SHOVEL EKG-12A Standard bucket capacity - 1 m Working bucket load - 0 t Working weight of the machine - 672 t
TECHNICAL SPECIFICATIONS The mining shovel EKG-12A (spec. TU 141-005-00210571-2000) offered by Uralmashplant JSC is designed for mining and loading ore and overburden rock into transport vehicles (including dump cars) or in dumps. Working conditions and fields of application Rock characteristics. The EKG-12A is designed for mining I and II rock categories without preliminary loosening, and III, IV, and V rock category with preliminary loosening. Other conditions: The EKG-12A model is designed for working at the height up to 1000m above the sea level. Working environment shall be free from conductive or explosive dust. Climatic conditions: Climatic modification of the machine is У1 according to GOST 15150-69. Working temperature range: Max. temperature: Min. temperature: Bucket capacity: + 45 С 45 С Capacity of the standard bucket is 1m (according to SAE). GENERAL OPERATING REQUIREMENTS Design service life of the machine is min. 20 years provided that the user observes all operation and maintenance regulations set forth in the manufacturer's manuals. The workface shall be prepared by blast-loosening (except for I and II rock categories). Average lump size of loosened rock shall be not more than 250 mm. Max. lump size is 800 mm. Working slope angle of the machine shall be within 5 degrees. The machine shall be controlled by a trained operator. It is necessary to observe the manufacturer's requirements set forth in the operating documentation when operating the machine. Theoretical output of the machine equipped with the standard bucket (according to GOST 4.77-85) is 1660 m /h. Design average overhaul period is min. 60000 working hours including time for moving the machine and preparing ramps. The yoke of the bucket is equipped with a balance pulley block fitted on a rocker. This assembly ensures uniform distribution of loads between four lines of the hoisting rope. FRONTAL EQUIPMENT Frontal equipment design: rigid rack-type crowd mechanism with double-beam stick and sheave-less bucket suspension. This design ensures rigid fixation of the bucket when cutting. Bucket. Capacity: Design: Material: Bucket door brakes: Bucket teeth: 1m (according to SAE) cast and welded. cast front wall is made of high-manganese steel. welded rear wall is made of low-alloyed steel. disc brakes mounted on the rear wall. secured on the front wall lip with bolts. 2
SHOVEL EKG-12А WWW.URALMASH.RU Boom and stick Stick design Boom design Boom suspension Crowd mechanism configuration all-welded box-section stick. Forged gear racks are welded to the bottom surface of the beams. all-welded box-section boom made of heavyduty steel. An axle with boom point sheaves is mounted in a bore in the boom end. the boom is suspended on four guy ropes. Crowd mechanism single-motor mechanism. A two-stage gearbox is built into the boom. Bearings of drive and intermediate shafts are mounted in bores in the boom body. All shafts of the mechanism are mounted in rolling bearings. All saddle bearings are supported (on their inner side) by sliding bearings flexible coupling pneumatic brake. Gearing lubrication Maintenance platforms Bucket door winch oil bath. located near the crowd mechanism and in the head part. mounted on the boom. The unit consists of an electric motor, a coupling, a single-stage gearbox, and a drum. Revolving platform Design Hoisting winch Swing mechanism Leg MECHANISM AND EQUIPMENT OF REVOLVING PLATFORM the platform consists of two bearing parts, a counterweight assembly, and side platforms. The bearing parts and the counterweight assembly are connected with heavy-duty bolts. four-motor single-gearbox winch with two cantilever drums secured on a shaft with keys. The winch is Pneumatic system equipped with pneumatic brakes. Hoisting rope lines are secured on the drum with retaining plates. Application for driving brakes and pneumatic tools. Two similar air compressor the swing mechanism consists of four similar units units are installed with a common 1 consisting of an electric motor, a planetary gearbox, and m - capacity air collector a shaft each. Gearings are lubricated by a circulating oilbath lubrication system. The units are located Air supply air is supplied to individual units symmetrically in order to avoid generating stress on a central trunnion bearing. consists of hinged front and rear frames. Equipment on the platform: Movable electric hoist (l/c: 500 kgf ) for lifting small loads on the machine or lowering them down. Portable manual hoist. Main and auxiliary electrical equipment. through pneumatic distribution valves electrically controlled from a panel in the operator's cabin. Compressed air is supplied to the carriage brakes through a swivel joint (rotary pneumatic connection). Filtering and consists of two high-power ventilation unit centrifugal fans and inertial dust separators. The unit maintains pressure differential in the operator's cabin.
