Wagon Tippler in Coal Handling Plant

Spread the love

Wagon Tippler is an industrial equipment also called “rack tippler” or “railway wagon unloader” is a huge machine used to empty heavily loaded wagons from the wagons of a train by tipping them. Wagon tippler is mainly seen in power plants, steel mills, cement factories and other industrial establishments where materials such as coal, ore, limestone, or sand are used in large quantities. Tippler is driven by hydraulic drive or electro-mechanical drive or hydro mechanical drive.

How does a wagon tippler work?

Wagon tippler is an important equipment in coal handling plant which is used to unload coal from railway wagons. It is a huge machine. When the wagon loaded with coal comes on the tippler, it is securely clamped. After this, the frame of the tippler slowly rises up and the wagon tippler inverts the wagon at a certain angle so that all the coal falls down and gets emptied into the bunker. Once the coal is completely unloaded, the frame of the tippler comes back to its original position and the next wagon is ready to be emptied. In this process, safety is important, so the tippler has many safety devices and sensors that help prevent potential hazards.

Types of Wagon Tipplers

There are two primary types of wagon tipplers:

Side Discharge Tippler: The wagon is tilted sideways, and the coal is discharged to a side hopper.
Rotary Tippler: The wagon is rotated 180 degrees, and the coal is discharged into a bottom hopper.

Components of a Wagon Tippler

1.Tippler Platform:

The tippler platform is designed to have the capacity to withstand extreme loads. It is usually made of high-quality steel that can effectively handle tension, bending and shear forces. The thickness and structural design of the platform are determined based on the load and size of the wagon.

2.Clamping Mechanism:

The clamping mechanism is an important safety component of the wagon tippler. It ensures that the railway wagon is securely clamped on the tippler platform, so that no mishaps occur during the coal unloading process.

Types of Clamping Mechanism:

Hydraulic Clamp: This type of clamp uses hydraulic cylinders that generate pressure to hold the wheels or body of the wagon. These clamps are fast and effective, and can be easily controlled by the operator.

Mechanical Clamp: These clamps hold the wagon using screws, levers or other mechanical devices. They are generally slower than hydraulic clamps, but can be more reliable.

3.Combined System:

Some tipplers have a combination of hydraulic and mechanical clamps, which increases both safety and efficiency.

Function of Clamping Mechanism:

Locking: When the wagon comes onto the tippler platform, the clamping mechanism is activated. The clamps firmly hold the wheels or body of the wagon.
Holding: The clamps hold the wagon securely until the tippler platform is in the tilting position.
Releasing: Once the coal is completely unloaded, the clamping mechanism is released and the wagon can be removed.

4.Hydraulic or Pneumatic System:

Hydraulic or pneumatic systems play a vital role in the operation of a wagon tippler. These systems provide the power required to tilt the platform, operate the clamps and perform other essential functions.

Hydraulic System Function: The hydraulic system uses the pressure of fluid (hydraulic oil). A pump pumps the fluid at high pressure, which pushes the piston in the cylinder. The motion of the piston is used to perform any mechanical work, such as lifting a platform or closing a clamp.

Advantages: Hydraulic systems are powerful, precise and controllable. They can handle heavy loads and provide different speeds and pressure levels.

5.Pneumatic System

Working: Pneumatic systems use compressed air. A compressor compresses the air, which is then controlled by valves in the cylinder. The compressed air pushes the pistons, causing mechanical work.

Advantages: Pneumatic systems are clean, safe and easy to maintain. They are usually less complex than hydraulic systems.

6.Tilting Frame:

It is a support structure for the tippler platform. It is strong and allows the platform to be tilted at a specific angle up to 180 degrees. This ensures complete discharge of coal from the wagon.

7.Drive Unit:

The drive unit is an important component of the wagon tippler that provides the power required to rotate the tilting frame and lift and tilt the wagon.

Types of Drive Units:

Electric Drive Units: These units are driven by electric motors. They are the most common type of drive unit and are available in various sizes and powers.

Hydraulic Drive Units: Powered by hydraulic pumps, these units use hydraulic fluid to rotate the tilting frame. They provide smooth and controllable operation.

Pneumatic Drive Units: Powered by compressed air, these units use pneumatic energy to rotate the tilting frame. They are lightweight and less complex.

8.Positioning Equipment:

Positioning equipment is an important component of the wagon tippler that helps to position and secure the railway wagon correctly on the tippler platform.

Types of Positioning Equipment:

Rail Guides: These devices provide guidance to keep the wheels of the wagon on the correct track. They help to keep the wagon centered on the platform.

Stoppers: These devices prevent the wagon from moving forward or backward. They help to keep the wagon in the correct position.

Wheel chocks: These devices are used to keep the wheels of the wagon fixed on the platform. They prevent the wagon from moving.

Sensors: Some modern tipplers have sensors that detect the position of the wagon and help in automatic positioning.

9.Control System:

The control system is an important part of the wagon tippler that controls and coordinates its operation. It ensures that the tippler works safely, efficiently and effectively.

Functions of the Control System:

Operator Interface: It provides an interface for the operator to control and monitor the tippler. It usually consists of buttons, switches, displays and other control devices.

Sensors and Data Acquisition: It collects data about the wagon position, tilt angle, speed and other important parameters.

Logic and Control Algorithms: It analyzes the data and makes decisions to control the operation of the tippler. It includes

Read More-