CHAPTER-6 WINDING PART-II 6.

CHAPTER
Winding Part-II
6
6.1 TYPES OF WINDING SYSTEMS-DRUM AND
KOEPE/FRICTION
Winding Systems are classified in mainly two groups : Based on
device employed to hoist the cage to the
surface
1. Drum Winding
2. Friction winding (koepe winding)
CHAPTER-6 WINDING 6.37
6.2 DRUM WINDING

• Drum winding employing cylindrical drum are a

variation of it that is bi-cylindro - conical drum.

• Drum winding employing cylindrical jdrum is the

earliest. Simplest system of winding adopted in
mines.

• One end of winding rope is secured to the hoisting

[Link] other end to secure the cage or skip is
suspended.

• All the mine winders are balanced [Link]

drum accommodates two ropes. One for the
hoisting cage other for the down going cage.

• The travel of two cages is simultaneous loaded

cage coming up empty cage going down.

• The drum in most cases is rigidly keyed to the drum

shaft through drums with provision of clutch are
used in sum cases.

• The shaft shall be swelled at the key seas with a

gradual change of sections at all changes in
diameter. Keys shall be of double tangential type
and fitted with a locking device.

• Installation of winder will be on to a prepared

concrete or steel beam type foundation.

• The foundation should be designed to safely accept

a rope pull of 1.25 times the breaking load of the
rope.

• The diameter of the winding drum should be large to

ensure longer rope life. The larger the D/d ratio, the
lower is the bending stress.
 6.38 MINING MACHINERY
Suggested Drum Diameter (D)/Rope Diameter Ratio
Type of Rope Rope size in mm Ratio (D/d)
Locked coil < 26 80
Locked coil 26 to 44 100
Locked coil > 44 120
Flattened/round
Strand rope All sizes

• The ratio between the drum to wire for stranded

rope is generally kept between 1000-1500.
• For locked coil rope it is recommended to keep the
ratio above 1200.
• Rope life is increased when large drums are used.
• Indian coal mine regulation species a ratio of not
less than 100.
To design the face width of a drum following equation is
used
Single drum - single rope - single layer
B = [(H + L/ D) + A] (d + e)
Where,
B =Drum width, m
H=Hoisting depth, m
L =30 m, spare rope for capping and adjustment
D =drum diameter, m
d =rope diameter, m
Drum width
A =Extra turn of rope usually 2-3 turns for drum winding
e =Gaps between the ropes 2-3 mm
CHAPTER-6 WINDING 6.39
6.3 TYPES OF DRUMS AND THEIR APPLICATION
Classification of Drums
application.

Description Drum Sha

Single,Double. Shallow depth

Type Conical. Moderate depth
Bicylindroconical. Greater depth
Mounting Ground Ground,Tower
Balancing Balanced/ Unbalanced Balanced

6.4 SAFETY DEVICES/EQUIPMENT USED ON

WINDING SYSTEM
1. Mechanical brakes
2. Automatic contrivances
3. Reverse direction prevention
4. Rope deviation limit switch (for keope winding)
5. Tacheo meter used on gear box
6. Saftey catches
7. Guide ropes
8. Keps
9. Safety catches
10. Detaching hook
11. Bell plate
12. Signaling system
13. Depth indicator
14. Over winding control system
15. Over speed control system
16. Time limit switch at pit top
17. Depth indicator
 6.40 MINING MACHINERY

