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BRUKS Circular Overpile Stacker Reclaimer


BRUKS Circular Overpile Stacker Reclaimer

A Circular Overpile Stacker Reclaimer is used to conveniently store bulk materials in an outside or inside pile in an organized manner, for automated reclaim.



BRUKS Circular Overpile Stacker Reclaimer

The BRUKS Circular Overpile Stacker Reclaimer reduces the space needed to store volumes of materials by organizing the process into a semi-circular pile arrangement. Rather than pushing materials around with dozers, the piles can be arranged so that the oldest materials are reclaimed first (FIFO), and are not trapped at the bottom of the pile and are reclaimed last. Blending occurs during the stacking and reclaiming phases, reducing variability in the pile. Chip quality is preserved by not driving over the pile with wheeled or tracked vehicles.

The BRUKS Circular Overpile Stacker Reclaimer is designed in versions ranging from less than 1 million cubic feet of live storage, to over 6 million cubic feet.

The lower center support ring supports the Reclaimer Main Frame, which is a machined ring mounted to the concrete foundation. This supports the double roll thrust bearing. The machine is all above grade installation. Between the support ring and the reclaimer mainframe is the primary thrust bearing, equipped with external gear teeth. The reclaimer main frame is of a heavy structural design and is the primary structure for the machine.

Located on the main frame is the:

  • Electrical Room
  • Reclaimer Chain Drive
  • Lubrication Header (By Others)

The Electrical Room houses the PCP, PLC, VFD’s, and Lighting Panel. It is an insulated single unit with an isolated control cab complete with industrial environmental controls. The heating and cooling unit is of sufficient capacity to maintain the temperature at the level required by all devices. It is shipped to the job site pre-tested and pre-assembled in one piece. Also included are two access doors and fluorescent light fixtures which are mounted in the ceiling providing ample lighting to all areas of the control room.

The Reclaimer Chain Drive is typically a shaft mounted type gear reducer with a motor delivering power to the reclaimer drive shaft. The drive shaft is designed with heavy-duty roller bearings and heavy-duty conveyor chain sprockets. The reclaimer chain includes vertical rollers and is designed to the specifications of BRUKS® Rockwood.

The Reclaimer Boom Hoist is mounted on the center of the machine. The hoist is typically a Demag type design.

The grouped Lubrication Headers (by others) for the lower and intermediate bearings are located at the mainframe level.

The hoist platform is mounted to the main frame on the centerline of the machine. This structure also houses the reclaimer drive shaft and protects against dusting caused by the reclaimed material dumping into the chute. Easy access for maintenance to the drive shaft arrangement is achieved with this open type design.

The Reclaim Inclined Pan and Chute are both designed for free flow of material and maximum wear life. Both are designed with no obstructions and are made of wear resistant AR plate. The reclaimed material is pulled up the reclaim pan located on the centerline of the machine via the reclaim chain and rakes. The rake design also includes the use of wings, or a curved profile to help direct the material into the pan and to increase the capacity.

The Stacker Support Column is supported off the Hoist Platform and the main frame. The machined upper surface of the cone is bolted to the intermediate double roll slew bearing.

The intermediate Torque Arm Support Column is machined on both ends. It bolts to the intermediate bearing and the upper thrust bearing equipped with external gear teeth. The torque arm platform is bolted to this column.

The Torque Arm Platform provides access to the thrust bearing and the slewing drives. Access to this area is achieved via a ladder on the last conveyor bent prior to the machine.

The Stacker boom is a truss structure. It is attached to the in-feed conveyor support via a pivot shaft and pillow block bearings. Mounted on the truss structure is the conveyor belt and idlers. Aluminum covers cover the stacker belt. The stacker counterweight is supported off the back of the stacker boom. The stacker belt conveyor drive consists of one shaft mount gear reducer combined with motor. Two heavy-duty cylinders control the luffing of the stacker. A local hydraulic unit operates the cylinders.

