2. Shuttle car is a large heavy duty unit
,designed to carry maximum payload at high
speed.
It collects the coal from continuous miner
working at the face and supplies to Feeder
breaker or mine cars or belt conveyors.
3. The car has four wheel positive drive and four
wheel hydraulic operated steering , which
provides maximum traction potential with a
minimum turning radius.
It contains hydraulic pumps, driven by a
separate electrical motor to power the cable
reel , steering and conveyor elevating
functions.
At discharge end a chain and flight conveyor
is fitted which can be elevated by hydraulic
cylinders.
5. Traction drive
Hydraulic system
Electric System
Steering Arrangement
Conveyor Drive
Cable reel mechanism
6. The 2 wheel on each side of
car are driven by 2 separate
traction motors through spur
gear reducers , which are
coupled to the receiving end
wheel drive units by universal
drive shafts.
The receiving end drive units
are connected to similar units
at the discharge end of the
car by universal drive shafts.
8. Of the four wheel drive units consists of a
bevel gear set , driving a ball type constant
velocity joint , which in turn drives a
planetary gear set within the hub.
There is no transverse connection between
the drive elements so that no mechanical
differential is needed.
Each traction drive carries an enclosed wet
brake unit coupled directly to gearbox.
9. This system regulates the flow of hydraulic
fluid at system pressure to raise and lower
the conveyor, extend and retract the steering
cylinders, releases of brakes and power the
cable reel.
Electric motor must be energised for starting
the pump before any hydraulic function is
operated.
10. Hydraulic Pump
The pump is a two-suction , gear style unit.
Each section of two-stage pump have
separate set of gears . The gears in the 46
lpm section are wider , thus having a larger
capacity.
The pump is splined and bolted directly to
the pump motor.
11. The high volume stage of pump delivers
(46LPM) fluid to cable reel valve(Since here,
shuttle car is in stationary mode, cable reel
motor will be in stalled position) & conveyor
elevating valve.
The Low volume Stage delivers (34LPM) fluid
to hydraulic cylinders in steering mechanism
and Brake circuits (emergency/ park &
service).
Pump circuit includes strainer and breather.
12. Service Jack Control valve
The shuttle car is fitted with four machine
lifting service jacks.
The service jacks are operated individually
from a common control bank.
The shuttle car must be positioned on a hard
ground before lifting it off the ground.
Brakes
Following the start up of pump motor, the
wet brakes are released.
The wet brakes are mounted on traction
reducer and has internal braking discs.
These are spring applied and hydraulically
released
13. Pressure and flow , provided by low volume
are used to release the park/emergency
brakes.
The sequence valve assures a constant
pressure for the correct operation of park
brakes.
When pump motor starts the brake solenoid
is energized.
The operators should not leave the
compartment without applying park
brake.The pressure gauge in operator
compartment must read 0 bar.
14. Consists of controller, an opto(digital I/O Box),
electronic overload relay’s, a display unit, Optical
drive units and electrical switches.
Digital I/O Box acts as a convertor. All inputs to
this box(110v ac) is converted to a 24v dc
output, before it passes to controller for circuit
operation and diagnosis. Here it acts a protector
of controller.
We have Power Supplies (PS1 & PS2):
PS1 is connected to Controller, Opti drive units,
Digital I/O Box and display unit.
15. CONTROLLER
This is one of the important features of
shuttle car which controls and monitors
various machine functions by correlating with
the operator inputs from the electrical
switches.
Communication and data exchange between
the overload relay’s, display unit and central
controller are effected by means of a CAN bus
communication.
16. Circuit Breaker
The electrical circuits of the shuttle car are
controlled by circuit breakers located in the
main controller case. These must be closed
before the power supply is given to electrical
components.
Breaker Function
Machine Main breaker Provides protection for all
electrical circuits on the
machine
Control and lighting Breaker Provides protection for the
lighting and the control circuits
Traction Breaker Provides protection for both
traction Motors.
17. Optidrives
The optidrive system utilizes 3-phase AC
motors for traction control on the shuttle car.
The 2 optidrives supply power at variable
voltage and variable frequency, to the
traction motors.