Brakes :
1. Mechanical brakes
2. Electrical brakes
Mechanical Brakes
1. Anchored post brake
2. Suspended caliper braking
Electrical brakes
1. Dynamic braking
2. Counter current braking
3. Regenerative braking
4. Eddy current braking
5. Reverse current braking.
Safety Devices
• A mine hoist must be protected from over travel.
• Travel of a conveyance past the planned/
programmed stopping.
• And over speed (speed more than that required for
programmed for any particular point at the travel in
the shaft).
• Over travel and over speed can cause serious/fatal
injury to men and damage to equipment.
Modern Hoist Controller (automatic contrivances)
provides the following controls
• Previous over speeding in hoisting and lowering.
• Sounds an alarm when normal speed is exceeded.
• Initiates brake application if the winder speed at any
point of the wind exceeds the designed cycle speed
i.e. shadowing the winding cycle.
• Warns the driver when to commence retarding the
hoist and stops it if the warning is not needed.
CHAPTER-6 WINDING 6.41
6.5 PRINCIPAL OF KOEPE/FRICTION WINDING
Friction Winding (Koepe Winding)
• The friction winder also known as koepe winder
after its inventor fredrick koepe.
• It consists of a steam or electrically driven sheave
fitted with renewable friction lining.
• The sheave is grooved to suit the main winding
rope. The arc of contact varies between 1850 and
2300.
• A cage or skip is suspended at each end of the
rope. The rope is not secured to the sheave.
• A tail rope whose ends are attached to the under
side of the cage is always used in koepe winding.
• The tail rope is arranged to hang freely in the shaft
below the lowest winding level.
• The winding rope along the attached cages is
raised or lowered by power transmission.
• The power is transmitted through the friction
between the winding rope and the lining of the
sheave, hence it is known as friction winding.
• The coefficient of friction between, the sheave lining
and the rope is minimum of 0.2.
• The static torque is constan as all the weights other
than the useful pay lode or balanced the power
required for winding is minimum.
• The power varies slightly as the winding levels are
deepened.
• The basic principle behind the friction winder is the
fact that hoist rope passing over a wheel driven by a
prime mover.
6.42 MINING MACHINERY

• The rope has different tensions at points where the

rope enters the wheel and where the rope leaves
the wheel.

e
• The relationship is given by the equation T1/T2 =
Where

T1 = Tensioning in the rope entering in the wheel

T2 = Tensioning in the rope leaving the wheel
e = Base of napierian logarithm
= The coefficient of friction between the sheave
lining and the rope is ranging from 0.35 and 0.5
depending up on materials.
= Angle of wrap of rope around friction wheel in
radians

• The rope may slip over the wheel when T1/T2

exceeds 1.5 to 1.6.

• In general lower the value of T1/T2 less the

possibility of rope slippage over friction wheel.

• Lower the value of T1/T2 less the out of balance the

torque the motor has to drive against.
• The friction winder may employ 2,4 or more ropes,
but the tail rope is only one.
• A tail rope is generally such a size that it has the
same weight per meter length as the weight per
metre length of combined number of main ropes.
• For example, in four rope friction hoist using four 2.5
cm dia flattened strand main ropes of 2.8 kg f/m.
• The correct tail rope would weigh approximately 4 ×
2.8 = 11.2 kgf/m.
CHAPTER-6 WINDING 6.43
• As the friction between between the friction rope
and wood of the thread has to be high for effective
working of the koepe system.
• The locked coil rope, because of its smooth surface,
was long considered to be unsuitable.
• So there was general tendency to use stranded
ropes.
• The flattened strand rope is much favoured.
• But now a days because of high capacity factor
locked coil rope is preferred.

FIG. 6.1
Ground Mounted Koepe Winder
• In the ground mounted koepe winding the winding
engine is installed at the ground level.
• The headgear sheaves are situated one above the other.
• The rope operates in the plane of the koepe driving
wheel without any angle of fleet.

Tower Mounted Koepe Winder

• In the tower koepe the winding engine is erected on
the tower over the shaft.
• This type of koepe winder posses many advantages
over the ground koepe.
• It has a large angle of rope contact on the driving
sheave.
• The angle of contact normally of 200 degrees to
230 degrees.

