d series apron feeders

d series apron feeders
Terex® Minerals Processing Systems
D SERIES
APRON FEEDERS
DEPENDABLE
Apron Feeders
Quality Equipment
and Support
You Can Depend On
Terex® Minerals Processing Systems understands
your business and we are dedicated to offering
cost-effective solutions for your needs.
In today’s competitive environment, you need
to have high quality equipment. It’s even better
to know that your equipment is backed by an
outstanding support network.
Customer satisfaction is our goal. Our service,
parts, applications and sales teams are trained
to provide our customers with crushing and
screening process knowledge and fast friendly
service. With over eight decades of experience,
you can depend on us.
TEREX JAQUES APRON FEEDERS
Capacities up to 14,500 tph
Proven design based on crawler tractor components
Custom designed for the duty
Please note: some photos in this publication show Terex® Jaques apron
feeders with the safety guards removed. This is only in order to make
technical features of the machine visible. It is not meant to illustrate the
machine’s normal operation.
Terex Jaques Apron Feeders use heavy-duty
crawler tractor track rollers and chain, a
fabricated support frame, and high-strength
steel head shafts and tail shafts.
Using long life components, Terex Jaques Apron
Feeders provide low maintenance equipment
even under severe conditions.
Rugged
Typical applications include primary hopper recovery,
stockpile reclaim,
crusher feed and reclaim, ship and rail-car
®
Terex
D Series
apron
feeders
loading
and Jaques
unloading stations,
ore pass
recovery
and other use heavy-duty
crawler
tractor
track
rollers
and
chain, a fabricated
installations requiring a controlled feed.
support
frame,
and high-strength
steel head shafts
We
have over 50
years experience
in designing and installing
heavy-duty
feeders. Our engineering application team
and tailapron
shafts.
ensures that each feeder is designed for the required duty,
whether it is a relatively low capacity or 14,500 tph.
Because of their durable, long-life components, our
Each
machine isapron
backed by
the Terex Jaques
total after-market
D Series
feeders
are low
maintenance even
service and spare parts.
under severe conditions.
Please note: the cover photo and certain other photos in this publication show Terex
Jaques Apron Feeders with the safety guards removed. This is only in order to make
technical features of the machine visible. It is not meant to illustrare the machines
normal operation.
2
Typical applications include primary hopper recovery,
stockpile reclaim, crusher feed and reclaim, ship and
rail-car loading and unloading stations, ore pass recovery
and other installations requiring a controlled feed.
We have over 50 years experience in designing and
installing heavy-duty apron feeders. Our engineering
application team ensures that each feeder is designed for
the required duty, whether it is a relatively low capacity or
as high as 14,500 mtph (16,000 tph).
Each machine is backed by total after-market service
and spare parts.
MOVE
MOUNTAINS
Terex® Jaques D Series Apron Feeders
• Capacities up to 14,500 mtph (16,000 tph)
• Proven design based on crawler tractor components
• Custom designed for any application
• Long wearing parts, low maintenance, low operating costs
• Variable speed optimises plant capacity
4
Benefits and Features
Long life, low maintenance and reduced
operating costs.
Proven heavy duty design.
Custom designed to suit each application
and capacity.
Many models of various widths and any length.
Long life because of impact and
wear resistance.
Cast manganese steel-ribbed flights.
Special purpose flights also available.
Single or twin bump rails as required.
Optimises plant capacity.
Reduces costly truck waiting time.
Variable speed electro-mechanical or hydraulic drive.
Correct feeder selection matches plant hopper capacity
to dump truck capacity.
Reduced tip height and ramp costs.
Can be installed at an incline of up to 25 degrees.
Sprockets can be replaced without splitting
the chain.
Easy to unblock bridging in the hopper.
Segmental drive sprockets.
Reversing capability.
Safety protection.
Easy to lubricate.
Nip point guards down each side and tail of feeder.
Centralised lubrication at head and tail.
Optional automatic lubrication.
High percentage surge pile recovery.
Reduced spillage under feeder.
Feeder can accept high head-load with long slots
under surge piles.
Optional in-built dribble or scraper conveyor.
Optimises plant and load-out station
performance.
Hydraulic chain tension adjustment is standard on
most models.
Simple to maintain the correct chain tension.
A constant feed rate, when speed is controlled by
a downstream conveyor belt scale.
5
Apron Feeder Construction Details
Frame
The frame is welded, with rolled-steel longitudinal beams
and cross members for rigid support of the carrying rollers.
Modular carrier roller support frames are bolted to the cross
beams for ease of removal and installation.
