shovel ekg 12a - uralmash...working conditions and fields of application 2 the mining shovel ekg-12a...
TRANSCRIPT
SHOVEL
EKG-12A
3 - 13 - 30 t - 672 t
mStandard bucket capacityWorking bucket loadWorking weight of the machine
Working conditions andfields of application
2
The mining shovel EKG-12A (spec. TU 3141-005-00210571-2000) offered by Uralmashplant JSC is designed for mining and loading ore and overburden rock into transport vehicles (including dump cars) or in dumps.
Rock characteristics.The EKG-12A is designed for mining I and II rock categories without preliminary loosening, and III, IV, and V rock category with preliminary loosening.
Bucket capacity:3Capacity of the standard bucket is 13m (according to SAE).
Climatic conditions:Climatic modification of the machine is У1 according to GOST 15150-69. Working temperature range:
+ 45°С – 45°С
Max. temperatureMin. temperature:
: – –
Other conditions:The EKG-12A model is designed for working at the height up to 1000m above the sea level. Working environment shall be free from conductive or explosive dust.
GENERAL OPERATINGREQUIREMENTS
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The workface shall be prepared by blast-loosening (except for I and II rock categories). Average lump size of loosened rock shall be not more than 250 mm. Max. lump size is 800 mm.
Working slope angle of the machine shall be within 5 degrees. The machine shall be controlled by a trained operator. It is necessary to observe the manufacturer's requirements set forth
in the operating documentation when operating the machine. Theoretical output of the machine equipped with the standard bucket
3(according to GOST 4.377-85) is 1660 m /h. Design average overhaul period is min. 60000 working hours including time for moving the machine and preparing ramps.
Design service life of the machine is min. 20 years provided that the user observes all operation and maintenance regulations set forth in the manufacturer's manuals.
FRONTALEQUIPMENT
Frontal equipment design: rigid rack-type crowd mechanism with double-beam stick and sheave-less bucket suspension. This design ensures rigid fixation of the bucket when cutting.
Bucket.Capacity:Design:Material:
Bucket door brakes:Bucket teeth:
– – –
– – –
313m (according to SAE)cast and welded.cast front wall is made of high-manganese
steel.welded rear wall is made of low-alloyed steel.disc brakes mounted on the rear wall. secured on the front wall lip with bolts.
The yoke of the bucket is equipped with a balance pulley block fitted on a rocker. This assembly ensures uniform distribution of loads between four lines of the hoisting rope.
TECHNICAL SPECIFICATIONS
Revolving platform Design
Hoistingwinch
Swingmechanism
Leg
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the platform consists of two bearing parts, a counterweight assembly, and side platforms. The bearing parts and the counterweight assembly are connected with heavy-duty bolts.
four-motor single-gearbox winch with two cantilever drums secured on a shaft with keys. The winch is equipped with pneumatic brakes. Hoisting rope lines are secured on the drum with retaining plates.
the swing mechanism consists of four similar units consisting of an electric motor, a planetary gearbox, and a shaft each. Gearings are lubricated by a circulating oil-bath lubrication system. The units are located symmetrically in order to avoid generating stress on a central trunnion bearing.
consists of hinged front and rear frames.
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MECHANISM AND EQUIPMENTOF REVOLVING PLATFORM
Gearing lubricationMaintenance platformsBucket door winch
Boom and stickStick design
Boom design
Boom suspensionCrowd mechanism
Crowd mechanism configuration
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all-welded box-section stick. Forged gear racks are welded to the bottom surface of the beams.
all-welded box-section boom made of heavy-duty steel. An axle with boom point sheaves is mounted in a bore in the boom end.
the boom is suspended on four guy ropes.single-motor mechanism. A two-stage gearbox is
built into the boom. Bearings of drive and intermediate shafts are mounted in bores in the boom body. All shafts of the mechanism are mounted in rolling bearings. All saddle bearings are supported (on their inner side) by sliding bearings
flexible couplingpneumatic brake.
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oil bath.
located near the crowd mechanism and in the head part.
mounted on the boom. The unit consists of an electric motor, a coupling, a single-stage gearbox, and a drum.
