bobrn wagon door operating mechanism
#1

please enlight us the system of opening and closing of group of BOBR wagons at track hopper




M/s. Matha Track & Infra Tech/Hyderabad.
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#2
This paper covers the aspects of the wagon loading and unloading system currently in
vogue in the Indian Industry. Generally the wagon loading systems are required in the
mines and ports for loading the material into the wagons for further transportation to the
process plants. Two major types of wagon loading systems are (a) Rake will be
stationary and loader will be moving (b) Rake will be moving and loader will be
stationary.
The wagon unloading systems are required in the process plants for unloading material
received from the mines / ports by the railway wagons. Two types of wagons are
generally used in the Indian Industry viz. BOXN wagons and BOBRN wagons.
This paper discusses the different types of wagon loading systems suitable for the
above and unloading systems suitable for the two types of wagons.
1. WAGON LOADING SYSTEM:
1.1 INTRODUCTION
Wagon loading systems are generally provided in the mines and ports for loading the
material into the wagons. The following are the major types of wagon loading systems:
Rake will be stationary and loader will be moving. The loading systems under this
type could be further classified into two types viz. (i) the mobile loader will be
travelling for the complete length of the rake (ii) series of loaders will be provided
with limited travel and would load a particular number of loaders at a time.
Rake will be moving and the loader will be stationary. This type is generally
known as rapid loading system or flood loading system. The loading systems
under this type could be further classified into two types viz. (i) Volumetric type
The type of wagon loading system depends on the properties of the material to be
loaded and limitations in the layout. Hence each type of wagon loading systems
mentioned above are applicable and are being adopted on different occasions.
Generally one rake consists of about 58 wagons and capacity of each wagon is 55
tonnes. The total quantity of material in each rake would be about 3200 tonnes.
The wagon loading system consists of a buffer storage silo and the wagon loader.
1.2 STORAGE SILO:
The capacity of the storage silo will be generally equal to one rake load of material to
enable loading of the rake without any interruption. However, this would depend on the
properties of material like flowability, moisture content etc. In cases where higher
quantity of material cannot be stored due to arching / chocking problems, the silo
capacity could be lower. This silo would act as a buffer silo and the feeding conveyor to
this silo shall be operated continuously to ensure that there will be no starvation of
material while loading into the wagons.
1.3 MOBILE WAGON LOADER:
The mobile wagon loader consists of a long conveyor, a travelling tripper, a cross belt
conveyor mounted on the tripper and a loading chute. This system will be provided
parallel to the rail track where the rake containing 58 wagons will be parked. The
travelling tripper will be travelling along the conveyor for loading the material into the
wagons. The storage silo will be located at the tail end of this conveyor and feeds the
material continuously onto the conveyor.
At the start of the loading operation, travelling tripper will be located at the starting edge
of the first wagon of the rake. The material from the silo will be fed onto the conveyor
which will be conveyed to the cross conveyor mounted on the tripper. The material will
be loaded into the wagon through the loading chute. The travelling tripper moves
forward while discharging the material into the wagon at a constant speed. When the
loading chute approaches the end of the wagon, the loading chute changes over from
one wagon to the next wagon and thus there will not be any spillage between the
wagons. The loading operation will continue to the next wagon without any interruption.
This process will be continued till the loading of the last wagon of the rake.
This type of system is suitable for all types of material and especially for the sticky
material. The limitation of this type of system is that the mobile loader will be too heavy
and bulky. The time taken for loading one rake is about 3 to 4 hours.
There is another type of mobile wagon loading system which consists of a set of six or
seven short pivoted conveyors. The pivot of these conveyors will be such that the
discharge chute of the conveyors will be travelling in a straight line. These conveyors
will be pivoted at the tail end and mounted over the rail track at the head end. The
bottom elevation of the conveyor will clear the wagons. The travel of the head end will
be limited to one wagon length. A surge hopper will be provided at the tail end of each
conveyor which ensures continuous supply of material. At the start of the loading
operation, the rake will be parked below the conveyor system such that the forward
edge of the first six wagons will be below the loading chute of each loading conveyor.
The loading operation will begin at the starting edge of the wagon and as the material
flows, the conveyor would travel along the wagon and loading will be completed as it
reaches the other edge of the wagon. Each wagon loader will load one wagon at a time.
At the end of the loading operation, the rake shall be shifted by six wagons so that the
next six wagons will be ready for loading the material.
This type of loader is simple and more compact. However it takes more time (4 to 5
hours) for loading one rake. The number of installation of this type of wagon loader are
very few. The accuracy of the load in the wagons will be less.
1.4 RAPID LOADING SYSTEM:
This type of loading system consists of a storage silo, a bin below the silo and the
loading chute. This silo will be mounted directly over the rail track. The rake will be
moving below the loading chute at a constant speed while material will be discharged
into the wagons. The rake consisting of 58 wagons will be connected to the loco which
will be provided with creep speed control system. With this system, it would be possible
to maintain the constant speed of the train. The desired speed of the train is 0.8 KMPH
for better accuracy. The track shall also be maintained truly horizontal to ensure that the
train will not gain or lose the speed due to gravity.
There are two types of Rapid Loading System (RLS) viz. volumetric type and
gravimetric type. In the volumetric type, the loading chute will be operated hydraulically
for a pre determined time for loading the material into the wagons. The volume of the
material discharged into the individual wagons will be controlled. At the start of the
loading cycle, the starting edge of the wagon will be brought below the loading chute.