6.6 STATE THE MERITS AND DEMERITS OF MUILTI ROPE

FRICTION WINDING OVER SINGLE ROPE FRICTION WINDING
MERITS:
 The multi rope friction winder is an improved
over the single rope friction winder and is
essentially a friction drum has as many
parallel grooves as the number of ropes.
 Small diameter ropes are used and the
diameter of the drum is relativey small.
 Reduction in diameter of drum means
increase in drum speed.
 Fever numbers of rope bends.
 Higher operating safety.
 Capable of loading heavy loads.
 Less wear and tear due to absence of fleet
angle.
 Rope is protected from the weather.
 Saving in space at pit top.
 The capital cost of installation is less.
DEMERITS:
 The need for bulky and expensive tower
head frame.
 Complicated .
 More number of ropes and more
maintainance is needed.
6.7 MERITS AND DEMERITS OF KOEPE/FRICTION
WINDING
Merits
• Koepe system is most suitable for winding heavy
pay lodes from large depths.
• Koepe winder is simple for manufacture, compact,
and lighter than the drum winder. Initial cost is
therefore less for similar duties.
• Less costly engine foundation are required for
koepe winder due to lighter weight and
compactness.
• In Koepe system inertia of rotating parts that have to
be set in motion is less compare to a drum winder.
• There is fleet angle in koepe system and where on
teh winding sheave is reduced.
• Operating cost are less due to the smallere rated
output of motor.
• Thus skip/cage doesn’t rest on the keps and
therefore to start it, no shock loads are transmitted
to the ropes and a smaller factor of safety, 6-7 is
adequate.
• A smaller length of main rope is required compare
with rum hoisting using a balance rope, as there are
no extra coil.
CHAPTER-6 WINDING 6.47
Demerits :
• The winding possible from one level only if the two
skips/cage are nearly balanced. Formulating level
clutched cylindrical drum winder have a definite
advantage.
• Koepe system can be used for only vertical shafts
not for inclined as guiding and tensioning of balance
rope possess problems.
• Koepe systems cannot be used during shaft sinking.
• Koepe system is not suitable for shallow shaft as
cylindrical drum size, if drum wind is adopted would
be nearly, the same as the koepe sheave size.

• A deeper shaft sump is required to accommodate

the tail rope loop.
• Separate run with one cage is impossible.
• The rope changing equipment cost more than the
balance rope requires heavier suspension gear and
stronger shaft conveyance.
• If the rope breaks both cages fall in the shafts.

6.8 DISTINGUISHES BETWEEN DRUM AND FRICTION

WINDING

Difference between drum and friction winding

[Link]. Drum Winding Friction/Koepe Winding

1. It s used for lowering and It is used for hoisting materials

raising men and materials.
2. Operated at low speed. Operated at high speed.
3. Production obtained is less. Production obtained is more.
4. Best suited for shallow depths Best suited for deep depths.
 6.48 MINING MACHINERY
5. Installation cost is less Installation costis more.
compared to friction winding.
6. Does not require elaborate It requires elaborate loading
and unloading arrangements. arrangements.
7. Dust produced is less. Dust produced is more.
8. Cannot be used in incline Can be used in incline shaft.
shaft.
9. Keps are used to hold the Keps are used in this type.
cage at pit top.
10. Time for loading and un- Time for loading and
loading is more. unloading is less.

6.9 THE SAFETY EQUIPMENT USED IN DRUM WINDING.

1. Mechanical brakes
2. Automatic contrivances
3. Reverse direction prevention
4. Tacheo meter used on gear box
5. Saftey catches
6. Guide ropes
7. Keps
8. Safety catches
9. Detaching hook
10. Bell plate
11. Signaling system
12. Depth indicator
13. Over winding control system
14. Over speed control system
15. Time limit switch at pit top
16. Depth indicater.
6.10 PRINCIPLES OF BREAKING IN WINDING

Principle of Braking :
• Whenever brakes applied it should controlled the
speed of the winding drum.
• The brake should apply uniform pressure over the
brake lining path.
• So that the brake immediately control the speed

PHOTO OF BRAKING.

The method of braking to be adopted in a particular case will depend upon the energy
To be absorbed in the retardation [Link] the energy to be absorbed is small the power
May be cut off and the wind allowed to slow [Link] can be adopted to winders upto a
Depth of 200m by mechanical brakes to bring the cages gently to rest.
For deeper shafts some form of electrical braking is normally adopted for electrical
Winders in additions to the mechanical braking which is required by the mining law.

Different types of Brakes used in Winding :

Types of brakes used in winding are mainly

1. Mechanical brakes

2. Electrical brakes

[Link] BREAKS.

1. Anchored post brake

2. Suspended caliper braking

[Link] BREAKS.

