dragline rigging - bradken · 12 13 rigging dump lock the dump block forms part of bradken’s...

33

DRAGLINE RIGGING

54 5

BRADKEN KNOWS THE MININGMARKET

OUR BUSINESSBradken is a global manufacturer of differentiated capital and consumable products to the mining, transport, general industrial and contract manufacturing markets with a sales and distribution network servicing customers around the world.

As a leading heavy engineering company we can manufacture fully machined cast iron and steel products from a

mass of 0.5 kg (1.1lbs) to 25 tonne (55,000 lbs). Bradken produces consumable wear products for all types of

earthmoving equipment to the global mining and quarrying industries. Our products include:

• Ground Engaging Tools (GET) and associated wear parts,

• Dragline rigging packages,

• A range of buckets to suit dragline, front-end loader, face shovel and hydraulic excavator equipment, and

• Undercarriage systems and componentry for hydraulic mining excavators and electric rope shovels.

Our experienced engineering team is able to adapt our range of Bradken designed products to address the

specific requirements and challenges presented by the diversity of the global mining market.

Bradken recognises that when it comes to dragline rigging, you’re only as strong as your weakest link. We manufacture an extensive range of dragline rigging components for a variety of applications and machines to provide customers with reliable and innovative solutions to suit their individual mine site needs.

With over 90 years’ experience

in the foundry business, the

accumulated wealth of knowledge

and depth of expertise in our

workforce enables us to offer our

customers a full service offering

with design, manufacturing,

maintenance and support services

ultimately providing improved

operational outcomes and safer

work practices.

With a worldwide network of

foundry and manufacturing

facilities and an established sales

and distribution network, our

geographical diversity allows us to

provide product, technical support

and advice, and exemplary service

to customers in the world’s major

mining and industrial regions.

EXPERIENCE DESIGN CAPACITY

Our range of Ground Engaging

Tools (GET), Buckets and

Rigging have been designed and

manufactured by our skilled and

experienced team to provide quality

and innovation that in turn provides

our customers with reductions

attributed to their Total Cost of

Ownership (TCO), whilst providing

improved safety features to reduce

the risk of injury at site.

76 7

SWIVEL MOTION

Harmonise Upper Hoist system has been designed with freedom

of movement where it is needed most. The Integrated

Socket Equaliser ISE has horizontal swivel

movement for better operator control. The Tri-

Link has a vertical swivel motion to reduce

the load on the lower rigging, bucket and

chains during the dig cycle. Overall the co-

ordinated design is stronger, lighter, reduces

inherent stresses and offers the operator

more control.

Bradken’s Harmonise Rigging/Jewellery solution is a collection of innovative designs with a revolutionary

approach to the upper hoist rigging assembly. The new design features the Integrated Socket Equaliser (ISE),

an innovation that seamlessly replaces five components in the upper hoist assembly creating an elegant solution

that also reduces rigging height and weight.

This innovative (ISE) design has proven itself to be a “Fit and Forget” component that can last up to 12 months

without any maintenance or repair, which in turn reduces machine down time and lowers maintenance costs.

• Reduced number of change-outs due to longer lasting parts

• Reduced inventory due to less components in the upper rigging assemblies and only three pin types used

• All Bradken Lifting lugs permit latched hooks to be used for a safer installation

• Bradken have maintained the Strength Safety Factor while reducing the mass on a number of rigging

components by using intelligent design and superior materials

• No welding of cover plates required to contain Bradken APT pins, saving time by eliminating unnecessary

labour thereby reducing the risk of injury.

HIGHER SPOIL

The innovative Integrated Socket Equaliser (ISE) is unique to the Bradken Harmonise range. The ISE reduces

rigging height by more than a metre,the resulting gain in spoil height (dragline dependant) is also a large

advantage at spoil bound mine sites to reduce rehandle and walking time. A saving of 1 metre in spoil height

can gain your site an extra 4% pile volume.