The loading chute will be lowered and the gate will be opened to allow the material to
flow. At the same time, the rake would also start moving at a constant slow speed. The
loading will continue till the end of the wagon. When the edge of the wagon is sensed
the gate closes slowly and the flow of material will be stopped. Uniform loading of
material is ensured across the width and length of the wagons.
The gravimetric type of loading system will be similar to the volumetric type. However; in
this case, the bin below the silo will be weighed before discharging the material into the
wagon. The rake below the silo will be moving at a constant speed and the weighed
material in the bin will be discharged into the wagon at a controlled rate to ensure
uniform loading of the material in the wagons.
The chute provided below the bin will be either wheel mounted telescopic type or
pivoted type. This chute will be moved out to allow the loco to pass through. When the
wagon is located below the silo, the loading chute will be brought to the loading position.
The storage silo will be similar to that elaborated in clause 1.2 above. It would be
preferable to have the storage capacity of one full rake to ensure uninterrupted loading.
However, if it is not possible to have the full rake capacity due to flowability problems,
silo of smaller capacity could be provided. In this case, the constant supply of material
shall be ensured at the required rate so that starvation of the material is not experienced
during the loading operation.
Various instruments will be provided to ensure uniform and accurate loading of the
material into the wagons. The photo electric sensors will be provided for sensing the
movement of the rake and would sense the loco for bypassing and senses the wagons
to start the loading operation. The complete controls will be provided in the silo building
at an elevated position. It would be possible to view the loading operation from this
control room.
The volumetric type and gravimetric types of loading systems are similar in construction
and operation. However, the accuracy of loading will be better in the case of gravimetric
type as the weighed quantity of material will be loaded.
The time required for loading one rake with the rapid loading system would be less than
one hour.
1.5 CONCLUSIONS:
The rapid loading system has many advantages like better accuracy, more
uniform loading and the loading operation will be much faster. The limitation
would be the storage silo for the material which does not flow easily.
The travelling wagon loader is more bulky and takes more time for loading the
rake. However, this could be used for the material which does not flow easily.
Considering the above aspects, it could be concluded that the rapid loading
system could be adopted for most of the materials and wagon loader could be
used where the material has problem associated with the flow.
2. WAGON UNLOADING SYSTEM:
2.1 INTRODUCTION:
The material will be received at the process plant by two different types of wagons as
indicated above viz. BOXN wagons and BOBRN wagons. Different types of wagon
unloading systems would be adopted for unloading the material from these wagons.
Generally the material will be discharged from the top from the BOXN wagons while in
the case of BOBRN wagons, it will be discharged from the bottom. The hopper will be
provided below the ground for receiving the unloaded material from these wagons.
Hence, the BOXN wagons need to be tilted for unloading the material into the hopper
while the BOBRN wagons are provided with pneumatically operated gates at the bottom
for unloading the material.
2.2 WAGON TIPPLING SYSTEM
The wagon tippling system consists of wagon tippler, the wagon positioning equipment,
underground hopper, and feeder below the hopper for evacuating the material unloaded
into the hopper.
2.2.1 WAGON TIPPLER
The wagon tippler consists of a table for positioning the wagon, wagon holding
mechanism, gears and pinions for rotation, drive unit, hydraulic power pack etc. The
unloading cycle starts when the wagon is positioned over the wagon tippler table and
the wagon along with the table rotates and discharges the material into the underground
hopper. The time taken for the unloading operation is about 90 seconds. There are two
types of wagon tipplers viz. rotaside which rotates about 135º and another rotary type
which rotates by 180º. The rotaside wagon tipplers are provided in most of the plants in
India. The drive for the rotation will be hydraulic type for smoother operation. It would be
possible to achieve average unloading rate of about 20 tips per hour with the rotaside
wagon tippler.
2.2.2 WAGON POSITIONING EQUIPMET
There are different types of wagon positioning equipment like hydraulically operated
side arm charger, beetle charger and shunting locos. The hydraulically operated side
arm chargers are being used in most of the plants in India as this equipment is much
faster compared to the others. The tractive force of the side arm charger shall be
suitable for hauling one fully loaded rake.
2.2.3 UNLOADING HOPPER
The hopper provided below the wagon tippler could be either RCC type or structural
steel fabricated type. In most of the plants this will be of RCC construction. Suitable liner
would be provided for this hopper depending on the abrasiveness of the material
handled. Generally steel grids of 250 mm square will be provided above the hopper to
avoid higher size of material going through. The higher size material will be removed
and broken separately and then passed through the grid. The grid will be sloping
outwards for easy removal of such larger size material.
2.2.4 FEEDER BELOW THE HOPPER
The feeder below the hopper could be either vibrating type feeder or apron feeder. The
apron feeder would be more suitable for heavy duty application for taking the impact of
the falling material. The apron feeder will be driven by hydraulic motor for smoother
operation.
2.2.5 RAIL TRACKS
The layout of the rail tracks shall be such that the track will be straight and horizontal for
one rake length on the inhaul side and also on the outhaul side. This would be
preferable for achieving faster unloading rate and the effort required by the side arm
charger would also be minimum. In case it is not possible to have straight length to
accommodate one full rake on either side, then shunting operation will be required using
the plant loco and hence it takes the turnaround time will be more.
2.2.6 DUST CONTROL SYSTEM
Plain water spray type dust suppression system will be provided for suppressing the
dust generated during the unloading operation. Spray nozzles will be provided at the top
of the wagon tippler and also around the hopper for spraying the water and settling the
dust. An enclosed shed will be provided for the wagon tippler so that the dust will be
contained within and will not be spread to the other parts of the plant.
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