Swing gear & bearing assembly Design central trunnion, roller circle, and gear rim. Central trunnion secured in the bores of the frame with a nut (lower bore) and a collet (upper bore). Roller circle it has a heavy-duty detachable cage centered on the central hub. The cage carries axles with conical singleflange rollers. The rails are made of forged billets. Gear rim solid-forged. It is secured on the bottom frame with pressfitted bushings. Free access to the fastening assemblies of the rim is provided from inside of the bottom frame. CABIN AND HOUSING Housing Rigid frame consisting of vertical supports and horizontal beams. Cover plates are bolted to the supports. The roof consists of separate welded sections. Quick detachable doors are provided above the compressor unit, swing mechanism machinery, and the hoisting winch. The housing is provided with two doors. An access ladder is located on the right platform. Cabin Design Working compartment Rest compartment two-deck cabin. The bottom deck houses a workbench and racks for tools and small spares. The top deck consists of two compartments: a working compartment and a rest compartment. There is also a platform for the maintenance of left and right windows. houses a control station which consists of the adjustable operator's seat with stepless control joysticks and the control panel with signal devices and controls. houses lockers, seats, and a table. The working compartment can be accessed from the rest compartment. The top deck of the cabin is provided with air conditioning and filtering system. CARRIAGE Cable drum Drum capacity is up to 50 meters of cable if winding in two layers. The drum with a drive is mounted on a separate frame attached to the carriage. The drum is equipped with a device for uniform cable laying. Carriage Design Tracks Track drive Brakes Electric motors Track takeup device hydraulic device driven by a separate pump unit. Track links Lubrication two-track carriage with separately-driven tracks. tacks with large diameter rollers. With raised drive sprockets and support rollers. the drive consists of two electric motors, two mounted two-stage spur gearboxes, and two doublestage gearboxes built into the track frames. pneumatic shoe brakes. the motors are installed horizontally on a special bracket. They are provided with forced ventilation facilities to ensure nearly unlimited duration of the propel drive duty cycle. 1800 mm-wide lings made of high-manganese steel with machined track springs. Of gearboxes: oil bath. Of drive shaft rolling bearings and takeup device sliding surfaces: lubrication by a lubricating unit. 4
SHOVEL EKG-12А WWW.URALMASH.RU ELECTRICAL EQUIPMENT Main drives - hoist, crowd, swing, and propel drives, are designed on the basis of transistor converter motor scheme: MCCs are manufactured by "Joint power" company; Main drive motors: Hoist drive: DPE-400-1/1U1 4 motors; Crowd drive: DPE-400-1/2U 1 motor; Propel drive: DPE-50-2/1U1 2 motors; Swing drive: MPVE 120-750U2-M 4 motors; Auxiliary transformer: dry-type transformer TSZE-250/UHL1. Information system, of the machine monitors main performance parameters of the shovel and perform the following functions: Monitoring the temperature of hoist and crowd unit drive shaft bearings; Monitoring the main drive motor bearings and MCC cabinet bearings temperature; Monitoring main drive motors cooling air flow; Monitoring the swing mechanism oil temperature in the circulation system; Monitoring the swing mechanism oil flow in the circulation system; Monitoring the main drive control system parameters; Monitoring the compressed air pressure in the pneumatic system. Monitoring the automatic lubrication system operation. Monitoring the machine slope angle in transverse and longitudinal planes. Measuring the air temperature