REDUCED RISK EXPOSUREBradken is committed to providing reduced risk wherever possible:

Swivel/Miracle Hitch Hoist Package

ISE Swivel/Miracle Hitch Hoist Package

ISE Tri-Link Hoist Package

CENTRELINE WEDGE

Wedge removal can often require heavy hammering - a potential safety risk. Bradken has included the centreline

wedge concept in our sockets. They are safe, easy and quick to change in the field and are designed to utilise

the hydraulic wedge removal tool already in use at a number of sites.

ISE centreline safety enhancement

Wedge centreline safety enhancement

98 9

pins

APT (Advanced Processing Technology)

Dragline Rigging Pins are manufactured with

high hardness and high toughness which

has proven to last at least three times longer

than conventional rigging pins. This in turn

reduces your maintenance costs and machine

downtime.

Bradken has a range of DRP pins that can fit to

your current rigging package without the need

for modification. Talk to your local Bradken

representative about our current offering of

DRP pins or the opportunity to customise a

pin to suit your rigging requirements.

Take advantage of Bradken’s innovative APT

pins and make the change today.

SAFE INSTALLATION AND REMOVALBradken’s APT pins feature an industry accepted RUD lifting lug, which enables lifting hooks to fully close for

safer removal. Since employing this feature, Bradken has further developed the lifting lug concept following our

continuous improvement process. The latest variation of the pin now has a fully recessed lift point, reducing

the risk of the RUD lifting lug being removed in unforeseen circumstances, where the lug was not used in the

manner that it was designed.

Bradken’s Lifting lug is inset in the pin head, shielding it from damage of being knocked off.

Bradken’s lifting lug allows enough room for lifting hooks to close securely

Traditional Pin

APT Pin

Standard Pin

Heavy Duty Pin

1110 11

HAMMER FREE LOCKING SYSTEM

All Bradken rigging incorporates safe hammer free locking systems. Designed for installation using conventional

tools, Bradken retainer systems are fast and easy to operate.

The unique P-Lock system allows removal of the keeper from two directions, ensuring less handling of heavy

parts.

The T-Lock and B-Lock systems provide your mine site with hammer free locking pin options that are easy to

install and remove. B-Lock provides the added benefit of a fully covered locking head to minimise the risk of

damage.

REDUCTION IN YOUR TOTAL COST OF OWNERSHIP

With operating costs playing a key role in any mine site operations, Bradken has formulated a tool to

showcase the cost savings that our APT pins can provide. Your local Bradken representative will be able to

sit down with you and highlight these savings using our APT Cost Analysis Benefits tool.

Key OEM Pin Costs Bradken Pin Costs

350,000

300,000

250,000

200,000

150,000

100,000

50,000

(AU

D$

)

(MONTHS)

1 2 3 4 5 6 7 8 9 10 11 12

T-Lock locking system B-Lock system features a completely covered head to minimise risk

of breakages

P-Lock pin removes from both ends allowing for no hassles when rigging is positioned on the ground

P-LockB-LockT-Lock

PIN PLACEMENT

Bradken’s Harmonise pins have been designed to fit flush in rigging parts, reducing the risk of pin damage

and unscheduled down time.

LONG LIFE

Bradken has actively trialled APT pins against competitor offerings and has continually been able to exceed

the OEM part by more than three (3) times, in some instances, the part has lasted more than eight (8) times.

REDUCED INVENTORY

Bradken’s Harmonise Dragline Rigging products were designed simultaneously, which enabled Bradken to

consolidate pins and reduce inventory.

ISO View Side View

APT Pin

APT Pin

B-Lock

Hoist Link

Pin sits inset protecting it from damage

OEM BRADKEN

(WE

EK

S)

14

12

10

8

6

4

2

0

Key OEM Pin Bradken Pin

1312 13

RIGGING DUMP LOCK

The dump block forms part of Bradken’s Harmonise rigging system. This system has utilised the very latest

technology in engineering and has already demonstrated massive productivity gains over the current market

offerings.

INTERCHANGEABLE CAST CLEVIS

Bradken’s Dump Block features the option of a vertical or a horizontal cast clevis, which can be made to suit

any size dump rope between 50mm and 95mm. Bradken’s Harmonise Dump Block can be used with Bradken’s

Harmonise Rigging Package or your existing rigging.

