Sandvik’s HM150 Roller in Action on the World's Largest Conveyor Bridge
The Swedes play a leading role in the production of lignite
Prince Herrmann Ludwig Heinrich von Pückler-Muskau, a landscape gardening genius, built the Muskau Park in the Lusatia region in 1817 – it is part of a UNESCO world heritage site today. In the same era, 1850, the first lignite was mined in the region and still today, Vattenfall, the Swedish company, extracts lignite without financial subsidies - in Jänschwalde among other places, one out of the five open-cast mines currently in operation. As one of the largest employers and apprenticing companies in East Germany, Vattenfall currently employs almost 8,000 employees and about 800 apprentices. Sandvik Mining and Construction also plays a leading role - in the literal sense. At the Jänschwalde location there are 320 sets of 5–roller garlands of HM150 formed rollers in action on the overburden conveyor bridge AFB 60m. On belt five, the main belt conveyor (belt type 3000 ST3000-18:8, idler spacing approx. 800 mm) and on belt eight, the stockpile belt conveyor (belt type 2750 ST2500-18:8, idler spacing approx. 800 mm).
It all began in the spring of 2004. Bernhard Hofmayer, Production Manager at Sandvik in Schöppenstedt, introduced the HM150 formed roller to Vattenfall. The engineers were impressed by the completely new design and the innovative assembly technique. The discussion about the advantages and disadvantages of the component optimised formed roller were ready to begin.
Quickly and unbureaucratically they were able to agree upon a test phase in the open-cast mine in Welzow-Süd. Due to the extreme operating conditions the highest requirements are demanded for rollers and conveyor systems. The belt speeds at the location are between 10 – 11 m/s and the tonnages add up to 52,000 tons waste hourly. Sandvik accepted this challenge and developed the innovative formed roller.
During the period August 2004 to April 2005 the first 250 rollers all passed the test phase. Vibrations in the entire steel construction of the conveyor bridge were minimised and noise emissions were reduced by about 20 dB (A). The weight savings were beneficial for the statics. The result: operational release by the TÜV [Technical inspection association in Germany]. In conclusion all formed rollers in use on the conveyor bridge were exchanged for the Sandvik HM150.
With the positive experiences from the Vattenfall open-cast mine Welzow-Süd the rollers were also installed in Jänschwalde 50 km away. Vattenfall’s intention for the planned operation of the formed rollers on the overburden conveyor bridge AFB 60m was to improve conditions for employees, residents and the environment by investing in modern technology. Furthermore, it was about fulfilling TÜV requirements.
Even here the focus was on the sophisticated statics of a conveyor bridge weighing 30,000 tons. Through the weight saving of 10 - 15%, which was obtained compared to conventionally manufactured rollers, the extensive and cost-producing modification of the steel colossal was prevented.
The weight optimisation is also an advantage in case of a replacement of a single roller or garland which is required less frequently due to the extremely long operation period of the rollers. "I do not remember that I ever had to exchange one of the 1,600 formed rollers in the last six months," stated Mechanist Christian Ramm. "In-house we call the HM150 fire extinguishers because of their orange-red colour and form," he added. In the first three years the failure rate was at 2.9% well below the statistical average for conventional rollers.
Operative Engineer Peter Hobracht wraps it up: “The lifetime of the rollers, which is prolonged by the low failure rate and the low-noise surrounding area due to the running smoothness, strongly convinced us to use the innovative formed roller".
Currently, more than 19,000 Sandvik formed rollers have been delivered to Vattenfall in the Lusatia region. The technicians as well as the purchasing managers are very satisfied with the relationship, which includes both the delivered formed rollers and the services provided by Sandvik. Vattenfall's order of another 1,700 sets of 3-roller garlands of HM150 for a cross country conveyor system shows the positive overall impression of the company, brand and product.
In the 19th century, Prince Pückler planted fully grown trees in his 750 hectare landscape park for the first time. Since 2007 Vattenfall has followed in his footsteps and afforested three million deciduous and coniferous trees as part of its recultivation programme of its used surfaces in a region which was characterised by only pine forests. Furthermore, by 2030 a 1,900 hectare large "Eastern Lake" shall be created which will be the largest artificial inland water in the Lusatia region – it may not be an UNESCO Word heritage site, but it will certainly be an attractive area for sports and relaxation for generations to come.
From this point of view Sandvik with the HM150 currently plays a leading role in the present era in production and the transportation of lignite.
Sandvik HM150 formed roller
The term "formed roller" refers to both the specific and optimised production procedure of Sankvik and also to the final product. By using high-precision production procedures and facilities, the HM150 formed rollers feature improved characteristics which are described in the following list:
- optimised load distribution in the ball bearings
- weight reduction of the formed roller by 10 - 30%
- inherent balance G smaller 14 according to DIN ISO 1940
- maximum concentricity deviation ~ 0.3 mm
The component optimised, patent-protected HM150 formed roller mainly consists of the load-resistant and deformation-reduced flow formed shell, bearing seats manufactured by means of deformation (end formed), the forged hollow shaft as well as the newly developed highly effective labyrinth seals.
Sandvik HM150 formed rollers are available in the following sizes (see Table below)
Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2009, the Group had about 44,000 employees and representation in 130 countries, with annual sales of nearly SEK 72,000 M.
Sandvik Mining and Construction is a business area within the Sandvik Group and a leading global supplier of equipment, cemented-carbide tools, service and technical solutions for the excavation and sizing of rock and minerals in the mining and construction industries. Annual sales in 2009 amounted to about SEK 32,600 M, with approximately 14,400 employees.
