TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates to a plough feeder apparatus and method for reclaiming higher capacity of stored bulk material from a bunker.

BACKGROUND OF THE INVENTION

[0002] Plough feeders feed bulk solid particulate material on a belt conveyor from a bunker at a controlled rate. The plough feeders includes plough blades projected in a bunker slot to scoop the bulk solid particulate material from the bunkers and discharge it on a belt conveyor running below. Plough feeders have been successfully used in coal handling plants and other installations for extraction of loose materials from stockpiles, silos and bottom discharge wagon systems. Conventional plough feeders are unable to continuously handle maximum amount of bulk materials. The maximum reclaim capacity of the plough feeder is 3000 TPH. Hence, to achieve higher capacity such as for example, 6000 TPH there is a need to install more numbers of plough feeders on a single coveyor.

[0003] For example, conventional approcahes to handle higher capacity of coal utilize three plough feeders each with 3000 TPH capacity that are placed under the over ground bunker. In such a case to reclaim 6000 TPH of material from the bunker three plough feeders are required in which two plough feeders of 3000 TPH is working and one plough feeders of 3000 TPH as standby. FIG. 1 illustrates a perspective view of three plough feeders PF-1, PF-2 and PF-3 each with 3000 TPH capacity placed under the over ground bunker, in accordance with a prior art. For instance, PF-1 and PF- 2 are working to feed the conveyor i.e., 3000 TPH+ 3000 TPH =6000 TPH and PF-3 is standby parked in maintenance bay-2. If there is breakdown in PF-2 the PF-1 needs to be parked at maintenance bay-1 for maintenance of PF-2. At that instance only PF-3 comes into operation feeding 3000 TPH to the conveyors against required capacity of 6000 TPH. PF-2 creates obstruction for operation in break down. This situation is similar with PF-2 and PF-3 in operation.

[0004] Hence, there is a need in that art to provide a solution to address the above mentioned problems. The present invention relates to an improved twin wheel plough feeder apparatus and method for continuously reclaiming higher capacity of stored bulk material from a bunker, which addresses and overcomes all these problems in a unique and simple manner.

SUMMARY OF THE INVENTION

[0005] The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

[0006] It is, therefore, one aspect of the present invention to provide for an improved twin wheel plough feeder apparatus and method for continuously reclaiming higher capacity of stored bulk material from a bunker, which addresses and overcomes all these problems in a unique and simple manner.

[0007] It is another aspect of the present invention to provide for an improved twin wheel plough feeder apparatus having twin plough wheel which is capable of working in tandem for reclaiming higher capacity of the bulk material and for ease of maintenance. [0008] It is yet another aspect of the present invention to provide for an improved twin plough feeder apparatus and method for continuously reclaiming higher capacity of stored bulk material and is inexpensive, dependable and fully effective in accomplishing its intended purposes.

[0009] In one aspect of the present invention, a method for reclaiming higher capacity of bulk material is disclosed. A pair of plough feeders each having twin plough wheel is installed in a tunnel of an over ground bunker stored with a bulk material. At least one plough feeder is continuously traverse along a reclaim shelf on rails provided in the over ground bunker and the other plough feeder is held in a standby state. The stored bulk material is swept from the reclaim shelf onto a belt conveyor using a plurality of curved arms of the twin plough wheel revolving on a vertical axis. The plough feeder is moved to a maintenance bay located at each end upon detection of breakdown and other plough feeder is traverse along the reclaim shelf to continuously reclaim higher capacity of stored bulk material.

[0010] The reclaim shelf is configured to intercept at an angle of repose to prevent the stored bulk material from flowing over edge of a reclaim table. The twin plough wheels are mounted in an output shaft of a planetary gearbox. An output tonnage of the twin plough wheels is automatically or manually controlled by varying and adjusting the plough wheel speed using a hydraulic motor or Variable frequency motor and the planetary gearbox based on requirement. A first plough wheel arms of the twin plough wheel is oriented in a clockwise direction and a second plough wheel arms in an anti-clockwise direction or vice versa or both the twin plough wheel is oriented in same direction to reclaim higher capacity of the bulk material.