Bradken Packages Competitor PackagesCast dump block clevis for strength

Plate dump block sides, reduces weight and costs

Dump block sides are manufactured separately to the clevis for easy removal

Competitor dump block sides and clevis combine into one castling, which increases weight and refur-bishment costs

Competitor clevis change out requires the clevis and side plate to be replaced

Option 2

Interchangeable Vertical Dump Block Clevis

Option 1

Interchangeable Horizontal dump block clevis

The Dump Block is known to wear faster than other parts of the Dump Block assembly. Bradken has developed a separate cast Dump Block Clevis to reduce maintenance costs and reduce downtime.

1514 15

COMPATIBLE WITH BECKETED ROPES

One of the unique features of Bradken’s Harmonise Dump Block is the ability to use it on a number of machines at

your mine site operations. The 48” Dump Block encompasses the most common dragline machines (see packages

page for machine classes) and is designed to be used with becketed ropes, ensuring there is no additional

downtime attributed to changing dump ropes during planned/unplanned maintenance breaks. The Dump Block is

also designed to suit rope sizes of 51mm (2”), 76mm (3”) and 83mm (3 1/4”).

ENGINEERED TO LAST THE DISTANCE

The Dump Block features 20% larger bearings compared to OEM offerings, enabling the bearing life to double

that of the competition. Finite Element Analysis (FEA) has been used to effectively reduce the weight by making

sure that there is no wasted mass in the dump block while at the same time optimising the material for maximum

strength.

CHAIN

Bradken’s Harmonise Chain combines innovative design with

world class manufacturing and inspection techniques to

provide reliability, safety and reduced operating costs.

Available in a range of chain lengths and sizes to suit

Hoist, Drag and Dump Chain configurations.

Clearance for rope ferrule

Flexible design allows for the use of standard rope

and becketed rope

Clearance for rope ferrule

36

30

24

18

12

6

Competitor Small Bearings

Competitor BearingsBradken Small Bearings

Bradken Bearings

Bearing Conparison Indentical Test Conditions

(Mon

ths)

OPTIMISED MATERIAL DISTRIBUTION

Bradken’s product development team optimised the crotch/bight contact between

all Harmonise links by increasing the surface area to improve sliding contact. This allows for

a more uniform wear, which in turn decreases the contact pressure and maximises chain life.

Hard Facing options to suit site specific conditions.

Competitor LinkUneven wear of crotch/bight

Bradken LinkEven wear of crotch/bight

Advanced geometry to evenly distribute contact pressure under load

Section View of a Intermediate Link

Competitor LinkBradken Link

Increased crotch/bight thickness increases strength and provides more

wear material

1716 17

INCREASED WEAR MATERIAL WHERE IT MATTERS

Bradken chain was designed using dynamic simulation analysis and Finite Element Analysis (FEA) in order

to provide increased wear material where needed whilst keeping the rigging weight to a minimum. The chain

features a greater section thickness in high-wear crotch/bight areas, particularly in the step-up and stud-end

links. The chain is cast in Bradken Intellectual Property (IP) alloys, with options suitable for abrasive and high

impact sites.

BRADKEN 3” DUMP CHAIN VS 2.5” DUMP CHAIN

Bradken’s dump chain provides unparalleled benefits to other like products currently being offered in the

market.

Bradken’s larger heavy duty 3” dump chain has been designed with additional wear material in high wear areas

while maintaining a similar weight to a standard 2.5” assembly.

The 3” chain assembly requires fewer links to achieve comparable lengths to the 2.5” assembly, which means

it can be installed without requiring modifications to the dump rope as there is no adverse effect on the bucket

carry angle.

The Bradken 3” dump chain offers improved wear life resulting in less downtime and reduced maintenance

costs.