inside and outside of the operator's cabin. Measuring the weight of rock in the bucket. Displaying and recording the list of messages about failures, events, and system errors with dates and times. The bucket door and cable drum drives are equipped with DC motors fed from a common static rectifier. The fans, compressors, heaters, and pumps of the machine are driven by 220/80V AC drives fed from a step-down transformer. The machine is equipped with a working equipment protection system, that ensures: Boom protection from collision with the bucket (bucket lift limitation) and the handle above the crowd shaft (handle movement limitation). Limitation of lateral loads when cutting Overhoist protection Rope unreeling length limitation Min. 5 surveillance video cameras. The machine housing is provided with LED lighting facilities. The machine is supplied with a laptop with software and cables for connecting to different units. LUBRICATION SYSTEM Grease lubrication system: Automatic; Lubrication points on machine units and assemblies are automatically lubricated with grease. Bucket bushings: are lubricated with a detachable grease gun. 5
INFORMATION SYSTEM The information system IS12 is designed for mining shovels EKG-12A as a facility for collecting, handling, and displaying information about main performance parameters to the user. The system is designed for the automation of the equipment operating and diagnostics processes, as well as handling, storing, displaying, and recording the performance parameters of the machine. FUNCTIONS OF THE IS12 The use of the IS12 allows the user to: Increase the efficiency of the machine operation due to on-line production process adjustment based on accurate information about the machine performance during a shift or a month linked to the name of the machine operator; Increase the operator's awareness about the machine equipment condition and the machine output per shift; Ensure longer service life and higher reliability of the equipment. 1. Temperature monitoring: 8. Monitoring the parameters of the automatic grease temperature of the main drive bearings lubrication system: temperature of the crowd gearbox shaft bearings monitoring the condition of the system components (feeders and pump motors); temperature of air in the operator's cabin monitoring the grease level in tanks. temperature of air outside the cabin. 9. Measuring the weight of rock in the bucket. 2. Monitoring the compressed air pressure in the pneumatic system. 10. Recording the machine output per shift, month, or year linked to the name of operator:. Monitoring the oil flow in the swing mechanism gearbox lubrication system. recording the weight of loaded rock; 4. Monitoring the machine slope angle in transverse and recording the quantity of loaded trucks; longitudinal planes. recording the time of performing primary and auxiliary 5. Measuring the rotary platform swing angle. works, movement time, and downtime; 6. Recording the working time of the electrical and recording active and reactive power consumption. mechanical equipment. 11. Collecting, handling, and storing actual performance 7. Monitoring the operation of the main drive control data. system operation and the automatic protection system. 12. Analyzing collected data about the condition of the machine equipment. Generating, displaying, and storing a list of warning and emergency messages with their time and dates. 1. Displaying required information on the operator's monitor installed in the cabin. 6