Pneumatic systemApplication
Air supply
Filtering andventilation unit
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for driving brakes and pneumatic tools. Two similar air compressor units are installed with a common 1
3m - capacity air collectorair is supplied to individual units
through pneumatic distribution valves electrically controlled from a panel in the operator's cabin. Compressed air is supplied to the carriage brakes through a swivel joint (rotary pneumatic connection).
consists of two high-power centrifugal fans and inertial dust separators. The unit maintains pressure differential in the operator's cabin.
Equipment on the platform:–
– –
Movable electric hoist (l/c: 500 kgf ) for lifting small loads on the machine or lowering them down.
Portable manual hoist.Main and auxiliary electrical equipment.
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SHOVELEKG-12А
CabinDesign
Working compartment
Restcompartment
CABIN ANDHOUSING
Housing–
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Rigid frame consisting of vertical supports and horizontal beams. Cover plates are bolted to the supports. The roof consists of separate welded sections.
Quick –detachable doors are provided above the compressor unit, swing mechanism machinery, and the hoisting winch.
The housing is provided with two doors. An access ladder is located on the right platform.
CarriageDesign
Track drive
BrakesElectric motors
Track takeup deviceTrack links
Lubrication
Tracks
CARRIAGE
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Swing gear & bearing assemblyDesign
Centraltrunnion
Roller circle
Gear rim
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central trunnion, roller circle, and gear rim.
secured in the bores of the frame with a nut (lower bore) and a collet (upper bore).
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it has a heavy-duty detachable cage centered on the central hub. The cage carries axles with conical single-flange rollers. The rails are made of forged billets.
solid-forged. It is secured on the bottom frame with press-fitted bushings. Free access to the fastening assemblies of the rim is provided from inside of the bottom frame.
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two-deck cabin. The bottom deck houses a workbench and racks for tools and small spares. The top deck consists of two compartments: a working compartment and a rest compartment. There is also a platform for the maintenance of left and right windows.
houses a control station which consists of the adjustable operator's seat with stepless control joysticks and the control panel with signal devices and controls.
houses lockers, seats, and a table. The working compartment can be accessed from the rest compartment. The top deck of the cabin is provided with air conditioning and filtering system.
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two-track carriage with separately-driven tracks.tacks with large diameter rollers. With raised drive
sprockets and support rollers.the drive consists of two electric motors, two
mounted two-stage spur gearboxes, and two double-stage gearboxes built into the track frames.
pneumatic shoe brakes.the motors are installed horizontally on a special
bracket. They are provided with forced ventilation facilities to ensure nearly unlimited duration of the propel drive duty cycle.
hydraulic device driven by a separate pump unit.1800 mm-wide lings made of high-manganese steel
with machined track springs.Of gearboxes: oil bath. Of drive shaft rolling bearings and takeup device
sliding surfaces: lubrication by a lubricating unit.
Cable drumDrum capacity is up to 350 meters of cable if winding in two layers. The drum with a drive is mounted on a separate frame attached to the carriage. The drum is equipped with a device for uniform cable laying.
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ELECTRICAL EQUIPMENT
Main drives - hoist, crowd, swing, and propel drives, are designed on the basis of transistor converter – motor scheme:– MCCs are manufactured by "Joint power" company;
Information system, of the machine monitors main performance parameters of the shovel and perform the following functions:–
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Monitoring the temperature of hoist and crowd unit drive shaft bearings;
Monitoring the main drive motor bearings and MCC cabinet bearings temperature;
Monitoring main drive motors cooling air flow; Monitoring the swing mechanism oil temperature in the circulation
system; Monitoring the swing mechanism oil flow in the circulation system;Monitoring the main drive control system parameters; Monitoring the compressed air pressure in the pneumatic system. Monitoring the automatic lubrication system operation. Monitoring the machine slope angle in transverse and longitudinal
planes. Measuring the air temperature inside and outside of the operator's
cabin. Measuring the weight of rock in the bucket.
Displaying and recording the list of messages about failures, events, and system errors with dates and times.
The machine housing is provided
The machine is supplied
with LED lighting facilities.
with a laptop with software and cables for connecting to different units.
