What is Wagon Tippler ? Components & Working Mode of Wagon Tippler

Introduction to Wagon Tippler

Wagon Tippler can receive, clamp, and tipple BOX/DFC wagons and other types of railway wagons. The wagon tippler empties the wagons by inverting them at a 160 degree angle (Max).

Wagon-Tippler.jpg
wagon tippler

Wagon Tippler Components

The following are the key components of a wagon tippler:

  1. Cradle
  2. End rings
  3. Side Beam (Side Bolster Beam)
  4. Top clamp assembly
  5. Drive system
  6. Wheel Grippers
  7. Wheel Chockers

Cradle

The cradle is a table structure made up of two major girders that are braced together. The major girders on which the wagon is to be positioned will have two rails installed. The cradle is long enough to hold a single broad gauge open wagon (any of the types used by Indian Railways).

Ring End

For rotation, a pair of end rings is attached on the trunion.

The end rings’ centers are reinforced to hold the trunnion shafts, which are supported in turn by pivot bearings resting on foundations. An arm known as the “toe” is linked to each ring and contains the slotted bearing as well as supporting the cradle and wagon during operation. To provide counterweight, a portion of the end ring is filled with concrete. This counter weight cuts down on the amount of effort required when tipping the wagon.

Each end ring has gear sectors positioned on the periphery, which are powered by pinions set on counter shafts.

Side Beam (Side Bolster Beam)

It’s mounted on the side beam to keep the wagon from jerking during the tippling operation. It’s a hydraulic cylinder-actuated device controlled by a PLC O/P through solenoids. After placing the wagon on the cradle in the proper spot, the side support clamp is actuated simultaneously with the wheel gripper operation. This data is sent to the PLC through a Magnetic Limit Switch.

The side support is constructed with the ability to move forward and backward, so that it can move and contact the wagon without putting any strain on the wagon side wall.

Top Clamp Assembly

This structure, which comprises mostly of one bolster beam, two clamp arms, and six transfer beams and hydraulic cylinders, is designed to hold the wagon from the top face in the tipped position.

With the help of a clamp arm and four hydraulic cylinders, the top bolster beam is fitted with the end ring of the wagon tippler. These hydraulic cylinders move the top bolster beam up and down, bringing the top clamps into contact with the wagon’s top faces.

This will allow for proper clamping of wagons of various heights, as well as bulged wagons.

Drive System

Both side drives are used to operate the wagon tippler. Two hydraulic motors are connected to the input side of the helical gear box through geared coupling in the drive unit. Two pinions (placed on the driving shaft) dedicated to each end ring send power to the end rings. The sector gear is fastened to the end ring’s perimeter with a fit bolt. For end ring rotation, the pinions on the driving shaft are attached to the sector gear. The hydraulic motor is powered by hydraulic pressure and flow generated at the drive pit by a power pack.

Wheel Grippers

These are mounted on the tippler table (cradle) to keep the wagons from moving during the tippling process. These are hydraulic cylinder actuated devices controlled by PLC O/P via solenoids. After the wagon is placed on the tippler table, the wheel gripper is triggered.

Wheel-Gripper.jpg

Wheel Chockers

These are situated on the in-haul and out-haul track sides to prevent wagons from rolling into the tippler table by accident (cradle). These are hydraulic cylinder actuated devices controlled by PLC O/P via solenoids. When SAC is traveling with the coupled wagon (single wagon) towards the tippler table, the Wheel chocker is triggered.

wheel-chocker

Automatic Wagon Tippler Operation

Wagon Tippler in Auto mode is controlled by a Cycle Push Button in the Control Desk. After the SAC reaches the DD position and the Wheel Chocker, Wheel Gripper, Side Support, and Weigh Bridge are all operational, this cycle push button function is activated.

In the cycle operation, after the SAC places the loaded wagon over the wagon tippler platform (exact placement is ensured automatically by Magnetic Limit Switch input to PLC), the control desk operator will press a push button (assigned gross weight) to give an input command to the PLC, which in turn gives an output command to the weigh bridge panel for taking gross weight.

After the Weigh Bridge has taken the gross weight, the Weigh Bridge panel will send an input command to the PLC, which will then send an output command to the indicator lamp, indicating that the gross weight has been taken.

The hydraulic pressure switch feedback for the wheel gripper, wheel Chocker, side clamp, and top clamp device will be interlocked in PLC logic. If all of the aforementioned inter-locked requirements are met, the PLC will issue an O/P for the ready tippling bulb, which will begin to glow, indicating that the Tippler is ready to tipple.

Now press the Siren button to notify the folks in the area of the wagon tippler. After the Siren has sounded, press the cycle operation push button, and the wagon tippler cradle will begin to rise. After a specific amount of time has passed after the wagon was started, the top clamping mechanisms begin to move to clamp the wagon. This time lag is based on a tippler rotation of approximately 10 degrees.

At around 65 degrees of rotation, the top clamping device will clamp the wagon. The PLC receives an input from the pressure switch at around 70 degrees of rotation once the clamping devices are fully clamped with the wagon. When the PLC receives the input, it permits the raise process to continue, and the tippler is raised to 135 degrees/set degrees (as required and based on a trial run, the maximum raise degree is set) for complete coal discharge from the wagon, before stopping via the raise limit switch.

The screw cam limit switch controls the degree of rotation. One of the contacts on this limit switch is used to stop the WT raise/lower contactor, while another contact on the same pad is utilized as an input to the PLC to withdraw the raise instruction. After the raise process is completed, there will be a 5-second wait before the wagon tippler begins lowering.

When the wagon reaches an angle of 80 degrees, the de-clamping procedure begins, and the lowering operation is stopped through the lower limit switch, allowing the tippler to return to its usual rest position while the clamps return to their normal position.

Operation of a Wagon Tippler in Manual Mode

Individual equipment can be activated in sequence one by one by triggering the start/stop push buttons supplied in the control desk in this mode of operation. On the Control Desk, there are two push buttons: WT Raise and WT Lower.

Wagon Tippler starts rotating when the WT Raise is pressed, and it stops when the Raise Screw Cam Limit Switch is engaged. In this setting, there is no defined pause period.

Only the Wagon Tippler will come down to its lower position when the operator presses the ‘WT Lower PB’. The tippling cycle is completed in this way. PLC manages the interlocking of particular pieces of equipment with their predecessors.

Operation of a Wagon Tippler in a Local Setting

Only maintenance of the equipment is possible in this mode of operation, and it can be controlled from a local control station in the field. This mode works only if the selection switch on the control desk is set to local and there is no interlocking with other equipment.

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