wagon tippler system: tippler side arm charger, indexer, wheel clamp dust suppression ...

1. Wagon Tippler System
(Car Dumper)
Liaoning Mineral & Metallurgy Group Co., Ltd.
Address: 1310-1312 Room Textile Building, No.35 Renmin Road,
Tel: +86 411 82580352 82656126 Fax: +86 411 82557586
http://www.lmmgroupcn.com
Zhongshan District, Dalian-116001, China
Email: bill@lmmgroupcn.com

2. 1
1 INFORMATION
Wagon dumper system is a kind of large equipment for unloading bulk goods in
open wagon. It’s preferred alternative in the countries that transport bulk goods by
railway. Compared to other ways, its advantages are as follows：
Wide range of application. Generally, all kinds of bulk goods in all sorts of open
wagons can be well handled.
Efficient and very easy to be automated.
Almost no leftover.
The unloading process is easy to be environment-friendly.
Wagon dumper system's mainly application area includes: port for bulk goods,
power plant's coal-transport system, and raw material feeding system of steel plant,
coke plant and large cement plant.
The main frame of wagon dumper system is car dumper, and be equipped with
various kinds dispatch vehicle arrangement and safeguards equipment to constitute
the unload line.
According to the number of cars that handled every work circle, railway wagon
dumper systems can be divided into single wagon dumper system, dual-wagon
dumper system and tripe-wagon dumper system. In the electric power plants and
steel works that the single wagon dumper system is the most popular one, in the ports
that the dual-wagon dumper system is the most popular one, tripe-wagon dumper
system and larger-sized dumper are the less popular.
2 Wagon dumper system forms of the layout, working performance, equipment
composition and work processes
Wagon dumper system could be run-through model or back-turning model which
depends on the layout of empty and full car's tracks.
Run-through model that is dumper's the layout of empty and full line are the same
railroad line. The outlet of dumper is empties line. Run-through model wagon dumper
system could be divide to unit-train wagon dumper system, mixed unit-train wagon
dumper system and multifunction (can dumping unit-train and mixed unit-train) wagon
dumper system. The run-through model system needs fewer equipments and more
efficient, but needs more field for the tracks.
The back-turning model system is that dumper in the railroad line tip, empty and
full line are parallel arrangement, the outlet of dumper set up the transfer that can be
square transfer motion train, the transfer move train from full line to empty line, train
can be back from empty line. The back-turning model system needs more equipments
and less efficient, but for it at the end of railway, it needs less field and easy to arrange,
so it more widely adopted.
About all kinds of dumper system’s dumping vehicle-type, working performance,
equipment composition as table:

3. 2
System
forms
of the
layout
operating
type
dumping vehicle-type
working performance
（Cycles/h）
System equipment composition
vehicle-type
gross
weight
(t)
load
(t)
single
wagon
dumper
system
Dual
wagon
dumper
system
Triple
wagon
dumper
system
Car Dumper Train Handling
Equipment
Safe
Equipment
Run-
through
model
mix rake
ChinaC61、C62、C63、
C64
84 60
25～33 25～33
23～27
single
vehicle
type
C type Car Dumper
Single/Twin/Triple
Side Arm Charger
Car Pusher
Wheel Clamp
Back Stop
ChinaC70 93.8 70
ChinaC80 100.5 80
China developing
vehicle-typeC100
132 100
India BOXC 81.28 56.28
25～33 25～33
23～27
single
vehicle
type
C type Car Dumper
Single/Twin/Triple
Side Arm Charger
Car Pusher
Wheel Clamp
Back StopIndia BOXN 81.28 58.08
India BOXNHA 88.4 65.23
India BOXNEL 100 76.9
Uniform rake
China C70S 93.8 70
30～45 30～40 27～30
O type Car Dumper
Single/Twin/Triple
One or Two
Positioners
Wheel Clamp or
Stop Arm
Back Stop
China C80 100.5 80
Australia KARARA 84 67
Australia ROY HILL 160 137.5
above
not
applicable
C type Car Dumper
Single/Twin
Positioner
Car Pusher
Wheel Clamp
Back Stop
Back－
turning
model
ChinaC61、C62、C63、
C64、C70、C80、C100 20～25 18～22
not
applicable
C type Car Dumper
Single/Twin
Side Arm Charger
Transfer
Car pusher
Wheel Clamp
Safe Stop
India BOXC、BOXN、
BOXNHA、BOXNEL 20～25 18～22
not
applicable
C type Car Dumper
Single/Twin
Side Arm Charger
Transfer
Car pusher
Wheel Clamp
Safe Stop
LMM GROUP Wagon dumper system
mix rake
mix rake
niform rake
&
U

