Head Gears

HEADGEARS
DEFINATION
• HEADGEARS ARE STRUCTURES PRESENT OVER THE MINE
SHAFTS AND USED TO HOUSE SKIPS OR AND CAGES.
• HEADGEARS ARE ALSO KNOWN AS GALLOW FRAMES,
WINDING TOWERS, HOIST FRAME, PIT FRAME OR HEADGEAR.
• IT GIVES DISTICT LOOK TO THE MINE THUS IT IS USED AS A
SYMBOLISM FOR THE MINES.
TYPES OF HEADGEARS
• HEADFRAME WITH BACKLEGS
USUALLY MADE OF STEEL THESE STRUCTURES CAN BE A –
FRAME, OR FOUR POST OR SIX POST ETC.
A- FRAME HEADGEARS ARE SUPPORTED BY AN A-SHAPED
BACKLEGS.
TOWER HEADGEAR
• BASICALLY CONSISTS OF A TOWER WHICH HOUSES THE
SHEAVE WHEEL.
• THE TOWERS ARE MADE OF EITHER STEEL OR CONCRETE OR
BOTH
ADVANTAGES OF STEEL
HEADFRAMES
• Faster construction time.
• Flexible design
• Construction mostly unaffected by weather
• Overal structure weighs less than concrete
• Generally less expensive than concrete structures
• Better suited for temporary mines
• Steel has resale value
ADVANTAGES OF CONCRETE TOWERS
• MORE STABLE THAN STEEL

