Project Overview:

This application required a transportable machine to provide a safe and effective means to pull/haul conveyor belt around multiple conveyor systems at a client’s iron ore mine operation in Western Australia’s Pilbara. Years of design and field experience were leveraged to develop a solution that featured;

• A 20 Tonne (200kN) unaided line-pull capacity with lockable tension limit selections (ie 10, 15 & 20 Tonne limit selections)

• Real-time measurement of belt tension with operator feedback

• A single-piece layout reducing transport cost and set-up time

• A drive & control system integrated into the single-piece machine frame, reducing set-up time and complexity

• Direct electric drive w/ VSD control

• A dual pressure-compensating hydraulic pinch-roll system (lowering normal & shear forces on pulley lagging)

• A robust, light & compact design weighing in at 21.6 Tonne

 

Scope of duties performed:

• Application research and conceptual design lead

• AS 4024 Design Risk Assessment lead (SiD RA’s throughout project)

• Development of safety performance level requirements

• Development of design loads in accordance with AS1170, AS1418, AS3990 and other relevant industry standards

• Drive system mechanical design inc, belt tensions, demand power, pinch roll system requirements & other.

• Selection of gearbox, AC drive motor, pulley bearings, couplings & other drive components

• Coordinating and leading the affiliated design team to complete structural checks of the machine including; structural frames, pulley’s & rollers, pinch roll system, other key load-bearing components

• Functional description development

• Co-design of electrical & control system

• Drafted equipment specifications for supply tenders (ie electrical system, steel structures & mechanical package, pulley & roller package, hydraulic system etc)

• Base design of hydraulic circuits for pinch roll mechanism. Coordinate with hydraulic supplier to complete design & component selection.

• Design reviews & approvals

• Authored the equipment IOMM (Installation, Operation and Maintenance Manual)

• Performed AS3007 Audit

• Calculated the system arc fault rating & associated risk category

• Oversaw the construction and commissioning of the machine including electrical and hydraulic systems, and live testing of the belt tension measurement system