Main drive motors:– – – – –
Hoist drive: DPE-400-1/1U1 – 4 motors;Crowd drive: DPE-400-1/2U – 1 motor;Propel drive: DPE-350-2/1U1 – 2 motors;Swing drive: MPVE 120-750U2-M – 4 motors; Auxiliary transformer: dry-type transformer TSZE-250/UHL1.
The bucket door and cable drum drives
The fans, compressors, heaters, and pumps of the machine
are equipped with DC motors fed from a common static rectifier.
are driven by 220/380V AC drives fed from a step-down transformer.
The machine is equipped with a working equipment protection system, that ensures:–
– – – –
Boom protection from collision with the bucket (bucket lift limitation) and the handle above the crowd shaft (handle movement limitation).
Limitation of lateral loads when cutting Overhoist protection Rope unreeling length limitation Min. 5 surveillance video cameras .
LUBRICATION SYSTEM
Grease lubrication system: Lubrication points on machine units and assemblies
Bucket bushings:
Automatic; are automatically
lubricated with grease. are lubricated with a detachable grease gun.
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SHOVELEKG-12А
The use of the IS12 allows the user to:–
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Increase the efficiency of the machine operation due to on-line production process adjustment based on accurate information about the machine performance during a shift or a month linked to the name of the machine operator;
Increase the operator's awareness about the machine equipment condition and the machine output per shift;
Ensure longer service life and higher reliability of the equipment.
FUNCTIONSOF THE IS12
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1. Temperature monitoring: 8. Monitoring the parameters of the automatic grease lubrication system:
9. Measuring the weight of rock in the bucket.2. Monitoring the compressed air pressure in the 10. Recording the machine output per shift, month, or pneumatic system.year linked to the name of operator:3. Monitoring the oil flow in the swing mechanism
gearbox lubrication system.
4. Monitoring the machine slope angle in transverse and longitudinal planes.
5. Measuring the rotary platform swing angle.
6. Recording the working time of the electrical and 11. Collecting, handling, and storing actual performance mechanical equipment.data.7. Monitoring the operation of the main drive control 12. Analyzing collected data about the condition of the system operation and the automatic protection system.machine equipment.
13. Displaying required information on the operator's monitor installed in the cabin.
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temperature of the main drive bearingsmonitoring the condition of the system components temperature of the crowd gearbox shaft bearings
(feeders and pump motors); temperature of air in the operator's cabinmonitoring the grease level in tanks.temperature of air outside the cabin.
ecording the weight of loaded rock;recording the quantity of loaded trucks;recording the time of performing primary and auxiliary
works, movement time, and downtime;recording active and reactive power consumption.
Generating, displaying, and storing a list of warning and emergency messages with their time and dates.
INFORMATION SYSTEM
The information system IS12 is designed for mining shovels EKG-12A as a facility for collecting, handling, and displaying information about main performance parameters to the user. The system is designed for the automation of the equipment operating and diagnostics processes, as well as handling, storing, displaying, and recording the performance parameters of the machine.
SUBGROUPS OFIS12 FUNCTIONS
Information functions–
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measuring, calculating, and storing (even with no primary power supply) process and technical data about the machine performance;
HMI;manual input of information required for setting
the operating mode and basic data; generating and displaying collected information
and diagnostic data about the machine performance on the operator's screen in a user-friendly style. The information can be displayed under the operator's request or automatically depending on certain conditions. The information is visualized on different system screens;
storing the machine performance data for a shift, month, or a year, with indication of the operator name;
storing the list of all emergency and warning messages with indication of their dates and times.
Diagnostic functions–––––
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m m m m
m
m
monitoring the temperature of the main drive bearings;onitoring the Temperature of the crowd gearbox shaft bearings;onitoring the Temperature of the crowd gearbox shaft bearings;onitoring the compressed air pressure in the pneumatic system;onitoring the oil flow in the swing mechanism gearbox lubrication
system;onitoring the parameters of the automatic grease lubrication
system;onitoring the limit levels of controlled parameters. Generating
audible alarm signals and on-screen warnings; predicting possible emergencies basing on the analysis of available
data about the actual condition of mechanical and electrical equipment.
