mill fans , cars to safety fins  (Later we will
Read more