[0011] In another aspect of the present invention, a twin wheel plough feeding apparatus is disclosed which includes a pair of plough feeders each having twin plough wheel mounted on an output shaft of a planetary gear box and installed in a tunnel of an over ground bunker stored with a bulk material. A plurality of curved arms of the twin plough wheel revolving on a vertical axis sweeps the stored material from the reclaim shelf onto a belt conveyor wherein if one plough feeder is parked for maintenance in a maintenance bay located at each end other plough feeder is in operation to continuously reclaim higher capacity of bulk material.

[0012] The twin plough wheels include a travel wheel that is keyed to a travel shaft that are mounted onto the main frame at each ends of the travel shaft. The travel drive is electro-mechanical or may be hydraulic. The reclaim shelf intercept at an angle of repose to prevent the stored material from flowing over edge of a reclaim table. The twin plough wheels are mounted in an output shaft of a planetary gearbox and an output tonnage of the plough wheel is controlled by varying and adjusting the plough wheel speed using a hydraulic motor /Variable Frequency motor and the planetary gearbox based on requirement. The hydraulic power is received in case of hydraulic drive is by a hydraulic power unit mounted on a main frame.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The disclosed embodiments may be better understood by referring to the figures, in which like reference numerals refer to identical or functionally- similar elements throughout the separate views, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.

[0014] FIG. 1 illustrates a perspective view of three plough feeders, in accordance with a prior art;

[0015] FIG. 2 illustrates a perspective view of a pair of plough feeders each having twin plough wheel for continuously reclaiming higher capacity of stored bulk material, in accordance with an exemplary embodiment of the present invention; [0016] FIG. 3 illustrates a flowchart of operation depicting a method for continuously reclaiming higher capacity of stored bulk material from a bunker, in accordance with an exemplary embodiment of the present invention;

[0017] FIGS. 4-5 illustrates a perspective view of a plough feeder apparatus with a pair of plough feeders each having twin plough wheel working in tandem for continuously reclaiming higher capacity of stored bulk material and for ease of maintenance, in accordance with an exemplary embodiment of the present invention;

[0018] FIG. 6 illustrates a cross sectional view of the bunker with the pair of plough feeders each having twin plough wheel, in accordance with an exemplary embodiment of the present invention;

[0019] FIG. 7 illustrates a cross sectional view of the pair of plough feeders each having twin plough wheel, in accordance with an exemplary embodiment of the present invention; and

[0020] FIG. 8 illustrates a top view of the pair of plough feeders each having twin plough wheel for reclaiming higher capacity of stored bulk material, in accordance with an exemplary embodiment of the present invention;

DETAILED DESCRIPTION OF THE INVENTION

[0021] The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.

[0022] In the following, numerous specific details are set forth to provide a thorough description of various embodiments. Certain embodiments may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.

[0023] The claimed subject matter has been provided here with reference to one or more features or embodiments. Those skilled in the art will recognize and appreciate that, despite of the detailed nature of the exemplary embodiments provided here; changes and modifications may be applied to said embodiments without limiting or departing from the generally intended scope. These and various other adaptations and combinations of the embodiments provided here are within the scope of the disclosed subject matter as defined by the claims and their full set of equivalents. Like numbers refer to like elements throughout.

[0024] The present invention relates to a twin wheel plough feeder apparatus and method for continuously reclaiming higher capacity of stored bulk material from a bunker, which addresses and overcomes all these problems in a unique and simple manner. The twin wheel plough feeder apparatus each having twin plough wheel is capable of working in tandem for reclaiming higher capacity of the bulk material and for ease of maintenance. This present invention continuously reclaim higher capacity of stored bulk material and is inexpensive, dependable and fully effective in accomplishing its intended purposes.

