Feeder Breaker(jhanjra)

Submitted By:Harshit Mishra

Abhik Chatterjee

IntroductionThe 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.

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.

Parts of Feeder BreakerDrag conveyorPick breakerHydraulic crawler drivesElectric systemHydraulic systemProgrammable sensor controller

Drag ConveyorThe 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.

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.

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.

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.

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.

Electric SystemThe 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 DriveConveyor DriveHydraulics

Safety Devices eg: horns, lights etcSensing Devices (breaker speed, oil level,

oil temperature, voltage, etc.)Heating/Cooling

Hydraulic SystemThe 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 DriveCrawler DrivesLevelling CylindersAuxiliary Functions (PTO, winches, cylinders,

etc.)

Hydraulic Motor

(piston type)

Hydraulic Cylinder-piston assembly

The hydraulic system is designed with maintenance features to provide safe and reliable operation of the feeder breaker Component test fittings

Oil level indicatorHand pump (reservoir fill)

Hydraulic pressure gauges are fitted for the visual monitoringPump operating pressuresConveyor drives system pressuresTram and levelling pressures

Programmable Sensor ControllerThe 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.

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 flowWater pressureOil temperatureOil levelSequence/waterSequence/Time outStopBreaker Run

Technical Specification of F.B. used in JHANJRA

Conveyor Hydraulic MotorHeadshaft rpm : 43.65Sprocket Ratio : 15T & 30TConveyor RPM : 101.84Relief Valve Setting : 2000

Electrical Motor(Induction Motor)

Serial no:050596Power(KW):112RPM:1175Potential Difference(K.V.):111Current(Amp.):71Ambient Temperature(˚C):40˚Weight(kg):1000Phase:3 Frequency(Hz):50Lubricant: ALBIDA RL2Temperature Rise(K):80

Additional Data

Heat exchanger type : water/oil & air/oilBreaker reducer ratio : 10:1Breaker diameter : 28.00Breaker sprocket ratio : 12T & 46TMounting : tracksTrack width : 120.75Maximum tram width : 132.26 Hopper width : 120.00Machine height : 45Conveyor width : 50.00

Hopper Slope : 35Dust suppression : water spraying

system110KW, 1.1KV AC FLP electrics2 speed conveyorSpeed reducer emulsion 60:40 oil/water

MaintenanceHead 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.

Head Shaft Assembly

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.

Breaker Shaft

Assembly

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.

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.

Shear sprocket

Shear hub assembly

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.

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.

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.

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