Technical Specifications HSG T-Class Two Bearing Vibrating Screens

Transcription

1 Technical Specifications HSG T-Class Two Bearing Vibrating Screens Page 1 of 26

2 Thank you for your interest in the Tycan HSG T-Class. GENERAL INFORMATION International markets have different demands and require custom solutions. With three manufacturing subsidiaries in Germany, Brazil and Canada the Haver Group has substantial application knowledge in the field of mining machinery. With the founding of the Haver Screening Group (HSG) an initiative was started to collect and bundle this knowledge and provide it to all HSG members and their customers. The Haver Screening Group deals in the field of specialty machinery and develops vibrating screens that often start where standard solutions end. The advantage of building a specialized machine for a certain application often carries the disadvantage of having a high percentage of machine specific components. The target of this design development was to establish a system of components that can be flexibly combined within one machine family. The individual screen therefore can be perfectly adapted to its application. Utilizing this concept to the fullest extent plus designing components using rigid design rules leads to families of vibrating screens built from the same pool of field-proven interchangeable components. In addition interchangeability works between metric and imperial systems. The reduced amount of different parts improves machine service and spare parts handling. International customers can utilize the same spare parts regardless in which part of the world they are active. Vibrating screens are in constant contact with abrasive material. An easy to change-out wear protection system has been developed to protect critical areas of the screen body and so prolonging the service life. Page 2 of 26

3 Cut Size vs. Stroke (HSG T-Class) Amplitude r [mm] 10,00 9,00 8,00 7,00 6,00 5,00 4,00 3,00 2,00 1,00 0,00 0,10 1,00 10,00 100,00 Cut Size d [mm] Design Tools The HSG T-Class is modeled in 3D environment prior to production. Using a 3D CAD system, the engineer produces a geometrically accurate, unambiguous, digital product model that is utilized throughout product development, manufacturing and assembly. Interacting with 3D model speeds up design, encourages innovation and identifies errors. It enables engineers to visually evaluate interference between parts, complicated geometric features, required tolerances, mechanism motion and assembly structure as the product evolves. Further, the virtual prototype enables concurrent collaboration between engineering, manufacturing and customers. Features Body Patented Rigid Reinforcing Frame Design Complete Component Interchangeability Standardized screening media support system and bar rail clamping assemblies Complete machine assembly weld-less Page 3 of 26

4 HUCK -Bolted Screen Body design for extra strength and rigidity under all working conditions Unique design angle box tension system 3-bend tension rails to engage hooked edges of the side tensioned screen sections high strength carbon steel (ASTM A-36) high rigidity due to formed double 90 bend at top and single 90 bend at bottom of side plate Decks: One to Three Inclination: 10 to 25 degrees Drive Adjustable fly wheel allows for quick amplitude & stroke change Available in grease or oil lubrication Drastically reduces noise emissions Structurally integrated drive guard Grease collector pan ensures clean operation Easy access for drive adjustments Drive Transmission: V-Belts and pulleys Drive Unit: Electric Motor Operating Speeds: 750 to 1050 RPM Alloy steel shaft ground to precision tolerances Heavy-duty, high performance, self-aligning spherical roller screen bearings with inner races fitted to the shaft and outer races mounted in the cast ductile iron bearing housing Labyrinth seals prevent grit or foreign matter from reaching the bearings Seamless steel tube shaft casing with cast iron tube heads to assure solid construction and protection for shaft assembly lock nuts used in shaft assembly and screen section tensioning for strong safe connections and easy maintenance Shaft driven from right or left side Teflon coated inner bearing race to eliminate end shaft greasing Wheel guards and drive guards provide protection from rotating parts Page 4 of 26

5 HSG SCREEN SIZES Under the global concept and to utilize both imperial and metric media screen width steps of 305mm (1ft.) have been selected. HSG machines are therefore available in inside side-plate width of multiples of 1ft. The following table shows the main series of screen sizes. Intermediate sizes are available in 2ft. increments. Table 1: HSG Main Series and Available Screening Surface per Deck [ft 2 ] Screen Width [ft] HSG Screen Length [ft.] * 32 * * * * To be verified by application Page 5 of 26