SHOVEL EKG-12А WWW.URALMASH.RU SUBGROUPS OF IS12 FUNCTIONS Diagnostic functions monitoring the temperature of the main drive bearings; monitoring the Temperature of the crowd gearbox shaft bearings; monitoring the Temperature of the crowd gearbox shaft bearings; monitoring the compressed air pressure in the pneumatic system; monitoring the oil flow in the swing mechanism gearbox lubrication system; monitoring the parameters of the automatic grease lubrication system; monitoring the limit levels of controlled parameters. Generating audible alarm signals and on-screen warnings; predicting possible emergencies basing on the analysis of available data about the actual condition of mechanical and electrical equipment. Video camera Gate Gate Panel PC with 15" screen Video camera Electricity meter Information functions measuring, calculating, and storing (even with no primary power supply) process and technical data about the machine performance; HMI; manual input of information required for setting the operating mode and basic data; generating and displaying collected information and diagnostic data about the machine performance on the operator's screen in a userfriendly style. The information can be displayed under the operator's request or automatically depending on certain conditions. The information is visualized on different system screens; storing the machine performance data for a shift, month, or a year, with indication of the operator name; storing the list of all emergency and warning messages with indication of their dates and times. Video camera Video camera Gate Video camera Main and auxiliary drive control system Inclinometer Converter Gate Carriage Converter Temperature transducers Temperature transducers Temperature transducers Digital sensors Functional diagram of the IS12 information system 7
N K C J A I H B L ЭК Г-12А G E D M OPERATING PARAMETERS Main bucket capacity, m (SAE J67 Bucket capacity range, m [ ] Working bucket load, t[ C ] Max. bucket sheave force, t[ C ] Crowd force, max, t[ C ] Time of working cycle, s[ C ] Digging height, max, m [ C ] Digging radius, max, m [ D ] Clean-up radius, m [ Е ] Dumping radius, max, m [ В ] Dumping height, max, m [ А ] )[ C ] 1 10-16 0 125 6 26 15 21 14, 18,5 10 MASSES AND OVERALL DIMENSIONS Working mass, t[ G ] Mass of ballast, t[ G ] 2 Ground bearing pressure, MPa (kg/cm ) [ G ] Height of boom point sheaves, m [ G ] Height of A-leg, m [ K ] Max. clearance radius over boom point sheaves, m [ H ] Max. clearance radius over revolving platform, m [ I ] Clearance under revolving platform, m [ J ] Clearance under lowest point, m [ M ] Operator's eye level, m [ N ] Overall width, m [ L ] 672 75 0,22 (2,25) 16,51 12 14,99 9,,14 0,575 8,2 11 8
SHOVEL EKG-12А WWW.URALMASH.RU Crowd mechanism type Stick design Boom design Boom sheave diameter, mm Electric drive type Voltage, kv Frequency, Hz Main transformer power, kva rack double-beam stick single-beam boom 210 transistor converter - motor 6 50 1250 FRONTAL EQUIPMENT ELECTRIC EQUIPMENT ELECTRIC MOTORS OF MAIN DRIVES Drive Power, kw Speed, rpm Qty, pc Hoist Crowd Swing Propel 200 200 120 175 450 450 750 450 4 1 4 2 GEARBOXES Gearbox Propel Hoist Crowd Swing Design Two-stage in-line Two-stage in-line Two-stage in-line Two-stage planetary Qty, pc 2 1 1 4 Length, m Width, m Design Gear rim diameter, mm number of teeth / module 1,4 9,2 with conical rollers 4907 162/0 REVOLVING PLATFORM SWING GEAR & BEARING ASSEMBLY Design Overall length, m Overall width, m Track gauge, m Track width, m number of links pitch of links, mm Speed, km/h two-track mounting with large diameter rollers 10,495 9,09 7,29 1,8 46 500 1,1 PROPEL MECHANISM 9
ROPES AND GUY STRANDS Structure Type Qty, pc Diameter, mm Length, m Hoist GOST 2 52 8 Boom suspension Guy strand 4 70 14,78 Bucket door opening Auxiliary winch GOST GOST 1 1 15,5 1,5 20 250 MAIN DRIVE MOTOR PARAMETERS Motor Type Power, kw Speed, rpm Q-ty, each Hoist motor DPE-400-1/1U2 200 450 2 Crowd motor DPE-400-1/2U2 200 450 1 Swing motor Propel motor Dipper door opening motor Cable drum motor MPVE 120-750U2 DPE 50-2/1U1 D 1 UHL1 D 12 UHL2 120 175 8 2,5 750 450/1000 870 1180 4 2 1 1 экг-18 10