The system uses power electronics technique
to convert AC to DC(rectifier),smooth the DC
(filter) and then to convert DC to AC
(inverter)to provide a variable voltage variable
frequency(VVVF) output.
18. Motor rotation is determined by the
Integrated Gate Bipolar transistors(IGBT)
within the optidrive.
Motor current is sensed by two closed loop
hall effect current sensors.
Each optidrive provides thermal overload
protection (TOL)for the traction motors.
19. Display Screens
The display unit registers both machine
operation and status information.
There are 9 different screens available , each
will display detailed information to aid in
operating and troubleshooting the machine.
Audible Siren
The siren sounds when the pump is being
started, which is directly powered from
central controller during the pump start cycle.
20. Switch name location function
Foot switch Near the foot of
operator.
Pressed during
tramming.
Emergency stop
switch
Master stations
cover
To stop moving
machine
instantly.
Pump switch On Master
station cover
Shut the
machine in
emergency & to
start pump.
Conveyor
switch
Master station Start and stop
the convryor
Low cable cut
off switch
Cable drum of
machine
To open pilot
line before
cable is
completely
wound off
Switches
21. Switch name Location function
Overfill cable
cut off switch
Cable reel drum
compartment
Open the
pilot line
when cable
reel drum is
overfilled
Brake pressure
switch
In line with
hydraulic brake
circuit
Sensing the
pressure of
hydraulic
fluid.
Oil level and
temperature
switches
Hydraulic tank Check level
and
temperature
of oil
respectfully
22. Consists of Upper & lower steering arms,
Drag links, Cross over drag links, steering
lever or butterfly and cross shaft.
A steering cylinder is mounted onto each
steering lever and when operator operates
steering control from his cabin, it pulls and
push the steering levers, which turn the
wheels to left and right with the help of drag
links.
These are found on both the sides of SC,
mounted onto the steering cross shaft.
24. As hydraulic oil is directed into the extend
port of the cylinders , the rod will extend
rotating the steering lever about the cross
shaft.
The draglinks will either push or pull the
steering arms attached to wheel units.
This results inwheel units rotating about a
kingpin and allowing the operator to steer the
shuttle car.
25. Steering Cylinder
The steering cylinders used on
the shuttle cars are double acting.
All shuttle cars are equipped with
a dual cylinder arrangement.
The function of them is to convert
hydraulic pressure into
mechanical force.
26. It is an integral part of SC, on which the coal
is loaded from receiving end and has a width
of 0.81m.
It is equipped with conveyor chain having
flight bars. Conveyor chain is adjusted for
tensioning and to avoid slackness using a
conveyor take up shaft.
27. Conveyor take up shaft
Conveyor take up shaft is equipped with
sprockets on both sides on which the
conveyor chain sits.
This conveyor take up shaft is connected
with a grease jack or take up cylinder.
spac
erTake-up
rod
pin
sprocket
nut
shims
washer
Take-
up nut
Take
up
shaft
Grease
jack
28. Conveyor Drive Motor/Reducer
Conveyor is run by conveyor motor of 18.6KW
(AC induction), attached with a conveyor reducer
through castle nut, split pin and O-ring.
Component Weight
Conveyor reducer 260 kg
Conveyor motor 275 kg
1.Reducer
2.Motor
3&4.Mounting bolts
5.castle nut
6.Pinion gear
7.Key
8.O ring
9.Nut
10.Split pin
29. The conveyor boom is connected
to the car by a pivot shaft.
Below the boom there are 2
conveyor elevating cylinders used
to lift up the conveyor.
The weight of these cylinders are
79 kg.
Conveyor Boom
30. The CABLE REEL MECHANISM is used by the
SHUTTLE CAR to wrap the sagging trailing
cable into the vehicle.
This prevents the cable from knot formation
and tampering.
It maintains a pulling force in the cable and
prevents sagging due to the weight of the
cable.
Stops the vehicle when cable is exhausted
and thus prevents tearing of the cable.
32. The cable reel drum is powered by a cable
reel drive motor through a cam spooler drive
chain.
The cable reel drive chain is lubricated with a
squirt of hydraulic fluid whenever the cable
reel starts rotating.
