Transcript
Shovels
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This presentation is about Electric Mining Shovels
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This presentation is about Electric Mining Shovels
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Shovels are used at both surface mines and the deeper open pit mines
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The
primary use for Shovels is to load material (coal, rock, ore) into haul trucks
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Hydraulic
Shovels are also used at mines in this presentation They are not discussed Whitmore's: ShovelsWhitmore 5
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Front
Loaders are also used. Not discussed in this presentation. August 2006
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Shovel Components and Operations August 2006
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Shovels are Electrically Driven
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Shovel Power Incoming AC is changed to DC by MG Sets MG Sets deliver DC to motors that drive the Swing, Propel, Hoist and Crowd systems (On a Shovel the ³Crowd´ system is similar to the Drag system on a Dragline) Speed reduction is done through both enclosed gearboxes and open gears August 2006
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The Bucket, usually called the ³Dipper´
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Shovel Digging Motion The August 2006
Dipper is filled by hoisting Whitmore's: ShovelsWhitmore
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The
contents of the Dipper are released by opening the Dipper Door
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The House
The
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Dipper
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The
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Boom
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The
Boom Point Sheave
Crawler Tracks August 2006
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The House
Rollers and Swing Rack on a Shovel operate in the same way as a Dragline, and are lubricated by the Multi-Service lubricant The
Center Pintle is lubricated either by the Multi-Service lubricant or the bearing grease August 2006
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Swing Rack
Lubricant: SurStik®
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Hoist
Ropes
Boom Suspension Ropes (Static)
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The
Dipper Sticks (sometimes called Dipper Handles)
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Note: There are no Drag Ropes on a Shovel August 2006
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Dipper Sticks August 2006
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The ³Thrust´ and ³Retract´ Motion of Dipper Sticks is Called the ³Crowd´ Motion
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P&H uses two rectangular Sticks
10/13/04
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Bucyrus uses a single round Stick
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P&H Dipper Sticks August 2006
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The
³Saddle Blocks´ are guides for the Sticks
The
Dipper
Dipper Sticks slide against guide Stick plates inside the Saddle Blocks
SADDLE BLOCK
SADDLE BLOCK (hidden)
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Multi-Service Lubricant is applied to the guide plates and Dipper Stick from Dipper Stick Drip Tubes fitted to the Saddle Block
SurStik
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August 2006
Rack gears are Crowd Rack built into the underside of the two sticks. These Crowd Rack are called the Whitmore's: ShovelsWhitmore Crowd Racks.27
Crowd Pinion is inside saddle block
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Crowd motion comes from the Crowd Pinion that engages with the Crowd Racks 28
Multi-Service lubricant is applied to the Crowd Rack and Pinion Note the mess created by the use of an asphaltic lubricant August 2006
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The Crowd Pinion is Driven by the Crowd Motor + Enclosed Gearbox on the Boom
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Bucyrus Dipper Sticks August 2006
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The Bucyrus Round Dipper Stick
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The
Saddle Block on a Bucyrus Shovel is circular
Saddle Block
Boom
Dipper Stick
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A View of the Dipper Stick in the Saddle Block
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Lubricant Ports in the Saddle Block
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Bucyrus dipper sticks are controlled by two sets of wire ropes that operate independently, the Hoist Cable and the Crowd Cable Both cables are driven by Drums in the House August 2006
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Hoist Cable
Crowd Cable Hoist Cable Crowd Cable
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The Crowd Cables perform the same function as the Crowd Rack and Pinion on a P&H Shovel, they control the Crowd Motion (Thrust and Retract)
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Lubricants August 2006
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Enclosed Gearbox Oil August 2006
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Enclosed Gearboxes on Shovels: Hoist enclosed gearbox In the House. Drives the Hoist Rope Drum
Crowd enclosed gearbox In a P&H the Crowd gearbox is located on the Boom. It drives the Crowd Pinion. In a Bucyrus the Crowd gearbox is located in the house. It drives the Crowd Rope Drum.
