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LONGWALL MINING TECHNOLOGY

Beam Stage Loaders

Beam Stage Loader

PERFECTLY MATCHED TO THE FACE CONVEYOR

TAILOR-MADE SOLUTIONS

Entry conveyor or stage loader pans are normally of the same type as used in the face. These are normally wider than the Armored Face Conveyor ( AFC). While the return roller is integrated into the cross-frame design, the head drive frame of the stage loader is pensionable using hydraulic cylinders.

The crusher, usually an impact roller, is integrated into the stage loader design. The following gooseneck lifts the stage loader discharge over the belt tail piece. Belt tail pieces are available in fixed-, skid- or crawler mounted versions with an overlap of up to 3.5 m (11.5 ft), all equipped with self-cleaning return drums. The operator can use any specified belt width in this tailor-made equipment.

HBT stage loader and crusher are completely matched to the face conveyor, both with higher capacity to prevent bottlenecks.

Tailor-made belt tail piece for required capacity and belt dimensions, allowing the belt tail piece to handle longitudinal and lateral entry gradients, automated chain tensioning system.

BSL Line Pans

Entry conveyor or stage loader line pans are normally of the same type as used in the face (HBT line pan models PF3, PF4, PF6, PF7and PFHD). These are normally wider than the AFC line pans.

Line Pan PF3

Line Pan PF4

Line Pan PF6

Line Pan PF7

Line Pan PFHD

Impact Roll Crusher

The HBT beam stage loader design incorporates an impact roll crusher. The crusher’s duty is to break the big lumps of mined material into a size suitable for belt conveyors. Due to its geometrical shape the crusher roll is wear protected by impact elements. The heavy-duty roll can save moment of inertia.

Features:

Horizontal crushing
Exchangeable impact elements as standard
Hydraulic height adjustment of crusher roll to match output size to belt capability
PMC® monitored overload protection causing BSL speed variation down to automatic stop
Spraying integrated into impact roll or spraying from the top cover for dust suppression available
Central lubrication system

Benefits:

High throughput
Minimum dust
Long lifetime of components
Low operating costs

Drive Frame Unit

While the return roller is integrated into the cross frame design, the head drive frame of the beam stage loader is tensible using hydraulic cylinders. Two tensible drive frames are available for HBT beam stage loaders – the HBT SPR3 and the HBT SPR5 with up to 400 / 500 kW and a stroke of 350 / 500 mm and built for capacities of up to 6,200 / 7,000 tonnes per hour. Both drive frames come with a universal sprocket. Optional features are a spraying system, a scrubber, and central lubrication.

Sprocket Design – One Type fits All

The universal sprocket combines the advantages of a split and a solid sprocket. Suitable for SPR3 and SPR5 drive frames – covering all BSL widths. The sprocket has the ability to rotate 180° and features independent exchange of sprocket and bearings. The drive module can be replaced underground without disassembly of the gearboxes.

Benefits:

Ease of maintenance
Low operating costs

Gearboxes

HBT beam stage loaders are using conventional HBT gearboxes. Suitable HBT bevel helical planetary gearbox models with an angular design are KP25/30 and KP35 –with 300,000 and 350,000 Nm maximum output torque.

Boot End (Belt Tail Piece)

Belt tail pieces are available in fixed-, skid- or crawler-mounted versions with an overlap of up to 3.5 m (11.5 ft), all equipped with self-cleaning return drums. The operator can use any specified belt width in this tailor-made equipment. Skid-mounted belt tail pieces are used for normal floor conditions. If the floor is soft the crawler-mounted version is recommended.

Goose Neck

The gooseneck lifts the beam stage loader discharge over the belt tail piece. The goose neck has a stiff design and features customized spill plates and inspection doors. Wear parts are exchangeable. The goose neckline pans catch up all forces in the stiff connection at the same time.

Belt Return Unit

Different styles are available, lifting foots or crawler. Cylinder push up to 3,5 m.

Automatic Chain Tensioning

The automatic HBT chain tensioning system for the beam stage loaders (BSL) provides the possibility to permanently adapt the chain tension and the resultant chain slack to different conveyor conditions. The system keeps the BSL chain constantly at optimum tension during operation.

Automatic chain tensioning eliminates the need for manual adjustment of the chain tension to the maximum load, resulting in excessive chain tension in most loading conditions. Thus, the automatic function significantly reduces wear on the chain and the sprocket.

A second function of the HBT chain tensioning system is to ensure precise alignment of the conveyor. Cylinders on both sides of the drive end of the conveyor assure that the conveyor is always positioned straight. To compensate the resulting slope caused by uneven weight distribution at the conveyor ends, the cylinder movement at both sides is automatically controlled to assure equal positioning. To control the tensioning process the cylinder tracking is measured separately on both sides.

Technical Data

General
Rated maximum output power:	2×1050 k
Noise level	> 85 dB(A)
Bearing service life	10000 h

Head gate
Drive frame:	Drive frame MR 35-1100, one-side shaft
Chain sprocket	DKB 42×146, Z=7, KA=165
Flange plate – gearbox	MRHS 35 / KP-45
Gearbox	KP-45 CST-V, i=33, left-hand design, from HBT
Drive connection	EK-S400-M950/120-45/65
E-motor	1050 kW, 3300 V, 50 Hz, Morley
Adaptor pan	PF 6/1142-3820
SH-rerouter pans 1L – 3L	PF 6/1142

Tail gate
Drive frame	Tensionable drive frame MRHS 35-1100, one-side shaft
Chain sprocket	DKB 42×146, Z=7, KA=165
Flange plate – gearbox	10000 hMRHS 35 / KP-45
Gearbox	KP-45 CST-V, i=33, left-hand design, from HBT
Drive connection	EK-S400-M950/120-45/655
E-motor	1050 kW, 3300 V, 50 Hz, Morley
SH-rerouter pans 1R – 6R	PF 6/1142

Panline
SH pan	PF 6/1142, 1756 mm long
SH pan	PF 6/1142, 1756 mm long with inspection door
Rack bar	Jumbotrack 2000

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Beam Stage Loader

PERFECTLY MATCHED TO THE FACE CONVEYOR

TAILOR-MADE SOLUTIONS

BSL Line Pans

Line Pan PF3

Line Pan PF4

Line Pan PF6

Line Pan PF7

Line Pan PFHD

Impact Roll Crusher

Drive Frame Unit

Sprocket Design – One Type fits All

Gearboxes

Boot End (Belt Tail Piece)

Goose Neck

Belt Return Unit

Automatic Chain Tensioning

Technical Data

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