[0025] FIG. 2 illustrates a perspective view of a pair of plough feeders (30, 32) each having twin plough wheel (34, 36), in accordance with an exemplary embodiment of the present invention. In general, plough feeder is a heavy duty machine used to reclaim stored bulk materials such as for example, coal that is designed to operate in a tunnel (66) beneath a storage pile. Note that in FIGS. 2-8, identical or similar parts or components are generally indicated by identical reference numerals. In a preferred embodiment, each plough feeder (30 or 32) with twin wheel (34, 36) has 6000 TPH capacity with 3000 TPH for each wheel. If any breakdown occurs in the plough feeder (30 or 32) the plough feeder (30 or 32) is respectively moved to a maintenance bay (1 or 2) located at each end and other plough feeder (30 or 32) is continuously traversed along a reclaim shelf (60) to continuously reclaim higher capacity of stored bulk material (54).

[0026] Referring to FIG. 3 a flowchart of operation depicting a method (20) for continuously reclaiming higher capacity of stored bulk material (54) from an over ground bunker (56) is illustrated, in accordance with an exemplary embodiment of the present invention. The pair of plough feeders (30, 32) each having twin plough wheel (34, 36) is installed in the tunnel (66) of the over ground bunker (56) stored with the bulk material (54), as shown at block (21). At least one plough feeder (30 or 32) is continuously transverse at any point along the reclaim shelf (60) on rails (38) provided in the over ground bunker (56) and the other plough feeder (30 or 32) is held in a standby state, as indicated at block (22). Note that if the plough feeder (30) is working then the plough feeder (32) is held in a standby state and vice versa based on design consideration.

[0027] Referring to FIGS. 4-5 a perspective view of a plough feeder apparatus (15) with the pair of plough feeders (30, 32) each having twin plough wheel (34, 36) for reclaiming higher capacity of stored bulk material (54) is disclosed, in accordance with an exemplary embodiment of the present invention. In a preferred embodiment, the plough feeder apparatus (15) is used in a coal handling plant to handle coal from coal mines. The pair of plough feeders (30, 32) each having twin plough wheel (34, 36) is mounted on an output shaft of a planetary gear box (48) and installed in the tunnel (66) of the over ground bunker (56) stored with the bulk material (54). The bunker (56) is an underground type structure for shelter or for storing coal. The plough feeder apparatus (15) is placed below discharge opening of the over ground bunker (56) and above a belt conveyor (58). Each plough feeder (30, 32) with the twin plough wheel (34, 36) is capable of reclaiming 6000 TPH of bulk material (54) from the bunker (56).

[0028] Note that the plough feeder apparatus (15) is adapted for use with various other types of existing storage facilities, such as silos, bins, open stockpiles or hoppers, as well as with various other kinds of transfer equipment. While the preferred embodiment, shown in FIGS. 2-8 is adapted to reclaim the coal onto the belt conveyor (58), the plough feeder apparatus (15) may also be adapted for use with various types of other conveyors all of which may be used to transport the bulk material (54) to a selected downstream process. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0029] The plough feeder apparatus (15) travel on the rails (38) inside the tunnel (66) with the cone-shaped bunker (56), continuously discharging the bulk material (54) onto the belt conveyor (58) also installed in the tunnel (66). The twin plough wheel (34, 36) includes a plurality of curved arms (52) that is revolved on a vertical axis to sweep the stored material (54) from the reclaim shelf (60) onto the belt conveyor (58). In a preferred embodiment, each twin plough wheel (34, 36) has six arms, each with wear resistant front plate and hard faced tip. The reclaim shelf (60) intercept at an angle of repose to prevent the stored bulk material (54) from flowing over edge of a reclaim table (70). The plough feeders (30, 32) are driven by a pair of hydraulic power unit (40) mounted on a main frame (46) or by Variable frequency drive. The travel wheel (42) are mounted onto the main frame (46) with bearing/bearing housings at each ends.