Impact rails
Impact rails incorporate Bolt on Bump Rail design for ease of
maintenance and replacement. These are fitted to the feeder
frame to prevent permanent distortion of the flights under
severe impact loading. Clearance is maintained between
the underside flight ribs and the impact rail to prevent the
flights dragging on the rail during normal operation. These
heavy-gauge structural members add rigidity to withstand
the impact loads during loading.
6
Head shaft and sprockets
Segmental hardened steel sprockets are machined at the
mounting interface with the sprocket hubs. The hubs are
keyed to the drive shaft.
Sprockets incorporate a hunting tooth design which have the
effect of increasing the life of the sprockets.
The segmented sprockets can be easily reversed for
increased life.
Head shafts are high-strength steel and sized to suit the load
requirements. The head shafts are fully machined to take
bearings, sprocket hubs, seals and the drive. The drive
may be located on either side of the feeder. Twin drives
can be supplied when required.
Tail shaft and traction wheels
The traction wheels are a cast steel segmented design
mounted to a steel hub, to allow maintenance and removal
without the need to split or dismantle the feeder chain. They
are machined and mounted to the tail shaft to accurately
centre and track the chain. Each traction wheel hub is
attached to the tail shaft with a friction grip locking assembly.
There is minimal load at the tail end of the feeder, which
assures a long life for the traction wheels.
An optional speed sensor can be supplied that provides a
pulsing signal, that can be used by the plant controls to
monitor speed.
Bearings
High capacity low-friction spherical roller bearings are used
for both the head and tail shafts. The bearings are doublerow, self-aligning spherical bearings in heavy-duty cast
housings. A combination of labyrinth and lip seals are fitted
to all bearing housings to protect from harsh environments.
At the tail end, the bearing housings have an adjustable
screw allows positive positioning of the housings over the
range of the chain adjustment.
All bearing housings are bolted to the main frame. The bolt
holes at the tail end of the frame are slotted as to allow the
tail shaft to be moved backwards for chain adjustment and
maintenance.
Lubrication
Centralised greasing points are installed as standard at
the head-shaft and tail-shaft ends of the feeder. An optional
single-point centralised and automatic lubrication system
options are also available.
7
Apron Feeder Construction Details
Carrier rollers
The carrier rollers are closely spaced, standard tractor
components. They are designed and manufactured for
long wear and maintenance-free service. Features include
lifetime-lubricated fully sealed bearings, a hardened and
ground shaft fitted with a central thrust shoulder, and
hardened rollers.
Chain
Sealed and Lubricated (SALT) track chains are supplied
as standard to give a long working life.
Pins and bushes are hardened on the wearing surfaces. The
chain links are dropped-forged for increased load capacity.
Their extra-wide design and large pin-bearing area reduces
wear. Cone-shaped metal seals between the bushing end
and the link counterbore keep contaminants out.
Return rollers
The return rollers support the return-strand of the flights
and chain. Each roller is a modified crawler tractor carrier
roller, with lifetime lubricated seals. Each roller is supported
by a bracket which is bolted to the main frame for ease of
removal and installation. Inspection ports located in the main
beams in close proximity to the Return Rollers offer visual
inspection of Rollers condition and wear, without disturbing
any components
8
Chain adjustment
Chain adjustment is carried out by loosening the tail shaft
bearing housing mounting bolts and then opening the double
acting hydraulic take-up cylinder to eliminate slack. Once this
is complete, bearing housing bolts are re-tightened.
Drive systems
Drive systems are selected for an efficient and cost-effective
solution to a given application. A range of drive types can
be supplied, including electro-mechanical and hydraulic.
Variable speed drives are standard.
Feeders speed can be easily controlled from zero speed
through to maximum from a remote location.
Electro-mechanical drive
The drive system for the feeder generally includes a
planetary reducer with a torque arm mounted on the head
shaft. The mounting is either in-line or right-angled, with a
direct-coupled AC electric motor. The speed of the motor
is controlled by a variable voltage, variable frequency drive
controller, which is commonly called a VVVF drive.
If needed for the application, independent coolers can be
provided for the reducer and electric motor.
Hydraulic drive
Hydraulic drives consist of a hydraulic motor, housed directly
on the head shaft, and a hydraulic power unit.
Individual feeders can be driven by their own power unit. Or
several feeders can draw their power from a single source.
The power unit can be custom-designed, with stand-by filters
and pumps to reduce maintenance down-time.
Manganese steel flights
Our standard flights are cast work-hardening manganese
steel which has properties making it ideal for high impact
and abrasive conditions. The flights are ribbed on the
underside for extra strength and have a machined chain
mounting interface. Alloy steel bolts fix the flights to the
chain. The clearance between adjacent flights is minimised
to reduce leakage.
