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Apron Feeders

Introduction to Apron Feeders


Osborn Apron Feeders provide reliable means of controlling the feed rate to prevent surge loads to the Primary Crusher or other plant equipment. An Apron Feeder is run at very low speeds and at a controlled feed rate as it absorbs the impact loads of the material falling from a dump truck or a front-end loader and is ideal for withdrawing material from under a stockpile or from under a Primary Crusher. Apron Feeders are of rugged, heavy duty construction and designed to handle feed sizes of up to 1500mm and where no fines removal is required or where fines are removed by a separate Vibrating Grizzly. When the feed material is wet, sticky or clay like, and where other feeding equipment can-not handle it, the Apron Feeder is the machine to select. Generally, the Apron Feeder can be installed in a horizontal or inclined position ( up to 15 ) depending on space limitations. Drives can be electromechanical or hydraulic. The manganese flights are designed to overlap so as to reduce spillage. Osborn Apron Feeders range in sizes from 900mm wide to 3500mm wide and are constructed using traditional D4,D6, D7 and D9 track components.

Osborn Range
Type
D4 D6 D7 D8 D9

Widths
900 2100mm 1200 2400mm 1500 3000mm 1500 3000mm 2000 3500mm

Capacities TPH
up to 1500 up to 2000 up to 2500 up to 2500 up to 5000

Note: Machines with heavier duty chains can be designed and built to suit specific duty requirements

Feed Capacity
Pan Width (mm) Burden Depth (mm) Chain Speed (m/min) 900 800 m/h 4 1000 6 8 10 192 288 384 480 1050 950 m/h 228 342 456 570 1250 1150 m/h 276 414 552 690 1500 1400 m/h 336 504 672 840 1800 Inside skirts (mm) 1700 m/h 408 612 816 1020 2000 m/h 480 720 960 1200 2300 m/h 552 828 1104 1380 2900 m/h 696 1044 1392 1740 3400 m/h 816 1224 1632 2040 2100 2400 3000 3500

Lengths vary from 3 000 mm - 19 000 mm or more depending on design. The capacities shown are based on a material mass of 1.6 tonnes per cubic meter and are indicative only. Upon receipt of all the material characteristics and design parameters, Osborn would be able to provide a more exact capacity for the selected Apron Feeder.

Loading Hopper / Bin


It is very important to ensure that the loading hopper or bin is designed to achieve the most efficient feed onto the Apron Feeder. The machine often has to cope with high loads at start-up and reduced loads whilst running, hence load distribution via the correctly designed hopper needs to be optimised. Ideally, the dumping of material into the hopper needs to be controlled so that the impact of the new load is absorbed by the last of the material from the previous load. The dumping of material into an empty hopper should be discouraged. If it becomes impossible to dump onto a bed of material, then the load should be tipped towards the tail end of the hopper so that the greater portion of the impact is borne by the sloping rear wall or drop box. This method would be beneficial if the bed of material on the sloping wall comes to rest on the Apron Feeder flights in such a position that it forms a bed for the succeeding portion of the load which is discharged from a greater height.

SIZING AN APRON FEEDER


The data sheet on the rear of this brochure, illustrates the information that Osborn requires to correctly size the Apron Feeder. Of significant importance on any Apron Feeder installation is the design of the bin or hopper which will be used to feed the machine. To enable Osborn engineers to calculate the optimum size Apron Feeder, also taken into consideration as well as the completed data sheet are the following points that we insert into our formulae. Flights and chain mass Start-up and running torque Chain factor of safety - Start-up conditions 5:1 minimum - Running conditions greater than7.5:1 For Drive sizing we calculate ; Breakaway torque Running torque Absorbed power Installed power Head shaft speed. Chain pull ( taking material shear resistance, installation inclination resistance etc, into consideration ) Osborn generally work on twice the maximum lump size feed to be the minimum width of the Apron Feeder pan as an indicator. Grading analysis is important for correct sizing of feeder width.

Apron Feeder with built in scraper belt. Leave at least 4 -5 flights or 800mm (minimum) clearance at tail shaft for maintenance.

FRAME
Full length beams manufactured from rolled steel joists form the top and bottom members of this one piece unit. Crossmembers tie the framework together for maximum strength. Bolted onto these crossmembers are the universal beams which carry the impact rails and the carrier rolls. For ease of removing the carrier rolls, the outside carrier roll channels are sectionalized and bolted to the cross beams.

HEAD DRIVE SHAFT


This heavy duty shaft is machined from high grade hot rolled steel. Each end of the shaft is machined for a drive unit, even on installations with a single drive specification. Should one end of the shaft get damaged, the shaft is handable and the other end could be used.

DRIVE SPROCKETS
The sprockets are of the bolt on segmental type made from wear resisting alloy steel. They are designed with an odd number of teeth which increases the life of the sprocket because contact with the teeth is only completed after two revolutions. The sprockets are bolted onto keyed on hubs.