4. 3
All kinds of wagon dumper system’s work process as follow:
Run-through model random wagon’s wagon dumper system include dumper,
side arm charger, wheel clamp, single acting stopper, spray dust-suppression system
and electric control system, its work procedure is as follows:
Locomotive pulls a load train to the place where side arm charger can fetch and
leave .Then the train is towed by the side arm charger to initial position and be
localized by wheel grippers .The coming moves are automated. The wheel clamp
loosen, and then side arm charger pulls the train through a wagon’s (for dual wagon is
two train ,tripe wagon is three train, same below)length distance and release the
coupler of first wagon manually, after that side arm charger tows the first wagon into
dumper's appointed position. The coupler between side arm charger and wagon will
be released automatically, side arm charger 's arm raises and returns to forepart of the
train in high speed. At the same time, the dumper overturns and back to initial place.
Side arm charger begins the second cycle, pulls the next wagon into position while
pushing the empty wagon in the dumper out and mass into line on the empty line.
Where necessary, to increase of efficiency, for dual or tripe wagon dumper system,
to increase an indexer to pull that unlock-coupler two train (for tripe wagon is three
train) to the dumper location, pushing the empty wagon in the dumper out and mass
into line on the empty line.
Run-through model unit train’s wagon dumper system include dumper,
positioner, wheel clamp, single acting stopper, spray dust-suppression system and
electric control system, its work procedure is as follows:
Locomotive pulls a load train to the place where side arm charger can fetch and
leave .Then the train is towed by the side arm charger to initial position and be
localized by wheel clamp .The coming moves are automated. The wheel clamp
loosen, and then side arm charger pulls the train through a wagon’s (for dual wagon is
two train, trinal wagon is three train, same below) length distance, the wheel clamp
clamps, positioner arm raises and returns to initial position in high speed. At the same
time, the dumper overturns and back to initial place. Side arm charger begins the
second cycle
Unit-train’s couple can be along with itself axis to rotate, dumper’s center of
rotation with couple centre line to coincide,
therefore it can coupling to work. Positioner’s
arm is snap-in two wagons striker, to tow entire
wagon.
Run-through model unit train’s wagon
dumper system is the most working
performance and dumper system. Where
necessary, it can adopt to two positioners to
improve on working performance.

5. 4
Run-through model random wagon and
unit-train’s wagon dumper system is include
dumper, multifunction positioner, car pusher,
wheel clamp, single acting stopper, spray
dust-suppression system and electric control
system. Two work procedure can transform, the
mode of random wagon that multifunction
positioner assume the function of side arm
charger, the mode of unit-wagon that
multifunction positioner assume the function of
positioner, car pusher can work in the last cycle.
This system more function can adapt to various
working condition, but its system is more
complex.
The back-turning model wagon dumper
system can be random wagon, it include the
dumper, side arm charger, wheel gripper, car
transfer, car pusher, single acting stopper, safe
stoppers ,spray dust-suppression system and
electric control system, its work procedure is as
follows:
Locomotive pulls a load train to the place
where side arm charger can fetch and
leave .Then the train is towed by the side arm
charger to initial position and be localized by
wheel clamp .The coming moves are
automated. The wheel clamp loosen, and then
side arm charger s pulls the train for a
wagon’s(for dual wagon is two train length
distance and release the coupler of the first
wagon manually, after that side arm charger
tows the first wagon in to dumper's appointed
position. The coupler between side arm charger
and wagon will be released automatically, side
arm charger’s arm raises and return to forepart
of the train in high speed. At the same time, the
dumper overturns and back to initial place. Side
arm charger begins the second cycle, pull the
next wagon into position while pushing the empty wagon in the dumper out and mass
into line on the empty line.

6. 5
3 Wagon dumper systems various single type’s main technical parameter and
instruction
3.1dumper
Type instruction
F Z C 1 － 1
Type serial number 1，2，3...
Each dumping vehicle 1－single
2－twin
3－tripe
Feature C type or Ｏ type
Rotor
Dumper
Type
Material
Handled
Car
Weight
Gross
Tonnes
End Ring
Centres
Metres
description
Customer
Example
FZC1-1 Coal 100 15 Equilibrium force beam clamp
Guigang
power plant
FZC1-2
Coal or
Iron Ore
100 15
Equilibrium force beam clamp
Electronic weigher
Ganjinzi
power plant
FZC1-3
Coal or
Iron Ore
100 15 Joint force beam clamp
Baogang
coking plant
FZC1-4
Coal or
Iron Ore
100 15
Joint force beam clamp
Electronic weigher
Lingwu
power plant
FZC1-5 Coal 85 14 Equilibrium force beam clamp India Bengal
FZC1-6
Coal or
Iron Ore
128 15
Joint force beam clamp
Designing, consider the future
C100 type
Taiyuan
power plant
FZO1-1
Coal or
Coke
100 15.8
Designing for dumping coal and
cock
Nanjing port
FZO1-2 Coal 100 15.8 Magang
FZC2-1 Coal 2*100 17.4(29) Radom wagon
Qingdao
port
FZC2-2 Coal 2*100
Adapting India market to design
Radom wagon
FZC2-3 Coal 2*100 18
Radom wagon C64
Unit-train C70S、C80
Hopper wagon
Shenhua
Tianjin
FZO2-1 Iron Ore 2*90 12 Unit-train KARARA