Functional diagramof the IS12 information system
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SHOVELEKG-12А
Panel PCwith 15" screen
Gate
Gate
Gate
Gate
Video camera
Video camera
Video camera
Video camera
Video camera
Electricitymeter
Main and auxiliarydrive control system
Inclinometer
Converter
Carriage
Converter
Temperaturetransducers
Temperaturetransducers
Temperaturetransducers
Digitalsensors
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A
K
J
N
C
G
I H
B
E
D
M
L
OPERATING PARAMETERS3Main bucket capacity, m (SAE J67
3Bucket capacity range, m
Working bucket load, t
Max. bucket sheave force, t
Crowd force, max, t
Time of working cycle, s
Digging height, max, m [ C ]
Digging radius, max, m [ D ]
Clean-up radius, m [ Е ]
Dumping radius, max, m [ В ]
Dumping height, max, m [ А ]
)[ C ]
[ ]
[ C ]
[ C ]
[ C ]
[ C ]
MASSES AND OVERALL DIMENSIONS
Working mass, t
Mass of ballast, t2Ground bearing pressure, MPa (kg/cm )
Height of boom point sheaves, m
Height of A-leg, m
Max. clearance radius over boom point sheaves, m
Max. clearance radius over revolving platform, m
Clearance under revolving platform, m
Clearance under lowest point, m
Operator's eye level, m
Overall width, m
[ G ]
[ G ]
[ G ]
[ G ]
[ K ]
[ H ]
[ I ]
[ J ]
[ M ]
[ N ]
[ L ]
672
0,22 (2,25)
12
9,3
0,575
11
75
16,51
14,99
3,14
8,32
13
30
63
15
14,3
10
10-16
125
26
21
18,5
ЭКГ-12АЭКГ-12А
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FRONTAL EQUIPMENTCrowd mechanism type
Stick design
Boom design
Boom sheave diameter, mm
rack
single-beam boom
double-beam stick
2130
ELECTRIC EQUIPMENTElectric drive type
Voltage, kV
Frequency, Hz
Main transformer power, kVA
6
1250
50
transistorconverter - motor
ELECTRIC MOTORS OF MAIN DRIVES
450
450
750
450
Qty, pcSpeed, rpmPower, kWDrive
Hoist
Crowd
Swing
Propel
200
120
200
175
4
4
1
2
GEARBOXES
Two-stage in-line
Two-stage in-line
Two-stage in-line
Two-stage planetary
Qty, pcDesignGearbox
Propel
Crowd
Hoist
Swing
2
1
1
4
REVOLVING PLATFORMLength, m
Width, m
13,4
9,2
SWING GEAR & BEARING ASSEMBLYDesign
Gear rim diameter, mm
number of teeth / module
with conical rollers
162/30
4907
PROPEL MECHANISMDesign
Overall length, m
Overall width, m
Track gauge, m
Track width, m
number of links
pitch of links, mm
Speed, km/h
two-track mounting withlarge diameter rollers
10,495
7,29
46
1,1
9,09
1,8
500
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SHOVELEKG-12А
9
ROPES AND GUY STRANDS
Hoist
Boom suspension
Bucket door opening
Auxiliary winch
GOST
GOST
Guy strand
GOST
Diameter, mmQty, pcTypeStructure
2
4
1
1
Length, m
52
15,5
70
13,5
83
14,78
20
250
MAIN DRIVE MOTOR PARAMETERS
Hoist motor
Crowd motor
Swing motor
Propel motor
Dipper door opening motor
Cable drum motor
DPE-400-1/1U2
MPVE 120-750U2
D 31 UHL1
DPE-400-1/2U2
DPE 350-2/1U1
D 12 UHL2
Speed, rpmPower, kWTypeMotor
200
200
120
175
8
2,5
Q-ty, each
450
750
870
450
450/1000
1180
2
1
4
2
1
1
экг-18
10
Overall dimensions of machine units
312M BUCKET
Height, mm – 3070
Width, mm 3640
Depth, mm 2890
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Weight, t – 27
HANDLE
Height, mm – 1000
Width, mm 3320
Length, mm 10700
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Weight, t – 18,3
BOOM
Width, mm – 2500
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Weight, t – 62,1
Width with mountedequipment, mm 3955
Length, mm 16570
A-LEG
Height, mm – 9000
Width, mm 4000
Length, mm 6000
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Weight, t – 8,9
CRAWLER ASSEMBLY
Height, mm – 1910
Width, mm 2530
Length, mm 10285
