SPECIALIST EQUIPMENT
CREATING THE SOLUTION A copper mine in Chile wanted a solution that would minimise the effects of power failures on its operations, particularly on its take-up winch that serves a 2,650m-long conveyor. To meet its need, the winch manufacturer asked Svendborg Brakes to develop a controlled braking system that would operate even during a power failure; protecting the life of the belt and other mechanical components of the conveyor.
Te brand, which is part of Altra
Industrial Motion, has extensive experience in the manufacture and supply of intelligent braking and coupling solutions to the most demanding industries. Svendborg Brakes was a logical choice to tackle the challenges presented by this particular project. To develop this innovative solution,
Svendborg Brakes worked closely with the OEM that supplied the winch to the Chilean mine. Tis close collaboration enabled its engineers to complete the project in only two weeks, despite the
uniqueness of the solution that was delivered.
IMPROVED CONTROL Initially, the brake controller used a speed feedback signal to control the tension during operation. However, this is generally a static method that cannot help in the event of power failures. Terefore, Svendborg Brakes decided to apply a torque feedback sensor to monitor the line pull instead. In this way, it is also possible to get a close relationship between the physical quantity being monitored and the actual tension. Te final product enhanced the Model BSFK 527 dual-spring hydraulically released caliper disc brakes with the addition of a Sobo iQ soft braking control. Te latter greatly benefitted the whole system by providing torque-limited braking and a power source in case of a loss of power. During power outages, the UPS backup power source in Sobo iQ would let the braking system operate long enough to allow the conveyor to stop normally. More precisely, when the line pull
reaches the set limit, the brake torque is being decreased by the Sobo iQ controller to make the winch drum slip. In addition, in the event of a communications failure with the Sobo iQ, the unit will activate the highest priority braking ramp. Besides the caliper disc brakes and Sobo iQ, the system also included a hydraulic power unit manufactured in-house by Svendborg Brakes, a brake disc, two dynamometers and an Ameridrives Amerigear FS 209 hub.
A SUCCESSFUL STRATEGY As a result of the positive outcome for the Chilean mine conveyor take-up winch project, the system that was developed is now an integral part of Svendborg Brakes’ Sobo iQ offering. Te company believes it is the only known ‘smart’ low-speed take-up winch that provides parking and tension control during a power failure. Tyler Calvert, application engineer at
Svendborg Brakes’ Model BSFK 527 dual-spring hydraulically-released caliper disc brakes were enhanced by the addition of a Sobo iQ soft braking control
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Svendborg Brakes, says: “Our customer directly benefitted from our deeper understanding of the whole mine conveyor system. Our familiarity with the machinery and the knowledge that brakes form part of a much larger interconnected installation, ensured the development of an advanced product that increased both reliability and cost effectiveness.”
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