Tippler

Section 1: Descriptions Tippler

The plant and equipment offered will be generally as described below. It may be desirable during the detail design phase to make changes and we reserve the right to do so provided this equals or improves the value of the offer.

1.1 General Plant Description

The SASDA Tippler is designed to tip a range of Spoornet wagons and to discharge their contents into a hopper with the whole machine and hopper requiring a minimal depth of civil works .ie: Reasonably shallow foundations.

Advantages

• This is particularly beneficial where ground conditions inhibit deep foundations and/or where the water table is very high.
• Thus the savings on civil costs are very significant as is the construction period.
• The installation and the maintenance of equipment situated deeply underground is eliminated.
• The savings on the takeaway conveyor system are significant.
• The length of groundwork required is minimal.
• The SASDA Tippler design enables the discharged material to be directed to the Hopper in a most effective manner reducing spillage and power consumption.

The SASDA Tippler is mounted on reinforced concrete plinths such that the rails on its top table surface line up with the station “ingo” and “outgo” rail tracks. This allows rail wagons to be pushed directly onto it.
The area of the tippler can be cordoned off via handrails for safety.
The SASDA Tippler is “rack and pinion driven” from a central drive fitted with line shafts and flexible couplings.
The SASDA Tippler raises the wagon and rotates it about a pivot shaft mounted to the side of the rail track.
During the tipping cycle the wagon is restrained at its top surface by gravity operated clamps.
Material is discharged from the wagon into a holding hopper and is gravity fed by gravity and automated vibrating floors, onto a takeaway conveyor.

An interlocked control system allows remote tippling to proceed. Suitable safety provisions are made.

The SASD Tippler is particularly suitable for use in conjunction with a Wagon Positioning Device such as a Side Arm Charger.

The machine comprises the following main elements:

• Two fabricated steel end frames fitted with drive racks, at each end of the machine, which are carried on substantial spherical plain bearings, all mounted on reinforced concrete pillars.
• One fabricated steel table, pin connected at each end to the fabricated supporting toes, and fitted with rails on which the wagons stand during tipping.
• One fabricated steel Side Beam against which the wagon rests during tipping.
• Gravity operated wagon restraining clamps to hold the wagon during tipping.
• One set of spill plates to direct the material into the receiving hopper.
• A centrally positioned drive with double output shafts and line shafts and fitted with pinions to engage with the e. frame racks.
• Counterweight towers to house the restraining clamps balance weights.
• One set of vibrating floors fitted to the hopper.
• One set of electrical control and instrumentation (E, C & I) equipment to control the tippler.

1.2 Operation and Control

A typical detailed description of operations and controls can be supplied, but a summary is as follows:

• Operation and control can be either remotely or locally executed.
• Wagons are placed singly on the tippler by whatever means the client uses for marshalling them.
• The SASDA Tippler tip cycle is actuated which enables the tippler to lift under controlled acceleration and deceleration to the tipped position.
• This is limit switch controlled.
• After a pause the tippler can return automatically to the rest position.
• Traffic control signals change and the empty wagon is replaced with the next full.

1.3 Features

Safety features include traffic control lights, visual and audible alarms. Proximity switches prove positions of tippler and interlocking prevents proceeding otherwise.

Design features include robust construction as a result of experience gained over many years of machine design and maintenance support.

1.4 Weighing Equipment

We have not included for weighing equipment at this stage, but it can be included if required. Our preferred system is rail mounted inline weighing.

Go to Section 2    

Section 2: Specifications Tippler

2.1 Design Parameters

Our offer is based on the following key design parameters, which are critical in the choice of equipment, offered. The design will be carried out to our own and national, international standards as appropriate.

2.2 Wagons to be handled

Spoornet type wagons being typically :-
BAL/J 1,2 : CAL/J 1, :CCL/R 1,3 : CFL 1,3 : CFR : CR 2,4,6,7,9,10 : CRM 11.
80 t gross mass and 60 t capacity.

The following information would be required from the client:


• maximum loco mass and wheel configuration that crosses the tippler

2.3 Time Cycle

Typically this is:

Tip        50 second
Pause    10 seconds
Return   50 seconds
Total    110 seconds

Allowing for a wagon change time of 90 secs., almost 15 wagons per hour can be handled. This equates to + 800 t/h.

2.4 Electrical Supplies

Power 380V 3 phase 50Hz
Control 220V 1 phase and 24V DC

2.5 Site and Ambient Conditions

Maximum ambient                  +40 °C
Atmosphere                            Dusty
Elevation                                Hiveld level
Area classification                   In the pit – zone 21
(SABS IEC 61241-3 : 1997)     Above ground level – non hazardous

2.6 Detailed Equipment Specifications

Rail gauge                         1065 mm
Tippler table length            18400 mm approx
Table width                       1385 mm
Angle of tip                       150°(157° wagon side)
Number of Drive Pinions     2
Tippler Drive motor size     90 kW
Restraining rope size          20 mm dia
Number of restraining ropes     2
Grooved Rope drum dia     800 mm

2.7 Electric and Instrumentation Specifications

2.7.1 Motors

Main Drive motor V.F.Controlled     90 kW 6 pole
Vibrating floor motors (16 off)        40 watts each.