Sandvik HM150 Rollers in Action
Sandvik’s HM150 Roller in Action on the World's Largest Conveyor Bridge
The Swedes play a leading role in the production of lignite
Prince Herrmann Ludwig Heinrich von Pückler-Muskau, a landscape gardening genius, built the Muskau Park in the Lusatia region in 1817 – it is part of a UNESCO world heritage site today. In the same era, 1850, the first lignite was mined in the region and still today, Vattenfall, the Swedish company, extracts lignite without financial subsidies - in Jänschwalde among other places, one out of the five open-cast mines currently in operation. As one of the largest employers and apprenticing companies in East Germany, Vattenfall currently employs almost 8,000 employees and about 800 apprentices. Sandvik Mining and Construction also plays a leading role - in the literal sense. At the Jänschwalde location there are 320 sets of 5–roller garlands of HM150 formed rollers in action on the overburden conveyor bridge AFB 60m. On belt five, the main belt conveyor (belt type 3000 ST3000-18:8, idler spacing approx. 800 mm) and on belt eight, the stockpile belt conveyor (belt type 2750 ST2500-18:8, idler spacing approx. 800 mm).
It all began in the spring of 2004. Bernhard Hofmayer, Production Manager at Sandvik in Schöppenstedt, introduced the HM150 formed roller to Vattenfall. The engineers were impressed by the completely new design and the innovative assembly technique. The discussion about the advantages and disadvantages of the component optimised formed roller were ready to begin.
Quickly and unbureaucratically they were able to agree upon a test phase in the open-cast mine in Welzow-Süd. Due to the extreme operating conditions the highest requirements are demanded for rollers and conveyor systems. The belt speeds at the location are between 10 – 11 m/s and the tonnages add up to 52,000 tons waste hourly. Sandvik accepted this challenge and developed the innovative formed roller.
During the period August 2004 to April 2005 the first 250 rollers all passed the test phase. Vibrations in the entire steel construction of the conveyor bridge were minimised and noise emissions were reduced by about 20 dB (A). The weight savings were beneficial for the statics. The result: operational release by the TÜV [Technical inspection association in Germany]. In conclusion all formed rollers in use on the conveyor bridge were exchanged for the Sandvik HM150.
With the positive experiences from the Vattenfall open-cast mine Welzow-Süd the rollers were also installed in Jänschwalde 50 km away. Vattenfall’s intention for the planned operation of the formed rollers on the overburden conveyor bridge AFB 60m was to improve conditions for employees, residents and the environment by investing in modern technology. Furthermore, it was about fulfilling TÜV requirements.
Even here the focus was on the sophisticated statics of a conveyor bridge weighing 30,000 tons. Through the weight saving of 10 - 15%, which was obtained compared to conventionally manufactured rollers, the extensive and cost-producing modification of the steel colossal was prevented.
The weight optimisation is also an advantage in case of a replacement of a single roller or garland which is required less frequently due to the extremely long operation period of the rollers. "I do not remember that I ever had to exchange one of the 1,600 formed rollers in the last six months," stated Mechanist Christian Ramm. "In-house we call the HM150 fire extinguishers because of their orange-red colour and form," he added. In the first three years the failure rate was at 2.9% well below the statistical average for conventional rollers.
Operative Engineer Peter Hobracht wraps it up: “The lifetime of the rollers, which is prolonged by the low failure rate and the low-noise surrounding area due to the running smoothness, strongly convinced us to use the innovative formed roller".
Currently, more than 19,000 Sandvik formed rollers have been delivered to Vattenfall in the Lusatia region. The technicians as well as the purchasing managers are very satisfied with the relationship, which includes both the delivered formed rollers and the services provided by Sandvik. Vattenfall's order of another 1,700 sets of 3-roller garlands of HM150 for a cross country conveyor system shows the positive overall impression of the company, brand and product.
In the 19th century, Prince Pückler planted fully grown trees in his 750 hectare landscape park for the first time. Since 2007 Vattenfall has followed in his footsteps and afforested three million deciduous and coniferous trees as part of its recultivation programme of its used surfaces in a region which was characterised by only pine forests. Furthermore, by 2030 a 1,900 hectare large "Eastern Lake" shall be created which will be the largest artificial inland water in the Lusatia region – it may not be an UNESCO Word heritage site, but it will certainly be an attractive area for sports and relaxation for generations to come.
From this point of view Sandvik with the HM150 currently plays a leading role in the present era in production and the transportation of lignite.
Sandvik HM150 formed roller
The term "formed roller" refers to both the specific and optimised production procedure of Sankvik and also to the final product. By using high-precision production procedures and facilities, the HM150 formed rollers feature improved characteristics which are described in the following list:
- optimised load distribution in the ball bearings
- tilt angle reduction for the ball bearings
- reduced noise emissions
- higher permissible rotational speeds
- smoothed bearing seats Rz ~ 0,5 µm (reduces fretting corrosion)
- weight reduction of the formed roller by 10 - 30%
- inherent balance G smaller 14 according to DIN ISO 1940
- maximum concentricity deviation ~ 0.3 mm
The component optimised, patent-protected HM150 formed roller mainly consists of the load-resistant and deformation-reduced flow formed shell, bearing seats manufactured by means of deformation (end formed), the forged hollow shaft as well as the newly developed highly effective labyrinth seals.
Sandvik HM150 formed rollers are available in the following sizes (see Table below)
Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2009, the Group had about 44,000 employees and representation in 130 countries, with annual sales of nearly SEK 72,000 M.
Sandvik Mining and Construction is a business area within the Sandvik Group and a leading global supplier of equipment, cemented-carbide tools, service and technical solutions for the excavation and sizing of rock and minerals in the mining and construction industries. Annual sales in 2009 amounted to about SEK 32,600 M, with approximately 14,400 employees.
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