Slewing is achieved through electromechanical drives. Pinion gears are mounted on the output shaft of the drives, which engage the bearing’s external gear teeth.

The stacker boom is attached to the fixed center column via a double roll thrust bearing with external gear teeth.

The stacker is provided with ample walkways and access platforms to all areas of maintenance. Access to the stacker is achieved via ladder from the torque arm platform.

Electrical and Controls

The PCP (Power/Control Panel) is located in the Electrical Room housed in a NEMA 12 enclosure. All necessary I/O blocks, relays, timers, starters, and terminal blocks are pre-wired and shop tested to terminals ready for field connection. Controls are designed in accordance with BRUKS Rockwood standards for manual and automatic operation.

Programming for the central programmable controller (PLC) and testing of the control panel will be done prior to shipping. An Allen Bradley PanelView Plus touch screen operator interface unit will be supplied for local operator control. The control and power cables (leads) enter the PCP and control enclosure at the bottom of the control cab.

Continued Limited remote control signals from off of the stacker / reclaimer will be accepted by the BRUKS Rockwood standard control design. Our design preference would be to interface to the customer’s remote control systems via an Ethernet Control Allen Bradley ControlLogix 1756-L61 programmed with RSLogix 5000. BRUKS Rockwood is not responsible for any design of controls off of the machine. Included in the standard supply of BRUKS Rockwood is an anti-collision system to prevent collision between the stacker and reclaimer. Included in this system is a series of properly placed limit switches in combination with PLC program logic.

Electrical System

Included, as part of our supply, is the complete electrical design of the power and control system, including motor controls. The BRUKS Rockwood stacker reclaimer is controlled by a ControlLogix PLC housed in a NEMA 12 Cabinet. The BRUKS Rockwood Stacker Reclaimer PLC Enclosure, PCP, and Drive cabinets are assembled, programmed, prewired and tested before shipment. The PLC communicates interface information with a remote plant control system via an Ethernet interface to exchange material handling interlock information, start stop signals, and reclaim rate. Our system can be setup to coordinate reclaim rates between two machines to blend mixtures of reclaimed material according to a rate signal to meet material demand requirements. With the Ethernet interface we propose to pass all alarms from the Stacker/Reclaimer to the remote control system for display by the customer in the remote control or DCS system. The local on machine operators interface is a Panelview Plus programmed with RSView Machine Edition software. The ControlLogix PLC would be programmed with RSLogix5000. The owner would be responsible for procuring his site software licenses to support the above. Our personnel have their own software for troubleshooting and programming, but this proposal does not include providing these software licenses to the owner. The Owner must have his own Software License, Maintenance, and support agreements with Allen Bradley as these software items need must be maintained under the owner’s site license agreement. This contract or agreement with Allen Bradley is necessary so that the correct versions of the software are maintained at the site after our work is complete.

Our design uses DeviceNet for interface to the slewing drives and reclaimer Variable Frequency Drives. If it desired to have DeviceNet interface to the PCP we can provide a quotation for that option as an adder to our base price. At this time our design has a hardwired I/O interface to the PCP. The VFD’s we propose to use would be AB Powerflex 70

with the optional Safe Off Board included. The reclaim rake drive we propose would utilize an Allen Bradley PowerFlex 700. Our VFDs have line side reactors included in our control cabinets with line side fuses and circuit breakers.

Control System

The operator's interface to the control system will be a Color Graphic Allen Bradley Panelview touch screen terminal.

All programming for the PLC is included with the Program documented with Allen Bradley ControlLogix programming software. The PLC documentation will contain a table of contents, description of interlocks above each rung, element labels, coil names, motor numbers, equipment numbers, switch numbers from elementaries, and device numbers to tie in to the electrical drawings for a complete documentation system to facilitate in ease and speed of troubleshooting. The color graphic terminal is programmed.

All programming will conform to BRUKS Rockwood in-house standards including the use of BRI tag numbers

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