6 VERSATILE DECK SYSTEM FOR SCREENING MEDIA Modern vibrating screen must accept a series of screening media. Aside form specialty media we look at two groups: Tailored Media o Tensioned wire cloth, tensioned Polyurethane or Rubber o Bolted or tensioned perforated plate o Harp screens and self-cleaning tensioned screen cloth Modular Media o Polyurethane or rubber modules o Module Frames with different Media e.g. PU frame with harp wire Figure 1: Various Made-To-Order Screen Media Tailored media can by purchased to order and is available in many sizes. This media does not determine the size of the vibrating screen body. Modular media on the other hand are standardized by market. While 300x500mm is a normal size in the metric system 1x1ft. or 1x2ft. is normal in the imperial system (North America). The differences in these present a huge challenge if one wants to adhere to a global concept. Page 6 of 26

7 Figure 2: Various Modular Media Design Grid Screen Body Families Following the idea of a global design a common design grid has been introduced. All machine series has been developed using this grid. The grid defines eligible connecting points for machine components. A part developed fore one HSG - machine using the rules of the design grid therefore fits all machines of the same family. This concept allows for a versatile combination of machine parts and a high degree of adaptation of the vibrating screen to the application. To cover the entire spectrum of screen sizes body families have been defined. Each family carries there own drive sizes which also define allowable deck spacing. Family 3 for example carries drive sizes of 150 and 180mm bearings. Deck spacing in this family can be selected between 250, 550 and 850mm. The machines therefore can be adjusted to either a smaller overall height or good accessibility. Page 7 of 26

8 Screen Body Design DECK SUPPORT STRUCTURE To allow for a long service life and a reliable machine vibrating components have to be sized below the fatigue-limit. Welding on structural supports lowers the fatigue-limit significantly and can lead to failures. Preferably welding should be avoided altogether. The screen body has to be built as a rigid vibration resistant block. The body of HSG machines is designed using cross-beams. To avoid welding the media support structure is clamped to the cross-members using a patented clamp arrangement. These clamps also carry the wear protection system. Figure 3: Cross Member Design with Patented Clamp Page 8 of 26

9 WEAR PROTECTION SYSTEM During developing the structural components a new wear protection system was developed. Aside from protection the focus lay on replace ability. Individual panels are being knocked onto the clamps of the support system. The replacement does not require tools other then a hammer and is very quick. The wear protection system can be applied as an after sales solution. The same concept is being used for discharge-lips and feed-boxes. Figure 4: Patented Wear Protection System Using the wear protection system individual sections of a screen deck can be sealed. This can be extremely useful to prevent water and material flowing back at the discharge end of wet screens. Page 9 of 26

10 Figure 5: Sealed Deck Section DECK DESIGN The concept introduced allows for a very flexible deck configuration. Positioning of the cross beam is adjustable. Since all components are developed according to the rules of the design grid they can be combined. This is also true for the different media systems. It is possible to combine different media systems in one deck (e.g. tensioned wire cloth and PU-modules). These combinations are also available as after sales adjustment with a minimal amount of additional parts. Page 10 of 26

11 Figure 6: Mixed Deck Setup Decks or sections of a deck can be equipped with ball-trays which aid the screening process for hard to screen products at small cut sizes. Page 11 of 26

12 Figure 7: Balltray SCREEN BODY Screen body components such as the feed box and discharge lips are self supporting structural members and contribute to the overall rigidity of the body. Page 12 of 26

13 Figure 8: Feedbox and Back-plate For heavy duty applications the screen body can be reinforced by utilizing structural members riveted to the side-plate. Page 13 of 26

14 Figure 9: Side View Basic Design Figure 10: Side View Premium Design with Patented Reinforcement Structure The reinforcement members connect with body brackets and cross members and form a rigid frame system in 3 planes. Forces are introduced into the reinforced frame structure only. Page 14 of 26

