Mine conveyors

MINE CONVEYORS

KSD28

This conveyor set was manufactured based on designs made by "DONGYPROUGLEMASH" - a leading project and production association in designing the coal-mining machinery in Ukraine and some promising designs and advanced technologies developed at NKMZ.
When designing this machine, the field experience accumulated in operating similar machines as well as the customers' requirements have been taken into the account.

The conveyor is designed to transfer coal from 3000 to 8000 tons/day output and 220 to 300 metre-long breakage faces with the coal seam thickness over 1.4 metres being advanced to the strike on-dip at up to 30°, and up-dip at up to 10°, in the mines including gassy and dust-explosion hazardous ones.
This conveyor is deemed to replace the standard SPC273 Flight conveyor from which it differs in higher capacity (increased by 50%), more powerful double-speed motor being employed and two-or three-fold extended service life of the panline.
The conveyor features a transfer machine which consists of the drive units, transition sections, main and transition pans and the flight-type traction unit.
The conveyor may be operated as a part of the powered mining complexes such as 2 MKD90, 3MKD90, 2MKDD, 2KMT and KMK700/800 and with the Types PKY13, TSh500, PKY10, 2GSh685 and 1GSh68 cutter-headers.

Design features:

Double-speed high-power high-starting torque water-cooled motor
Epicyclic-gear-train or right-angle and epicyclic-gear-train speed reducer versions. Speed reducers may be disconnected from the motor shaft with a special device and are water-cooled. Speed reducer service life amounts to 25,000 hours.
Specially-reinforced sigma-shaped pan with the bottom of 30 mm thick made of the new wear-resistant steel grade
Sized-bar chain traction unit made of the new high-strength wear-resistant steel grade with the lower content of detrimental impurities and with the connecting link of a new design fitted with the high-strength teeth
Sevent-point detachable-type sprocket
Chain tensioning hydraulically-controlled bottom drive.

TECHNICAL DATA

Capacity, ton/hr	1000
Length, m	250
No. and arrangement of drive units, pcs.	2, one-sided
Motor rated power, kW	85/250
Traction unit speed, m/s:
- main (operating)	1.063
- auxiliary (travelling)	0.345
No. and arrangement of chains, pcs.	2, centred
Chain type (size, pitch, strength grade)	30×108-C
Pan side frame height, mm	255
Pan width across side frames, mm	800
Pan length, mm	1500
Service life, mln. tons	3.0

Main components of the conveyor are as follows:

2 drive units;
Panline;
Flight-type traction unit;
Chain tensioning device;
2 transition sections;
Speed reducer and motor cooling system;
Electrical equipment;
Control facilities;
Set of spares, tools and accessories.

The conveyor provides:

Operation both in the right-hand and left-hand faces with some units being reassembled in the mine conditions;
Dismounting of the unit to transportable pieces that allow delivery of the same into the mine and assembly/disassembly in the face area;
Adaptability to the varying face lengths through changing the number of pans and the length of the traction unit;
Powering of the coal loading in the panline;
Smooth motion of the traction unit over the drive frames, transition sections and panline;
Setting the drive frames on mated supports or distance pieces;
Setting traction unit on the drive frames through the use of the chain feed systems;
Safe attachment and tensioning of the traction unit;
Reciprocal turning of the conveyor pans both in a horizontal (2°) and vertical (5°) planes;
Drive protection against overloads and jamming;
Connection of the dust-suppression (water spray) facilities at the place of loading coal onto transport facilities;
Connection of the panline motion and conveyor drive facilities;
Replacement of the chain sprockets without disconnecting the speed reducer.

Drive units

electric motor;
speed reducer;
drive frame;
chain sprocket;
shaft of sprocket;
chain traction unit installed in the bottom unit.

The drive units may be fitted with various speed reducers which enable to mount the electric motors both lengthwise and crosswise the panline
The speed reducer design provides operation of the conveyor both in the left-hand and right-hand faces by reassembling some components
The speed reducer is fitted with the mechanism that serves to disconnect it from the motor shaft thus improving safety during repairs
Application of the epicyclic-gear-train speed reducer enables to drastically reduce the overall size and weight of the drive assemblies. The speed reducer service life was extended from 12,000 to 25,000 hours
A new 250-kW double-speed motor was used being provided with the operating and traveling speeds. Thanks to the traveling speed rate being 1/3 of the operating one, the conveyor startup and operation conditions may be improved. Startup at lower speed enables to obtain a three-fold rise of the starting torque at less current consumed. Changeover to the operating speed rate is performed automatically
Both the speed reducer and motor are water-cooled.
A 7-point sprocket is made detachable to provide its dismounting with the drive being intact. In contrast to the similar welded-type sprockets this one is made solid thus being stronger.
A hydraulic-operated chain tensioning mechanism is provided with the tension control device and separated from the drive thus simplifying the tension control and improving safety during operation.

Panline

The panline consists of the main and transition pans joined with each other and with the transition section by means of the special high-strength lock. The joint strength is sufficient to take a breaking force arising between the pans and amounting to 340 tons (2×170 ton).
The pans are made up of the bottom, side frames, brackets that serve to join the pans with each other and the overhead equipment.
A new sigma-shaped section was designed and implemented for the side frames with the shelf thickness being increased from 20 to 30 mm and made of special high-resistant and high-strength steel grade. The section height is 255 mm.
The pan bottom is made of the same steel with the thickness increased up to 30 mm.
The pan bottoms are engaged with each other while the side boards are chamfered to provide smooth passage for the traction line and to remove dynamic loads applied to the chain and drive assemblies.
The pans are joined in such a manner that they can reciprocally rotate within 2° and 5° in horizontal and vertical planes respectively.

Flight-type traction unit

A traction unit features an endless belt consisting of the two high-strength round-link chains arranged at the panline center portion with the flights being fastened thereon through each 1.08 m.
The belt is made up of the chain seetions of 25 metres long joined through the connecting links. By varying the number of sections, the total conveyor length may be set depending upon the face length.
The chain dia was increased from 26 to 30 mm in the traction unit. The chain was made of the new high-strength and high-resistant steel grade with the quaranteed chemistry and reduced content of detrimental inclusions. Moreover. to fabricate the chain, a cold-rolled sized rod was used instead of the hot-rolled non-sized rod formely employed.
The use of a new material and improvement of the rolled product quality enables to raise the chain strength 1.5-fold.
Connecting links are made of the steel grade similar to that of the chain. In contrast to conventional designs, a new design with the strengthened tecth was employed.

Electrical equipment

The electrical equipment is supplied at rated voltage of 1140 V. The conveyor electric circuit is connected to the integral electric circuit of the cutter-loader set. A specially - designed control station will be delivered in a set with the conveyor fitted with the conveyor provided with the microprocessor - based controls and diagnostics that enable the on-line control of the conveyor equipment operation. The appropriate protections, diagnostics and indications of the conveyor faults and failures will be provided. A double-speed water-cooled Type EKVF 355L 12/4, 85/250 kW, 500/1500 rpm, 1140 V electric motor will be used fitted with the thyristor-based overheat protection and made by PERVOMAYSKY ELECTROMEKHANICHESKY ZAVOD.

BELT CONVEYORS FOR MINES

Conveyor belt width, mm	800	1000	1200	1400
Conveyor speed, m/s	1 ... 2.5
Max. conveying capacity, m³/hr (ton/hr)	(350)
Conveyor route slope angle, deg	0 ... 15
Horizontal length, m	up to 50
Installed motor power, kW	5 ... 22
Motor speed, min^-1	1000