MECHANICAL REPAIR LINKS - HAMMER FREE

The Harmonise range features a hammer free Mechanical Repair link to suit a wide range of chain sizes

and OEM equivalents. The mechanical repair link reduces unscheduled downtime caused by chain

failures

Competitor Link Competitor LinkBradken Link Bradken Link

Wear Material distributed towards high wear areas at the

ends of the link

Increased material on tie bar for added strength

Increased crotch/bight thickness in common

high wear areas

3410mm

3345mm

2.5”

3”

Mechanical Link

Temporary solution to reduce unscheduled downtime

Hammer free system for improved safety

• Made from superior cast alloy

• Standard dump or becketed socket options

• Centreline socket system allows for easy wedge

removal with a hydraulic ram

• Hammer free locking system(s)

• Optimised fit with other Bradken linkages

• Significant mass reduction compared to

competitors

• Optimised fit with mating anchor links, dump

links and dump equaliser

• Added wear material in high wear areas


• Hard Facing Options available

• APT pins allow for reduced inventory and

operating costs

• Selection hammer free of locking systems

• Fits existing bucket hitches

• Increased wear material where needed

Pin Size Rope Size

CLASS 1, 2 ,3

4.25”

HARD FACING OPTIONS AVAILABLE

Pin Size

DUMP SOCKET

DUMP SHACKLE/HITCH LINK

CLASS 1, 2 ,3

5”

80mm to 83mm31/8” to 31/4”

4.25”5”

1918 19

CLASS 2

6” 4.25”

80 to 89mm31/8” to 31/2”6” NO LUG

6” 4.25”

CLASS 3

7” 4.25”

92 to 102mm3 5/8” to 4”

7” 5”

7” NO LUG

6” 4.25”

7” 4.25”

CLASS 4

9” 5”

119 to 127mm4 3/8” to 5”

9” NO LUG

9” NO LUG

DRAG SOCKET


• Centreline socket system allows for easy

wedge removal with a hydraulic ram

• Optimal force flow design, distributing

pressure evenly on rope



DRAG SHACKLE /HITCH LINK



• Surface crotch fit with Pear Links

• APT pins allow for reduced inventory and costs

• Selection of locking systems

• Fits existing bucket hitches


HARD FACING OPTIONS-AVAILABLE IN ALL SIZES

CLASS 1

6” 80-98mm31/8” to 31/2”

CLASS 2

8”92 to 102mm

3 5/8” to 4”

CLASS 3

8”9”

110 to 127mm4 3/8” to 5”


• Male and female hoist sockets

• Centreline socket system allows for easy wedge

removal with a hydraulic ram

• Hammer free locking system(s)




• Optimised to fit 3”,3.5”,4” and 4.5” hoist chain

• APT pins allow for reduced inventory and

operating costs

• Selection of hammer free locking systems


Pins PinsLug Pins Rope Size Rope Size

SPREADER BAR


• Cast ends

• Incorporates safe hammer free locking

system(s) and APT Pins

• Reversible – Connecting pins can be

inserted from either side

• Available in a range of different lengths


Class 2

Class 2 & 3

Class 4

HOIST SOCKET

Y-LINK

CLASS 2

6”

CLASS 3

7”

CLASS 4

9”

Pin Size

CLASS 2

6”

CLASS 3

8”

CLASS 4

8”9”

Pins

CLASS 2 & 3 HOIST PACKAGES CLASS 4 HOIST PACKAGES

PACKAGE OPTIONS PACKAGE OPTIONS

NAMING CONVENTIONS NAMING CONVENTIONS

Rigging Locking Pin

Spreader Bar Class 2

Chain Size Number of Links Hard Facing

Hoist Chain End Link Type

(optional)

Lower Spreader Bar

Class 2

Length (6.0m)

Upper Hoist Cluster Class 2



Lower Spreader Bar

Class 4

Length (7.0m)

Rigging Lock Length

Lock Type Profile

Rigging Locking Pin




(optional)

Lower Spreader Bar

Class 2

Length (6.0m)




Lower Spreader Bar

Class 4

Length (7.0m)

Rigging Lock Length

Lock Type Profile

Rigging Locking Pin




(optional)

Lower Spreader Bar

Class 2

Length (6.0m)




Lower Spreader Bar

Class 4

Length (7.0m)

Rigging Lock Length

Lock Type Profile

TT TT T

H H

D D

BB BB B

PP PP P

SS SSSS SS

(T -Lock) (T -Lock)(T -Lock) (T -Lock) (T -Lock)

Intermediate Link Intermediate LinkIntermediate Link Intermediate Link

(B -Lock) (B -Lock)(B -Lock) (B -Lock) (B -Lock)