15 Drive REQUIREMENTS The amplitude of a vibrating screen is selected by the cut size. Large cut sizes require large amplitudes. The acceleration of this kind of a vibrating screen is usually 4g which automatically determines the speed of the drive. The traditional shaft-drive usually has a limited range of operation. In many cases adjustments of speed and stroke are difficult if not impossible to create. HSG SHAFT DRIVE In the scope of this project a drive was developed that supports a wide range of speedand stroke-adjustments. The drive is available in oil and grease design. Designs can be converted from one to the other. To utilize the full life of a modern screen bearing, special care has to be taken in the design phase for example to minimize shaft-deflection. During the development a logical selection of bearing sizes has been made. Stepping up from one bearing size to the next provides a logical increase in bearing life or vibrating weight. Common bearing sizes are also available in double shaft design. Page 15 of 26

16 Figure 11: Patented HSG Fly-wheel The patented design of the HSG-Flywheel allows the flexible combination of the weights. Therefore the static moment of the wheel therefore is adjustable in a wide range. In addition the angle of the two outer weights allows fine tuning in a range of about %. This adjustment is very fast and easy. This option is very interesting, especially when the machine speed or weight has been changed. Greater adjustments are possible by adding or removing weights. The drive is available in oil and grease lubrication. One system can be easily converted into the other by exchanging the seal system. Page 16 of 26

17 Figure 12: Oil Version DRIVE SIZES The HSG drive is available in the following bearing sizes. Main sizes are also available in double shaft design. Double shaft drives provide a significant increase in carrying capacity and raise the speed limit. Table 2: Vibrating Weight per HSG Drive Drive HSG Vibrating 850 min -1 [kg] S S S S S S S D S D D Page 17 of 26

18 Table 3: Bearing Sizes by Screen Width Screen Width [ft.] HSG Bearing Size STATIC MOMENT The required static moment of a vibrating screen is the product of vibrating weight and desired amplitude. This affects the design of the drive of a vibrating screen mainly its fly-wheel. The bigger the amplitude the bigger the unbalanced weight has to be. The graph below shows the comparison of some drive systems. Shown are three double exciter drives, two single shaft drives in 140mm and 160mm bearing sizes and the HSG150/180 drive in single shaft design. Page 18 of 26

19 Exciters Exciters 400 Drive System 2 Exciters 260 Shaft Drive 160 Shaft Drive 140 HSG 150/180 Static Moment [kgm] Figure 13: Working Range of Various Drive Systems This working ranges shows that HSG Drive is adjustable in a very wide range and outperforms the other drives in this area. The biggest stroke can be set to ¾. Page 19 of 26

20 Mounting Options The T-Class screen can be designed with one of four mounting options: 1. Direct support with coil springs used in conjunction with stabilizing units. The stabilizing units provide lateral stability and control machine movement limiting critical frequencies during start up and shut down. Stabilizing Units Figure 1 Coil Springs and Stabilizing Unit Page 20 of 26

21 2. Direct support with Ty-Rider mounts Figure 2 Ty-Rider Mounted HSG T-Class Ty-Rider mounts are offered as an alternative to conventional spring mounting systems. Ty-Rider mounts are based upon the principle of four elastomeric elements inside the base of each oscillating unit. The elements transmit the oscillations of a system, while simultaneously damping vibration, shock, and noise. Due to the unique design, neither shear nor bending stresses occur at the support points, assuring long life. Page 21 of 26

22 Figure 3: Double Ty-Rider Configuration The key features of Ty-Rider mounts that are superior to coil springs are: Extended life Lateral stability Support tensile, compressive and shear stresses Reduced noise level Prevents excessive and uncontrolled oscillation through start-up and shut down 3. Cable suspension Figure 4 Cable Suspension 4. Combination of floor mounting and cable suspension. Page 22 of 26