[0030] An output tonnage of the twin plough wheels (34, 36) is automatically or manually controlled by varying and adjusting speed of the plough wheel (34, 36) using a hydraulic motor (50) or Variable Frequency drive and a planetary gearbox (48), as depicted at block (23). A first plough wheel arms (52) of the twin plough wheel (34, 36) is oriented in a clockwise direction and a second plough wheel arms (52) in an anti clockwise direction or vice versa or both twin plough wheel (34, 36) in same direction to reclaim higher capacity of the bulk material (54), as shown at block (24).

[0031] Referring to FIG. 6 a cross-sectional view of the bunker (56) with the pair of plough feeders (30, 32) each having twin plough wheel (34, 36) working in tandem for reclaiming higher capacity of bulk material (54) and for ease of maintenance, in accordance with an exemplary embodiment of the present invention. The twin plough wheels (34, 36) are mounted in the output shaft of the planetary gearbox (48) and the output tonnage of the plough wheel (34, 36) is controlled by varying and adjusting speed of the plough wheel (34, 36) using the hydraulic motor (50)/Variable frequency motor and the planetary gearbox (48). The reclaim shelf (60) is configured to intercept at an angle of repose to prevent the stored bulk material (54) from flowing over edge of the reclaim table (70).

[0032] The stored bulk material (54) is swept from the reclaim shelf (60) onto the belt conveyor (58) using the plurality of curved arms (52) of the twin plough wheel (34, 36) revolving on a vertical axis, as indicated at block (25). A determination is made whether any breakdown occurs in the plough feeder (30 or 32), as depicted at block (26). If any breakdown occurs, the plough feeder (30 or 32) is moved to a maintenance bay (1, 2) located at each end and other plough feeder (30 or 32) is continuously traversed along the reclaim shelf (60) to continuously reclaim higher capacity of the stored bulk material (54), as shown at block (27). The traversing speed of the plough feeder (30, 32) during reclaiming is lesser than parking speed. The twin plough wheel (34, 36) works in tandem to achieve higher capacity reclaiming of material and for ease of maintenance. [0033] Referring to FIGS. 7- 8 a cross sectional view and top view of the pair of plough feeders (30, 32) each having twin plough wheel (34, 36) is illustrated, in accordance with an exemplary embodiment of the present invention. The plough feeder apparatus (15) ploughs the accumulated bulk material (54) from the bottom of the bunker (56) and feeds it into the moving belt conveyor (58). The bulk material (54) previously stacked and stored in the storage bunker (56) flows via gravitational forces through a discharge opening slides on to table and which is reclaimed by twin plough wheel (34, 36) placed below the storage bunker (56).

[0034] The arrangement of the storage bunker (56) prevents the stored material from flowing over the edge of the bunker (56). The twin plough wheel (34, 36) is also oriented in same or opposite direction to reclaim higher capacity of bulk material (54). In a preferred embodiment, if one plough feeder for example, plough feeder (30) is parked for maintenance other plough feeder (32) is in operation or vice versa to continuously reclaim higher capacity of bulk material (54). When travelling back and forth, the discharge arms (52) of the twin plough wheel (34, 36) dig deeply into the coal through slots arranged in the tunnel (66). Each twin plough wheel (34, 36) is driven by the motor (50) and actuated by the hydraulic units (40)/Variable frequency motor. The plough feeder apparatus (15) provides continuous and control coal flow based on requirement.

[0035] The pair of plough feeders (30, 32) has a maximum capacity of feeding the bulk material for example 6000 TPH so that if one plough feeder (30 or 32) is parked for maintenance other plough feeder (30 or 32) is in operation feeding maximum amount of bulk material (54) to the belt conveyor (58). The plough feeder (30, 32) is continuously traversed or positioned at any point along the storage bunker (56) for maximum flexibility. The speed of the rotary plough wheel (34, 36) is adjusted automatically or manually so that the bulk material feeding capacity is controlled based on requirements. [0036] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.