2.7.2 Field Devices

All field electrical equipment will be suitable for the ambient temperature and atmospheric conditions as specified above.

2.7.3 Area or Location Classification and degree of protection

We consider the tippler and pit to be a non-hazardous classification

The equipment offered is generally IP 65. However, in the operator’s control room the equipment will be to IP55.

Change in area classification can have a marked effect on the cost of the electrical and control equipment, requiring specially rated and certified components. Please note that our offer does not include for any individually certified components or the testing thereof, and degree of protection will simply be stated on the component or certified by the supplier.

2.8 Hopper Vibrating Floors

The floors are designed and manufactured in France and an extensive reference list is available A guarantee of 99 % clearance of material is given. The use of floors enables shallower foundations. Please refer to the attached detailed specifications information in section 8.

2.9 Corrosion Protection

• Fabricated structural steel will be to a specification reasonable for the location. We have assumed a good quality marine environment specification for the purposes of estimating our price.
• Proprietary equipment, such as motors, gearboxes, limit switches etc. will be in manufacturer's standard finish.

Go to Section 3    

Section 3: Descriptions Side Arm Charger

3.1 Plant Description

One SASDA Tippler and One Side Arm Charger.

The side arm charger is a machine that is self propelled and is mounted on rails which run parallel to the main rail track. It is an indexing device which is capable of pulling a rake of railway wagons and position each one, singly, onto the SASDA tippler. A side arm charger can provide a throughput of 15 wagons per hour.

Generally the side arm charger is rack and pinion driven using hydraulic pumps and motors. The side arm charger installed power is dependent on the number of wagons to be pulled and their velocity.

3.2 Specifications and Drawings

The system is based on the Plant Layout drawings SASD 001 REV A.

3.3 Overview of Operation Requirements

A Side Arm Charger will operate in conjunction with a “SASDA Tippler” to index rakes of railway wagons through the system.

The locomotive will bring the train until the lead car is within reach of the Charger Arm. Due to marshalling arrangements the rail cars will be pushed into position. Railway signalling will inhibit further locomotive access while the tippler system is active.

The charger can now, under manual operation be engaged to the new loaded train. With its arms raised, the charger will move back towards the lead wagon. When the charger is clear of the tippler at the ingo end arm interlock switch, the main charger arm will be lowered. The charger will then travel back to engage with the coupler of the leading wagon.

Under manual operation the charger moves forward to position the rake of the full wagons so that the gap between the leading wagon the next wagon is at the uncoupling point.

3.4 Start of Auto Cycle

Provided the outgo operator has pressed his “Coupler Check Confirm” button, it is possible to start an auto cycle. The operator pulls and holds the “coupler release lever” (between the lead and second car) and press the “Cycle Start” button. The Charger Variable Speed Hydraulic Drive will be energised and ramp up to speed in the forward direction. The Charger will move forward to the Wagon Forward Limit, pulling the single leading wagon. The drive will then ramp down to zero speed and de-energise. The Charger Decouple Actuator will be extended until the Decouple Actuator Extended Limit is made. This will allow the Charger Coupling to uncouple from the wagon. During this movement, the previously emptied wagon is ejected from the Tippler.

The Charger moves clear and the Main Arm is raised so the arm raised limit switch is made. The Charger is reversed by ramping to reverse speed until the return limit switch is activated at which point the forward arm lowers to the arm down limit switch and the charger ramps down to zero speed. The Charger travels to the Arm Interlock Limit where it decelerates to stop.
Note – as soon as the Charger Arm is clear of the Tippler Platform, the Tippler will start to tip.

At the Arm Interlock Limit, when the Arm Lowered Limit is reached and provided the Decouple Actuator Extended Limit is made, the Charger can reverse to engage with the next leading wagon. The Charger Drive will then energise and ramp up to speed in the reverse direction. When the Arm Coupler Engaged Limit is made, it will ramp down to zero speed and de-energise. The Charger is now coupled to the next leading wagon.

The tippler will rotate to 150 degrees where it will dwell for a reset time before returning. The tippler will then return to rail level (zero degrees).
Note – Whilst the tippler is rotating, the outgo operator must open the trailing coupler of the previously ejected wagon, and press his “Coupler Check Confirm” button. Otherwise charger forward will be inhibited.

When the tippler has completed it’s tip cycle, provided the “Coupler Check Confirm” button has been pressed, the charger pulls the rake of wagons forward until the gap between the leading wagon and the next wagon is at the uncoupling point.
The auto cycle is now complete and the operator is now in a position to start another auto cycle.

Go to Section 1