Swing enclosed gearbox In the House. Turns the House
Propel enclosed gearbox August 2006
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Recommended Products Whitmore recommends Paragon for Shovel gearboxes Choose viscosity based on the OEM recommendations and the climate, or consult Whitmore Technical Services Dept. Where synthetic oil is required, use Decathlon HD series Where a Flender-approved oil is needed, use Decathlon F August 2006
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Grease August 2006
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Bearings Many customers use Whitmore¶s SurStik Multi-Service lubricant in the automatic system for lubricating bearings Whitmore greases used on Shovels: ± Omnilith 360 EP 1 ± DuraFilm EP 1 ± Matrix® EP 1 ± Legacy M EP 1 ± Based on synthetic oil ± Used year round in very cold conditions August 2006
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Multi-Service Lubricant Applied by automatic lubrication system August 2006
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Multi-Service Lubricant Applications Hoist: Open Gear on Hoist Rope Drum Crowd: ± P&H: Crowd Rack and Pinion (on the Dipper Stick) ± Bucyrus: Open Gear on Crowd Rope Drum
Dipper Stick (and Saddle Block) Swing Rack and Pinion Circle Rail and Rollers SurStik Multi-Service lubricant may be used in bearings (except electric motor bearings) August 2006
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Because it Performs Exceptionally Well on Dipper Sticks, Whitmore Recommends SurStik MultiService Lubricant for use on Shovels
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SurStik on Dipper Sticks SurStik does not make the Dipper Stick prone to contamination by dust Easy to maintain a good coating using SurStik On Bucyrus machines SurStik spreads easily around the Stick to form a black protective coating SurStik will not flake off in freezing conditions August 2006
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Choosing the Grade of SurStik Choose the grade based on the climate ± Use SurStik Extra Heavy:
-7°C to 110°C
± Use SurStik Summer:
-12°C to 110°C
± Use SurStik Winter:
-35°C to 25°C
Distributors report that the best results are obtained using the heaviest possible grade for the climate conditions August 2006
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Whitmore Lubricants for Wire Ropes Sam amee as as fo for Dra Dragl glin ines es Wire Ropes: ± Whi Whitm tmore¶ ore¶ss Wire Wire Rope Lubric Lubricant ant,, or ± Rene Renew® w® 20 20 or 30 (uses recycl recycled ed oil oil), ), or ± WRWR-5 5 (cont (contain ainss a solvent solvent))
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Motor Couplings Us Usee Wh Whit itm mor ore¶ e¶ss Vo Vort rtex ex Sp Spec ecia ially lly de desi sign gned ed for for use use in in coup couplin lings gs Extremely ta tacky Very Very low ble bleed ed on on the the K3 K36 6 Cent Centrif rifuga ugall bleed bleed test Shell Coupli Coupling ng Grease: Grease: 1.87% loss after after 24 24 hours Whit Whitmore¶s more¶s Vortex Vortex: : 0.94% loss after 24 hours August 2006
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Shovel Models August 2006
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Bucyrus (formerly Bucyrus Erie, now Bucyrus International)
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Bucyrus 195B Shovels Dipper capacities: 9.2 to 23.9 m3
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Bucyrus 295B Shovels Dipper capacities: 18.48 to 39.27 m3
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Bucyrus 395B Shovels Dipper capacities: 26.7 to 53.5 m3
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Bucyrus 495B Shovels Dipper capacities: 30.6 to 61.2 m3
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Bucyrus 595B Shovels Dipper capacities: 24.5 to 64.3 m3
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Marion Marion is now part of Bucyrus
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Marion 182-M Dipper capacities: 5.7 to 17.6 m3
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P&H August 2006
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P&H 2800XPB Dipper capacities: 25.2 to 53.5 m3
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P&H 4100BOSS Dipper capacities: 30.6 to 61.2 m3
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P&H 4100XPB Dipper capacities: 35.9 to 76.5 m3
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