SHOVEL EKG-12А WWW.URALMASH.RU Overall dimensions of machine units 12M BUCKET Height, mm 070 Width, mm 640 Depth, mm 2890 Weight, t 27 HANDLE Height, mm 1000 Width, mm 20 Length, mm 10700 Weight, t 18, BOOM Width, mm 2500 Width with mounted equipment, mm 955 Length, mm 16570 Weight, t 62,1 A-LEG Height, mm 9000 Width, mm 4000 Length, mm 6000 Weight, t 8,9 CRAWLER ASSEMBLY Height, mm 1910 Width, mm 250 Length, mm 10285 Weight (of assembled frame), t 6,6 TRACK Link height, mm 82 Ling width, mm 710 Link length, mm 1800 Weight, t 6, 11
117 200 125 20 BOTTOM FRAME Height, mm 194 Width, mm 4180 Length, mm 4200 Weight, t 26, PROPEL GEARBOX Height, mm 2190 Width, mm 1750 Depth, mm 1255 Weight, t 4,99 OPERATOR'S CABIN Width, mm 2460 Height, mm 5220 Length, mm 490 Weight, t 7,5 CABLE DRUM Height, mm 1850 Width, mm 440 Weight, t 4,7 HOIST WINCH DRUM WITH CABLE Diameter, mm 150 Width, mm 770 Cable diameter, mm 52 Weight (w/o cable), t 2,8 GEAR RIM OD, mm 4907 Height, mm 5 Weight, t 8,6 12
SHOVEL EKG-12А WWW.URALMASH.RU Overall dimensions of machine units CURRENT COLLECTOR ENCLOSURE Height, mm 091 Weight, t 0,64 BEAM CRANE Length, mm 625 Height, mm 1128 Weight, t 0,41 ROLLER CIRCLE Height, mm 240 Diameter, mm 4000 Weight, t 8,5 SWING MECHANISM Height, mm 950 Weight, t 21,5 VENTILATION UNIT Height, mm 272 Width, mm 7925 Weight, t,02 1
4 0 8 1.5 ДМ8008-ВУф 12 2 kgf/cm 16 FRONT PART OF THE REVOLVING PLATFORM Height, mm 1665 Width, mm 456 Length, mm 6800 Weight, t,5 COUNTERWEIGHT ASSEMBLY Height, mm 100 Width, mm 285 Length, mm 845 Weight, t 12 MIDDLE PART OF THE REVOLVING PLATFORM Width, mm 4500 Height, mm 1070 Length, mm 4880 Weight, t 17 HOIST WINCH GEARBOX Height, mm 250 Width, mm 200 Length, mm 400 Weight, t 29,4 AIR COMPRESSOR UNIT Height, mm 1792 Width, mm 146 Length, mm 2172 Weight, t 1,77 CENTRAL TRUNNION Diameter, mm 500 Height, mm 2410 Weight, t,1 14
WWW.URALMASH.RU NOTES SHOVEL EKG-12А 15
ABOUT US Uralmashplant is one of the leading Russian machine-building plants. For more than 80 years Uralmashplant has been a key provider of basic machinery for mining, chemical, metallurgical, construction, oiland-gas, and power engineering industries, since fundamental national industries have originated here, at the Ural heavy machinebuilding plant. The trademark "UZTM" is well-known all over the world. The plant supplies its products to CIS countries, Western and Eastern Europe, Middle East, South and Southeastern Asia, Africa, North and Latin America. Uralmashplant has its own highly efficient design center. The plant comprises welding, machining and assembly, heat-treatment, and toolmaking facilities. Uralmashplant offers complex solutions from technology development and engineering to supply, installation, and maintenance services. Uralmashplant offers to its customers highly-effective, reliable, low maintenance, energy-saving, and highly automated equipment designed with a glance to actual ecological requirements. MAIN PRODUCTS Mining equipment: crawler-type excavators, walking and crawler-mounted draglines, jaw and cone crushers for all reduction stages, ball and rod mills, autogenous and semi-autogenous mills, crushing and screening plants for producing cubiform particles. Metallurgical equipment: Lifting and handling equipment: sintering equipment, heavy metallurgical cranes, indurating equipment, lifting equipment for nuclear power plants, rolling mill rolls general-purpose special and EOT cranes. CONTACTS 620012, Pervoi Pyatiletki Sq., Ekaterinburg, Russia E-mail: mail@uralmash.ru Fax: +7 (4) 6-60-40 Information Service: +7 (4) 6-69-79 Sales Direction +7 (4) 27-59-1 Procurement and Logistics Direction +7 (4) 6-69-01 Press Center +7 (4) 6-60-54 Museum of Uralmash History +7 (4) 27-10-6