Stud-End Link Stud-End LinkStud-End Link Stud-End Link

(P -Lock) (P -Lock)(P -Lock) (P -Lock) (P -Lock)

H2UH83S

30HC 40HC30HC 40HC

30HC09 40HC0930HC09 40HC09

2UH83ST

Optional Locks Optional Locks Optional Locks

Lower Hoist Package Lower Hoist PackageUpper Hoist Package Upper Hoist Package

Harmonise Harmonise

Dragline Dragline

Connecting Ring & Spool Connecting Ring & Spool

Y-Link Y-Link

Optional Parts Optional PartsY-Link

Y-Link

Optional Part

Optional Part

SS SSSS SS

Only three different sized pins are used in the entire

rigging package.


rigging package.


rigging package.


rigging package.


rigging package.

Traditional Pin108mm (4.25’’)

Traditional Pin108mm (4.25’’)

Traditional Pin152mm (6’’)

APT Pin108mm,127mm,152mm

(4.25”, 5”,6”)


(4.25”,5”,6”)

APT Pin 108mm (4.25’’)

APT Pin 152mm (6’’) Standardisation Standardisation Standardisation Standardisation Standardisation

Spreader Bar Spreader Bar

LSB2 - LSB2 -

50 64

77 84

LH: UH:

LH: UH:

Lower Hoist Upper Hoist

Lower Hoist Upper Hoist

H: Harmonise D: Dragline Replacement

H: Harmonise D: Dragline Replacement

S: Swivel LinkT: Tri-Link

S: Swivel LinkT: Tri-Link

SS: Stud end, Stud endPP: Pear link, Pear link

SS: Stud end, Stud endPP: Pear link, Pear link

Rigging Cluster: Rigging Cluster:

Link Type: Link Type:

End Link Type: End Link Type:

Locking Pin: Locking Pin: T: T-LockB: B-LockP: P-Lock

T: T-LockB: B-LockP: P-Lock

Assembly: Assembly:

07

15

07

15

07

15

07

15

Rigging Locking Pin




(optional)

Lower Spreader Bar

Class 2

Length (6.0m)




Lower Spreader Bar

Class 4

Length (7.0m)

Rigging Lock Length

Lock Type Profile

Rigging Locking Pin




(optional)

Lower Spreader Bar

Class 2

Length (6.0m)




Lower Spreader Bar

Class 4

Length (7.0m)

Rigging Lock Length

Lock Type Profile

4UH127TT

H4UH127T

Upper Hoist ClusterUpper Hoist Cluster

Rigging Locking Pin




(optional)

Lower Spreader Bar

Class 2

Length (6.0m)




Lower Spreader Bar

Class 4

Length (7.0m)

Rigging Lock Length

Lock Type Profile

4


(5”, 6”, 9”)

APT Pin 279.4mm (11”)

UPPER HOIST CLUSTER CLASS 2 UPPER HOIST CLUSTER CLASS 2

HOIST CHAIN HOIST CHAINSPREADER BAR SPREADER BAR

Australia

China

Europe

North America

South America

Africa

© 2017 - Bradken®

20 McIntosh Drive, Mayfield West, NSW 2304 Australia T +61 2 4926 8200 F +61 2 4926 8201E [email protected]

PACIFIC20 McIntosh Drive, Mayfield West, NSW 2304 Australia T +61 2 4926 8200 F +61 2 4926 8201E [email protected]

AMERICASSuite 647, 12200 NW Ambassador DriveKansas City MO 64163 USAT +1 816 270 0700F +1 816 270 0799E [email protected]

AFRICAUnit G1 The Palisades 39 Kelly RoadJet Park South AfricaT +27 11 390 0100F +27 86 615 0876E [email protected]

ASIANo.120, XuHai Road SouthEconomic Development ZoneXuzhou P.R. China 221131 T + 86 516 8355 3958F + 86 516 8355 3959E [email protected]

Regional Head Offices

Global Corporate Centre

Visit bradken.com for your local representative.

Ref: 3 BKM SP MKT Dragline Rigging - July 2016

dragline rigging - bradken · 12 13 rigging dump lock the dump block forms part of bradken’s...

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