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P 7213 TF

This document summarizes a braking control system for downhill conveyors installed at a power station in Australia. The system uses 4 Twiflex spring-applied hydraulically-released fail-safe disc brakes on two discs to safely control a conveyor belt that transports overburden 90 meters downhill over 1.3 km. A closed-loop control system interfaces with the conveyor and uses solenoid valves and an accumulator to provide controlled braking during stopping and startup. It also has a fast approach circuit and open loop braking mode for power failures to ensure safe stopping at a pre-determined ramp down rate.

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Tran Duc
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
81 views

P 7213 TF

This document summarizes a braking control system for downhill conveyors installed at a power station in Australia. The system uses 4 Twiflex spring-applied hydraulically-released fail-safe disc brakes on two discs to safely control a conveyor belt that transports overburden 90 meters downhill over 1.3 km. A closed-loop control system interfaces with the conveyor and uses solenoid valves and an accumulator to provide controlled braking during stopping and startup. It also has a fast approach circuit and open loop braking mode for power failures to ensure safe stopping at a pre-determined ramp down rate.

Uploaded by

Tran Duc
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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A l t r a I n d u s t r i a l M o t i o n

Warner Electric

Boston Gear

TB Woods Braking Control for Downhill


Formsprag Clutch Conveyors
Wichita Clutch

Marland Clutch

Industrial Clutch

Nuttall Gear

Warner Linear

Delroyd Worm Gear

Stieber Clutch

Ameridrives Couplings

Inertia Dynamics

Matrix International

Huco Dynatork

Bibby Transmissions

Bauer Gear Motor

Twiflex Limited

Kilian Manufacturing

Ameridrives Power
Transmission
Braking Control for Downhill Conveyors
Correctly engineered braking These solenoids are inter-linked with the primary drive motor
systems are of paramount circuitry, and when de-energized they open the discharge valve
importance when ensuring and closes the input flow valve. This releases oil pressure from
the safe control of downhill the calipers and arrests the input flow of oil allowing the springs
conveyors. One such example to apply force to the brake pads.
is at the Hazelwood Power Conveyor control is activated by signals fed through a PLC.
Station in the Australian State of A tachogenerator mounted on the drive drum shaft measures the
Victoria. Here some 4500 TPH RPM and converts this to frequency signals which are fed to the
of overburden is conveyed 90 PLC. The controller is pre-programmed to compare RPM against
meters downhill on a 1.3 km long time to a ramp down velocity rate which is suitable for optimum
belt. conveyor retardation.
A total of four Twiflex VKSD If the measured speed becomes lower (conveyor retardation
spring applied / hydraulically slows down) a signal is transmitted to operate the solenoid valve
4 Twiflex fail safe disc brakes on released fail safe disc brakes are towards its closed position until the speed corresponds to the
two discs.
installed on two discs, 1.5 meters programmed ramp down. This increases the back pressure on
in diameter. One disc and brake the brakes and decreases the braking torque. Alternatively, if the
set is mounted directly on the primary drive drum and the second measured speed becomes higher a signal is transmitted to operate
on the tail pulley. The brakes, which provide a controlled release the valve in the open direction.
during start up and controlled application during stopping, A fast approach circuit is also integrated into the system. It
operate from a hydraulic power pack. A closed loop control consists of an auxiliary circuit which is the first to be activated
system designed by Twiflex interfaces with the conveyor. The when stopping the conveyor. The control valve in this circuit
principle is as follows: operates immediately to the fully open position and quickly
relieves the back pressure to a pre-determined level. This is
A positive displacement pump discharges its flow through achieved by controlling the flow of hydraulic fluid into a separate
a check valve to an accumulator and is automatically switched accumulator which is charged to a controlled level.
off when the system pressure is reached. Two solenoid valves This level gives enough back pressure relief to allow the
are employed, one on the flow line into the brake and one on brakes to just touch the disc. No braking force is applied at this
the discharge side. When the primary drive motor is energized stage; it is simply to quickly close the gap between the pads and
the discharge valve closes and the input flow valve opens. This disc to the point where controlled braking can commence. With
permits the oil to maintain pressure on the brake springs to keep the gap closed the PLC activates control to the programmed
them compressed and the brakes released. deceleration rate.
During a power failure an open loop braking mode is
activated. Under this condition the control switches to an
alternative source which provides power to control braking
within a pre-determined ramp down rate. This is not adjustable,
but over-stress in the drive train and belt is avoided by
programming the ramp down to suit a fully loaded belt. A
partially or empty belt will take longer than is actually necessary
to stop.
Full system monitoring is also provided with this system to
Customer Service ensure safe control at all times.
+44 (0) 20 8894 1161
www.twiflex.com

Asia Pacific
For a list of our APsales offices:
www.AltraMotion.com/ContactUs

P-7213-TF 12/11 Printed in USA

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