23 Vibration Analysis Inspection Every HSG T-Class vibrating machine is backed by years of engineering experience. Prior to shipment each machine is carefully examined and operated over a prolonged period assuring correct balance, satisfactory bearing operating temperatures, smooth operation, acceptable noise levels, and quality workmanship. Each machine is evaluated using a computer vibration analysis tool to find any dynamic irregularities in a vibrating screen. This information makes it possible to view in the monitor the orbit points, peak to peak, median acceleration, displacements, frequency (RPM) and FFT analysis. The combination of speed and stroke on a vibrating screen results in acceleration forces. Operating a screen outside of its proper accelerations reduces screening performance and poses risks to the mechanical integrity of the machine. Measuring the mechanical performance of a vibrating screen builds the basis, minimizing these risks, ensuring proper operation. The healthy screen will display a stable waveform and close to zero acceleration in the side axis. Figure 5 Vibration Analysis Data Acquisition Horizontal and vertical vibrations analyzed together allow orbit plots to represent the 2D shape of the screen motion (Figure 19). This shape also holds valuable information Page 23 of 26

24 about the condition of the screen. The integrated FFT-analysis separates and analyzes frequency patterns that indicate mechanical problems. Figure 6: Vibration Analysis Orbit Plots A software suite processes the information resulting in a report featuring detail information for each measuring point and an evaluation for the entire machine. The summary brief points to modifications that are necessary to achieve optimum performance. Page 24 of 26

25 Warranty W.S. TYLER CANADA LTD. hereinafter designated the Company warrants to the Purchaser / End-user that the equipment will be free from defects in material, design and workmanship, provided that the equipment is commissioned by a certified TYCAN technician, for a period of eighteen (18) months from the date of shipment or twelve (12) months from installation, or six-thousand (6,000) operation hours from installation whichever is first provided the Purchaser or user operates the equipment according to and in accordance with the conditions of operation specified herein and in accordance with operating manuals furnished. Claims for wear and tear are excluded from the company s warranty. If during the warranty period, any part of the equipment is found to be defective in material or workmanship, the Company will furnish a replacement part FCA ST. CATHARINES. Such parts claimed to be defective shall be returned to the Company's manufacturing plant, transportation prepaid, for inspection by the company to determine to its satisfaction that said Part or Parts are defective, or, at its option, repair such defective part in place, provided the Purchaser or user operates the equipment according to generally approved industry practices and in accordance with the conditions of operation specified herein and in accordance with operating manuals furnished if any, and further provided that the Purchaser notifies the Company in writing as soon as any defects occur. The performance of a screening machine is subject to so many variables in the user's plant and are beyond the control of the seller, that there can be no warranty of any particular performance. THE EXPRESS WARRANTIES, GUARANTEES AND REMEDIES SET FORTH HEREIN ARE EXCLUSIVE AND NO OTHER WARRANTIES, GUARANTEES OR REMEDIES OF ANY KIND, WHETHER STATUTORY, WRITTEN, ORAL, EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTIABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY. The liability of the Company to the Purchaser arising out of the manufacture, sale, delivery, use or resale of the equipment whether based on warranty contract negligence, tort, strict liability, or otherwise, and whether for direct, indirect, special, consequential, exemplary, punitive or other damage, shall not exceed the cost of correcting defects in the equipment as herein provided. Upon the expiration of the warranty period, all such liability shall terminate. The Company shall not be responsible for work done, equipment or parts furnished or repairs made by others, or for loss, damages, or expense arising from such work, equipment, parts or repairs. The Company shall not be liable to the Purchaser or User for loss of anticipated profits, Page 25 of 26

26 loss by reason of plant shutdown, non-operation or increased expense of operation of the other equipment or other consequential loss or damage of any nature arising from any cause whatsoever by reason of the manufacturer, sale, delivery, use or resale of the equipment covered by this contract. No person, agent or dealer is authorized to give any warranty, other than the one herein expressed, on the Company's behalf or to assume for it any liability pertaining to such Equipment. THIS WARRANTY IS NULL AND VOID IF OTHER THAN GENUINE TYCAN R PARTS ARE USED Page 26 of 26