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Weight (of assembled frame), t – 63,6
TRACK
Link height, mm – 382
Ling width, mm 710
Link length, mm 1800
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Weight, t – 36,3
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SHOVELEKG-12А
11
PROPEL GEARBOX
Height, mm – 2190
Width, mm 1750
Depth, mm 1255
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Weight, t – 4,99
OPERATOR'S CABIN
Width, mm – 2460
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Weight, t – 7,5
Height, mm 5220
Length, mm 4390
CABLE DRUM
Height, mm – 1850
Width, mm 4340 –
Weight, t – 4,7
HOIST WINCH DRUM WITH CABLE
Diameter, mm – 1350
Width, mm 770
52
–
Cable diameter, mm –
Weight (w/o cable), t – 2,38
GEAR RIM
OD, mm – 4907
Height, mm 335 –
Weight, t – 8,6
BOTTOM FRAME
Height, mm – 1934
Width, mm 4180
4200
–
Length, mm –
Weight, t – 26,3
200 125 320
117
12
CURRENT COLLECTOR ENCLOSURE
Height, mm – 3091
Weight, t – 0,64
BEAM CRANE
Length, mm – 6235
–
Weight, t – 0,41
Height, mm 1128
ROLLER CIRCLE
Height, mm – 240
Diameter, mm 4000 –
Weight, t – 8,5
SWING MECHANISM
Height, mm – 3950
Weight, t – 21,5
VENTILATION UNIT
Height, mm – 2372
Width, mm 7925 –
Weight, t – 3,023
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SHOVELEKG-12АOverall dimensions of machine units
13
MIDDLE PART OF THEREVOLVING PLATFORM
Width, mm – 4500
Height, mm –
–
Weight, t – 17
1070
Length, mm 4880
AIR COMPRESSOR UNIT
Height, mm – 1792
Width, mm 1346 –
Length, mm– 2172
Weight, t – 1,77
CENTRAL TRUNNION
Diameter, mm – 500
Height, mm 2410 –
Weight, t – 3,1
FRONT PART OF THEREVOLVING PLATFORM
Height, mm – 1665
Width, mm 4536
Length, mm 6800
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–
Weight, t – 33,5
4
16
8
12
0
ДМ8008-ВУф
kgf/cm
1.5
2
HOIST WINCH GEARBOX
Height, mm – 2350
Width, mm 2300
Length, mm 4030
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–
Weight, t – 29,4
COUNTERWEIGHT ASSEMBLY
Height, mm– 100
Width, mm – 2835
Length, mm – 8453
Weight, t – 12
14
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SHOVELEKG-12АNOTES
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Uralmashplant is one of the leading Russian machine-building plants. For more than 80 years Uralmashplant has been a key provider of basic machinery for mining, chemical, metallurgical, construction, oil-and-gas, and power engineering industries, since fundamental national industries have originated here, at the Ural heavy machine-building plant.
The trademark "UZTM" is well-known all over the world. The plant supplies its products to CIS countries, Western and Eastern Europe, Middle East, South and Southeastern Asia, Africa, North and Latin America. Uralmashplant has its own highly efficient design center. The plant comprises welding, machining and assembly, heat-treatment, and toolmaking facilities.
Uralmashplant offers complex solutions from technology development and engineering to supply, installation, and maintenance services. Uralmashplant offers to its customers highly-effective, reliable, low maintenance, energy-saving, and highly automated equipment designed with a glance to actual ecological requirements.
CONTACTS
620012, Pervoi Pyatiletki Sq., Ekaterinburg, RussiaE-mail: Fax: Information Service: Sales DirectionProcurement and Logistics DirectionPress CenterMuseum of Uralmash History
[email protected]+7 (343) 336-60-40
+7 (343) 336-69-79 +7 (343) 327-59-31+7 (343) 336-69-01+7 (343) 336-60-54+7 (343) 327-10-63
ABOUT US
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