2. Introduction
The 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.
3. 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.
4.
5. Parts of Feeder Breaker
Drag conveyor
Pick breaker
Hydraulic crawler drives
Electric system
Hydraulic system
Programmable sensor controller
6. Drag Conveyor
The 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.
7. 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.
8. 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.
9. 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.
10. 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.
11.
12. Electric System
The 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 Drive
Conveyor Drive
Hydraulics
15. Hydraulic System
The 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 Drive
Crawler Drives
Levelling Cylinders
Auxiliary Functions (PTO, winches, cylinders,
etc.)
17. The hydraulic system is designed with
maintenance features to provide safe and
reliable operation of the feeder breaker
Component test fittings
Oil level indicator
Hand pump (reservoir fill)
Hydraulic pressure gauges are fitted for
the visual monitoring
Pump operating pressures
Conveyor drives system pressures
Tram and levelling pressures
18. Programmable Sensor Controller
The 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.
19. 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 flow
Water pressure
Oil temperature
Oil level
Sequence/water
Sequence/Time out
Stop
Breaker Run
20. Technical Specification of F.B. used
in JHANJRA
Conveyor Hydraulic Motor
Headshaft rpm : 43.65
Sprocket Ratio : 15T & 30T
Conveyor RPM : 101.84
Relief Valve Setting : 2000
23. Hopper Slope : 35
Dust suppression : water spraying system
110KW, 1.1KV AC FLP electrics
2 speed conveyor
Speed reducer emulsion 60:40 oil/water
24. Maintenance
Head 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.
26. 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.
28. 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.
29. 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.
31. 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.
32. 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.
33. 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.