Alternatively, for some less severe applications, pressed steel
flights are also available.
9
Checklist for Purchasing an Apron Feeder
10
Terex® Jaques Apron Feeders
Why it matters
Complete range, with capacities to 14,500 tph.
Feeders available for any application.
Standard SALT tractor chain and carrying rollers used.
Very robust, low wear, low maintenance.
Over 50 years experience in designing
heavy-duty apron feeders for all applications.
Ensures a feeder suited to the purpose.
Return rollers sealed for life.
Long wearing, no maintenance.
Full range of drive types, including electro-mechanical
and hydraulic.
Efficient and cost-effective solutions
for each application.
Positive continuous drive.
Effectively moves materials with poor flowability.
10% reversing capabilities.
Assists in clearing blockages in the hopper and turning
material on the feeder pan.
Reduced tip height.
Can be inclined up to 25 degrees with lifter bars.
Rugged construction and rigid support.
Able to withstand high head loads.
Correct selection of feeder model and drive
Capable of pulling out from large cross-sectional areas
under surge piles and within dump hoppers.
Ore pass feeders and stockpile reclaim feeders.
A means for extracting material when there are
high head-loads.
Bolt on modular carrier roller support frame.
Allows replacement of carry rollers without splitting
the chain.
Half-pitch sprockets with an odd number of teeth.
Doubles the life of the sprockets.
Closely spaced carrying rollers, using standard
tractor components.
Long wear and maintenance-free service for the rollers.
Hydraulic chain tension adjustment is standard.
Quick method of tension adjustment.
Standard flights are cast work hardening
manganese steel.
Flights resist impact and abrasion.
Extensive branch network for spares and
service support.
Greatly reduces downtime and lets you plan
production confidently.
Process knowledge of technical staff.
Expert help in integrating apron feeders into your plant.
Proven in the field.
A factor in your Duty of Care in selecting equipment.
190190
I
190 190
230 275
230 250
210 210
500 500
275 300
Footnote: Dimensions shown are approximate only and could be subject to change. Use only certified installation drawings for construction purposes.
Dimensions shown are in millimetres.
* Nominal 300mm for Electro-mechanical Drive and 150mm for Hydraulic Drive.
A
Width to suit requirement
A
B
C
G
D
E
F
I
H
Length to suit requirement
H
Apron Feeder Specifications & Dimensions
9
Approx. dimensions
D3 D3
D3
D4 D4
D6 D6
D7 D8
D8 D9
D9D10
D9
D9D11
D11
A
150150
178 178
200 200
205 225
205 260
260 250
290 290
B
158158
165 165
165 165
190 190
190 200
200 275
340 340
C
To suit drive requirements*
D
457457
457 457
528 528
612 700
612 716
716 816
12001200
E
607607
663 663
725 725
877 985
8771046
10461080
14601460
F
864864
1048
1048
1139
1139
1560
1384
1689
1390
16891705
23222322
G
65 65
38 38
60 60
60
60
70 70
100 100
H
500500
600 600
750 750
750 750
7501000
10001000
12001200
I
190190
190 190
210 210
230 250
230 275
275 300
500 500
60
70
Footnote: Dimensions shown are approximate only and could be subject to change. Use only certified installation drawings for construction purposes.
Dimensions shown are in millimetres.
* Nominal 300mm for Electro-mechanical Drive and 150mm for Hydraulic Drive.
11
Terex Minerals Processing Systems
®
North America
Latin/South America
Europe, Africa, Middle East
Australia
+1 (800) 248-3821
+1 (989) 288-3121
+44 (0) 28 82 418 790
+61 3 8551 9300
Hosur, India
Delhi, India
Kuala Lumpur, Malaysia
Bangkok, Thailand
+91 4344 302000
+91 11 4361 0000
+60 3 5631 6199
+66 38 214761
Give us a call to learn more about our extensive equipment range.
www.terexmps.com
Effective Date: March 2011. Product specifications and prices are subject to change without notice or obligation. The photographs and/or drawings in this
document are for illustrative purposes only. Refer to the appropriate Operator’s Manual for instructions on the proper use of this equipment. Failure to
follow the appropriate Operator’s Manual when using our equipment or to otherwise act irresponsibly may result in serious injury or death. The only warranty
applicable to our equipment is the standard written warranty applicable to the particular product and sale and Terex makes no other warranty, express or
implied. Products and services listed may be trademarks, service marks or trade-names of Terex Corporation and/or its subsidiaries in the USA and other
countries. All rights are reserved. Terex is a registered trademark of Terex Corporation in the USA and many other countries. © 2011 Terex Corporation.
Terex® Minerals Processing Systems
Form 25519 A4 (3/11)
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