• STRUCTURE CAN BE USED FOR STORAGE OF MATERIALS
• VISUALLY MORE APPEALING THAN STEEL STRUCTURE
• NOT PRONE TO CORROSION
SHEAVE WHEEL
• A LARGE GROOVED WHEEL ON TOP OF A HEADFRAME OVER
WHICH THE HOISTING ROPE PASSES.
• THE SHEAVE ALLOWS THE ROPE TO CHANGE DIRECTION
WITHOUT DEMAGE TO THE ROPE.
• IT IS MADE OF HARD MATERIAL THAT CAN WITHSTAND THE
HIGH PRESSURE EXERTED TO IT BY THE ROPE UNDER LOAD
AND THE EFFECTS OF ATMOSPHERIC CONDITIONS.
MATERIAL USED TO CONSTRUCT
SHEAVE
• UPTO 2.75MPa GREY CAST IRON
• UPTO 5MPa CAST STEEL
• UPTO 6MPa CHILLED CAST IRON
• ABOVE 6MPa MANGANESE STEEL
SHEAVE GROOVE
• THE RADIUS OF THE GROOVE MUST BE SMOOTHLY FINISHED
TO FORM A TRUE ARC OF A CIRCLE 10% GREATER IN
DIAMETER THAN THE ROPE DIAMETER.
• RUBBER AND POLYURETHANE HAVE BEEN USED
SUCCESSFULLY AS GROOVE LINERS AND CAN BE REPLACED
EASILY
TRED PRESSURE
• IS THE AMOUNT OF PRESSURE EXERTED ON THE SHEAVE, TOO MUCH
PRESSURE AND THE SHEAVE WILL FAIL.
• TRED PRESSURE IS CALCULATED AS FOLLOWS
• P=2f/Dd WHERE
• P= PRESSURE
• F= ROPE TENSION
• D= SHEAVE DIAMETER
• d= ROPE DIAMETER
INSTALLATION OF SHEAVE
• A SHEAVE CAN ONLY BE INSTALLED IN THE PRESENCE OR UNDER
SUPERVION OF AN ENGINEER. A SHEAVE CAN ONLY BE INSTALLED
AFTER THE FOLLOWING INFORMATION HAS BEEN ESTABLISHED.
• SERIAL NUMBER AND DATE OF MANUFACTURE
• THE DIAMETER OF ROPE FOR WHICH IT WAS DESIGNED FOR
• THE BREAKING STRENGTH OF THE ROPE FOR WHICH IT IS
DESIGNED FOR.
• THE MAXIMUM GROOVE WEAR THAT IS PERMITED
INSTALLATION OF SHEAVE
• IS FITTED WITH A WOBBLE INDICATOR SWITCH
• HAS DIAMETER THAT PROVIDES THE SAME RATIO OF SHEAVE
TO ROPE DIAMETER AS IS PRESCRIBED FO THE DRUM TO
ROPE-DIAMETER.
FLEET ANGLE
• FLEET ANGLE IS DEFINED AS THE LARGEST ANGLE OF ROPE
BETWEEN THE SHEAVE AND THE DRUM FLANGE RELATIVE TO
THE CENTRE LINE OF THE DRUM.
• IT CAN ALSO BE DEFINED AS THE INCLUDED ANGLE BETWEEN
TWO LINES, ONE WHICH EXTENDS FROM THE FIXED SHEAVE
TO THE FLANGE OF A DRUM AND THE OTHER WHICH EXTENDS
FROM THE SAME FIXED SHEAVE TO THE DRUM IN A LINE
PERPENDICULAR TO THE AXIS OF THE WINDING DRUM.
ILLUSTRATED FLEET ANGLE
EFFECTS OF FLEET ANGLE ON
WINDING
• WHEN WRAPPED IN MULTIPLE LAYERS THE UPPER LAYERS OF THE ROPE
HAVE A TENDENCY TO CRUSH THE LOWER LAYERS WHILST THE LOWER
LAYERS HAVE A TENDENCY TO PINCH THE UPPER LAYERS. THE RUBBING
OF ROPES AGAINST EACH OTHER HAS A TENDENCY TO WEAR THE ROPE.
• IF THE FLEET ANGLE IS TOO BIG ,THE ROPE WILL TEND TO PULL AWAY
FROM THE FLANGE AS THE LAYER CHANGES, IT WILL TEND TO SPOOL
TOWRDS THE CENTRE THUS LEAVING GAPS.
• GAPS CAUSE RUGGED SPOOLING WHICH MEANS AT BEST EXCESSIVE
ROPE WEAR OR AT WORST ROPE FAILURE.
• IF FLEET ANGLE IS TOO SMALL, THE ROPE MAY NOT PULL
AWAY FROM THE DRUM SOON ENOUGH AND WILL PILE UP ON
THE FLANGE.
• THE ROPE WILL EVENTUALLY ROLL OFF THE FLANGE
CREATING A SHOCK LOAD IN BOTH THE ROPE AND THE
STRUCTURE OF THE MECHANISM, AN UNDISIRABLE AND
UNSAFE OPERATING CONDITION
RECOMMENDED FLEET ANGLES
• OPTIMUM FLEET ANGLES MEANS MAXIMUM ROPE LIFE AND SMOOTH SAFE
SPOOLING SYSTEM.
• IT IS RECOMMENDED TO KEEP THE FLEET ANGLE BETWEEN 0.25 AND 1.25
DEGRESS.
• FLEET ANGLE GREATER THAN 1.25 MEANS THE SHEAVE IS TOO CLOSE TO THE
DRUM.
• FLEET ANGLE LOWER THAN 0.25 MEANS THE SHEAVE IS TOO FAR FROM THE
DRUM.
• THE DISTANCE BETWEEN THE SHEAVE AND THE DRUM SHOULD BE AT LEAST
20 TIMES THE WIDTH OF THE DRUM.
STATUTORY INPECTIONS AND
MAINTANANCE OF SHEAVE WHEEL
• IN TERMS OF SI 109 0F 1990 THE SHEAVE SHALL BE INSPECTED
AND MAITAINED AT LEAST ONCE IN EACH WEEK AT
INTERVALS NOT EXCEEDING 10DAYS AND THE RESULTS THERE
OF LOGGED IN THE MACHINERY RECORD BOOK.

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HEADGEARS

• MORE STABLE THAN STEEL

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