7. 6
FZC1-1 Type Dumper FZC1-2 Type Dumper（local）
FZC1-3 Type Dumper FZO1-2 Type Dumper
FZC2-1 Type Dumper
FZO2-1 Type Dumper（manufacturing）

8. 7
3.2 Positioner (side arm charger) and car pusher
Type instruction：
D Z C 1 － 5000
Pull weight（t）
Type serial number 1，2，3 ……
Drive type C- rack gear；S- Rope drive
Z-tow heave car K-pull empty car
Positioner, side arm charger, car pusher
Type Name
Train
Weight
Gross
Tonnes
Track
Centres
MilliMetres
description
Customer
Example
DZC1-****
Side arm
Charger
6000 4700
Mating Type FZC1
dumper
Random wagon
Ganjinzi
power
plant
DZC2-****
Multifunctional
Positioner
7200 4000
Mating Type FZC2-3
dumper
Convert random
wagon and unit-train
Shenhua
Tianjin
CD4
DZC3-****
Multifunctional
Positioner
7200 4000
Mating Type FZC2-3
dumper
Convert random
wagon and unit-train
Have two pusher arms
Huanghua
CD2
DZC4-**** Positioner 10000 3200 Unit-train KARARA
DZC5-**** Positioner 32000 3200
Unit-train
Design stage
DZS1-****
Side arm
Charger
3000 2700
Mating Type FZO1
dumper
Magang
coking
plant
DKC1-**** Car Pusher 2000 2800
For back-turning
model wagon dumper
system, pulling the
empty wagon to
transfer
Lingwu
power
plant
DKC2-**** Car Pusher 3600 6250
Mating Type FZC2-3
dumper
Shenhuan
Tianjin
CD4
PS: Tow (pull) weight can be as required to design.

9. 8
DZC1-6000 Type side arm car pusher DZC2-7200 Type multifunction indexer
DZC3-7200Type multifunction
Dual-arms indexer DZS1-3000 Type side arm car pusher
DZC4-10000 Type positioner
DKC1-2000 Type car pusher DKC2-3600 Type car pusher

10. 9
3.3 Car Transfer
Type instruction：
QT C 1- 1
Type serial number 1，2，3 ……
Each dumping vehicle 1－single;2－twin
Drive type：C-pin tooth drive; L-wheel drive
Car Transfer
Type Name
Car Weight
Gross
Tonnes
Length of
Main Beam
Metres
description
Customer
Example
QTC1-1 Car Transfer 100 14.5
For back-turning model
wagon dumper system
Mating Type FZC1
dumper
Ganjinzi
power
plant
QTC2-1 Car Transfer 2*100 29
For back-turning model
wagon dumper system
Mating Type FZC2
dumper
QTC1-1 Type transfer

11. 10
3.4 Wheel clamp
Type instruction：
JL 1- 300
Clamp force（kN）
Type serial number 1，2，3 ……
Wheel clamp
Type Name
Clamp
Force
kN
Length of
Clamp
Beam
Millimetres
description
Customer
Example
JL1-300 Wheel Clamp 300 2*1750
Single wheel clamp
Not allowed
locomotive pass
Ganjinzi
power plant
JL2-600 Wheel Clamp 600 3500
twin wheel clamp
For run-through
model allowed
locomotive pass
Qinhuangdao
port
JL1-300 Type wheel clamp
JL2-600 Type wheel clamp

12. 11
3.5 Safety Stop
Type instruction：
ZA - 1
Type serial number 1，2，3 ……
Safety Stop
Type Name description
Customer
Example
ZA-1 Safety Stop
For back-turning model
Transfer linkage
Ganjinzi
power
plant
ZA-2 Safety Stop
For run-through model,
avoiding empty train
retro gradation
Can motor-driven
remove
Shenhua
Tianjin
CD4
ZA-1 Safety stop and DKC1-2000 Type car pusher

13. 12
4. About dumper system adaptive railway standard
Wagon dumper system must satisfy with user that the country one belongs to
railway standard and requirement.
4.1Dumper system adaptive satisfies with Chinese railway standard and
stipulation
Chinese railway standard and requirement：
GB/T18818 Railway wagon dumper and bulk cargo unfreezing warehouse
detection conditions
TB/T1335 Rail truck strength design and accreditation test
TG/CL259-2010 Railway wagon dumper and bulk cargo unfreezing
warehouse detection rules
4.2 Dumper system adaptive satisfies with India railway standard and stipulation
India railway standard and requirement：
Amendment No.1 of December 2007 applicable to the technical pamphlet for
requirements of wagon tippler installation for approval by RDSO
No.G-33(February 2000)