• Dynamic braking

• Reverse current braking

• Regeneraive braking
CHAPTER-6 WINDING 6.49

6.11 SUSPENDED CALIPER BRAKE

• The mechanical brakes act directly on the winding

drum.
• The brakes exhibit uniform pressure on brake lining
path of winding drum.
• In suspension caliper brakes the brake lining arms
are connected by means of bent levers.
• The braking arms are attached to the pivot arm.
• The pivot arm keep the brake arms in position.
• The brake arms so connected to the bent lever inter
connected to the operating lever counter weights.
6.50 MINING MACHINERY

• The weights are used to provide required braking

force.
• The braking force is applied over the drum
whenever lever is operated.
• When the operator wants to apply brakes simply he
operates the lever.
• When the operating lever point is pressed.
• The lever point will cause to apply pressure over the
drum.
• So the drum speed is reduced.
• In suspended caliper brake the lever is operated.
• The uniform load is applied on A, B, C, D as shown
in figure.
• If uniform pressure is not applied there is a chance
of un even wear and tear of the brake lining path
and the braking is not efficient.
CHAPTER-6 WINDING 6.51
6.12 ELECTRICAL BRAKING
There are three methods of applying electrical braking to
an electrical winder :
• Reverse -current braking.
• Regenerative braking.
• Dynamic braking.
Reverse Current braking
• To apply reverse current or counter current braking
(plugging) the supply to the motor is reversed.
• So an opposite torque is developed opposing the
load torque.
• The rotor voltage under full speed lowering
condition will be approximately twice the normal
voltage.
• Consequently a high resistance is required to limit
the current in the rotor circuit.
• This method is safe from full speed down to zero
and can be easily controlled by the driver.
• This can be effectively adopted in shallow mines.
From energy point of view this method is very
wasteful and inefficient.
• This needs motor to be specially designed to with
stand voltage reversing stress.
• This requires an increase in the insulation of the
rotor and the slip ring.
• Further more, unless a wide range of resistance is
provided the reverse current braking is too fierce
under most conditions.
 6.52 MINING MACHINERY

Regenerative Braking
• Regenerative braking occurs when motor runs at a
speed higher than the synchronous speed.
• A rise of about 5 to 10% above synchronous speed
will cause the motor to develop twice full load
torque.
• It can only be applied in full increase in .speed
above synchronous is permissible.
• Obviously this limits the application of the system to
deeper shaft.
• The driver must be highly skilled and level headed
and any mistake may lead to over speeding.
• At the end of the cycle either mechanical brake or
reverse current braking is applied.
• In a MG system this type of braking is normally
available by reversing the poles of the winder motor
and the MG set.
• The back emf generated by the winder motor is
higher when the generator field is reduced and the
winder motor acts as a generator and feeds power
back to the main supply and braking torque is
generated.
• It is obvious that are serious drawbacks with both
the above methods of braking.
• To over come this, several supplementary systems
such as eddy current generator etc . were
introduced.
• They did not gain popularity and only added to the
complexity of the problem.
CHAPTER-6 WINDING 6.53
Dynamic Braking
• A slip ring motor can be made to function as an A.C.
generator.
• If the stator is supplied with [Link] and the
rotor is connected to a variable resistance.
• Due to the interaction between the stationairy
magnetic field set up in the stator by D.C. and the
current induced in the rotor.
• A braking torque is developed which can be utilized
to control the load.
• The magnitude of this torque depends upon the
amount of excitation applied to the stator and the
value of the resistance which determines the
current in the rotor circuit.
• This value rotor resistance at which maximum
braking torque which is developed is usually called
“critical resistance”.
• Increasing excitation increases the torque and
reduces the value of rotor resistance at which the
charge occurs, moving the peak as shown in typical
curves.
• The torque resistance characteristics also change
with the speed of the motor.
• The peak value of torque developed on the
excitation applied to the stator but will occur at
lower values of rotor resistance as the speed is
reduced.
• The mechanical and electrical inter locks ensure the
correct sequence of operations.
• This modified circuit has been introduced in many
installations.
6.54 MINING MACHINERY

REVIEW QUESTIONS

1. List the types of winding system.

2. Explain the drum winding.
3. List the types of drums.
4. List the Safety devices used on winding system
5. Explain the principle of friction winding.
6. Merits and demerits of multi rope over single rope friction winding.
7. List the merits and demerits of koepe winding.
8. Comparision between drum winding and friction winding.
9. List the Safety equipment used in drum winding .
10. State the principle of braking in winding .
11. Describe the suspended calliper brake.
12. List the electrical braking.
ss