TAIL TRACTION WHEELS


Cast steel traction wheels are lighter duty as they act purely as a directional guide to centralise the track. Long service life can be expected as there is minimal load carried on the traction wheels.

FLIGHTS
Cast steel flights ( or pans ) are fitted as standard and reinforced with longitudinal packers which run in close proximity to the impact rails thus preventing excessive loads being taken by the carry rollers. Manganese flights are available as an option. All flight sets are individually machined to ensure the optimum overlap of each flight is obtained to minimise leakage. The flights are bolted to the track chain using high tensile grade bolts.

BEARINGS
Anti-friction spherical roller bearings are fitted to the head and tail shafts and housed in heavy duty plummer blocks. Bearings are grease lubricated and a grease reservoir is included in the design of the bearing housings and end caps. The Apron Feeder has a remote mounted electrically operated automatic greasing system as standard.

CARRYING ROLLERS
The carrying rollers are standard tractor type featuring a hardened and ground shaft fitted with a centre thrust shoulder and hardened roller. The sleeve bearings on the carrying roller takes high impact loads and, with the duo-clone seals providing lifetime lubrication an extended wear life can be assured. Closely spaced along the length of the Feeder, smooth travel of deck during operation is maintained.

RETURN ROLLERS
The return rollers on the Apron Feeder are steel rollers with bearing sleeves to support the deck on its return. The rollers are mounted on a stub shaft that is fabricated onto a plate and bolted to the lower joist. Removable stub shaft plate.

CHAIN
Crawler tractor type track chains , sealed and lubricated , are used on all Osborn Apron Feeders . The pins and bushes are all made from heat treated alloy steel and hardened on the wearing surfaces. The chain links are drop forged for increased carrying capacity and strength. The chains can be adjusted by means of a threaded screwed take-up arrangement. Hydraulic ram adjustment is available as an option.

IMPACT RAILS
These full length heavy duty steel rails are fitted to the frame to prevent permanent distortion of the flights under severe impact loading. Ample clearance is provided to ensure that the flights do not drag on the rail.

Osborn Apron Feeder Sectional View


EFFECTIVE WIDTH

Impact Rail Impact Rail Support Clearance Pan Chain Support Roller Roller Support Beam Cross Member

Main Beam Return Roller Protector Return Roller Feeder Skirt Idler Rolls Optional Scraper Belt STD Apron Feeder

Dribble Conveyor Frame Return Rolls

SECTIONAL VIEW THROUGH OSBORN APRON FEEDER


As an optional extra, the Osborn Apron Feeders can incorporate a Dribble Conveyor which is located under the feeder to catch the small pieces , fines and lumps of material that became trapped on the feed side of the apron flights and dribble out on the return side. This feature eliminates manual clean up and saves on man hours. The Dribble Belt conveys this material into a discharge chute. To protect the apron feeder return rolls from material build-up caused by spillage over the edges of the apron flights, angle iron deflectors are fitted. The use of impact rails and rail supports are generally determined by the width of the apron feeder and range from one to three or more as the width and duties increase.

Application Data Sheet - Osborn Apron Feeder


Customer Phone No./Email Fax.No Date of Enquiry SITE CONDITIONS Location Altitude Operating Temp. Min Operating Temp. Max. MATERIAL Type Loose Bulk Density Angle of Repose Compressive Strength Abrasiveness Moisture Content Flowability Shape of Material DUTY Design Capacity Max.Feed Lump Size Running hours per day Drive selection type Rate control Variable feed rate BIN GEOMETRY A) B) C) D) E) F) G) H) J) K) L) M) Hopper Wall Angle Hopper Length Hopper Height Hopper Skirt Height Bin Height Bin Length (Calculated) Burden Depth Skirt Length Inside Skirt Width Rear Projection Feeder Inclination Rear Wall Angle Bin Volume Bin Capacity Deg mm mm mm mm mm mm mm mm mm Deg Deg m tonnes Top speed tph mm hours Hydraulic Fixed Bottom speed tph Kg/M Degrees Mpa High % Max Free Contact Person Phone No./Email Enquiry No. Tender No.

Metres C C

Medium % Min Average

Low Sticky

Electromechanical Variable 60-100%

0-100%

HANDING (View from tail end) Left hand Right Hand


Ref No. AF/11/Rev1

NOTE

Minimum feeder length should be 1.5 x larger than lumpsize (width or height) Feeder width = 2 x maximum lump size - if high % of max lumps Burden depth = 2 x maximum lump size SPECIAL CONDITIONS

Head Office: PO Box 8182 Elandsfontein, 1406 Johannesburg South Africa Tel: +27 11 820 7600 Fax: +27 11 388 1136 E-mail: osborn@osborn.co.za www.osborn.co.za

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