Train Mover Design

KMK was awarded a contract for designing an Indexer machine as part of a new Car Dumper system for 8000 tph (tonnes per hour) throughput.

Wagon handling plants around the world require machines to handle trains of wagons to enable the unloading of these wagons. Typical bulk materials include Coal, Iron ore, Bauxite, etc.

KMK have extensive experience in the design of these Train movers.

A recent project was the supply of a design of Train mover (“Indexer”) to handle a train of 152 wagons. This required a Train mover of a pulling load capacity of 150t. This capacity puts this machine into the category of the largest train movers in the world.

This machine was designed to client’s requirements, fully compliant with all modern design codes (e.g BS EN 13001 parts 1, 2 & 3) and include the production of all mechanical procurement specifications.

The features of this machine include:

• Load calculations conducted using KMK in house developed, verified and validated train simulation software KSIM.

• 12 drive, Pinion/rack driving system utilising a back-to-back twin track system.

• Compact, (short) design due to the use of a twin drive rack system. (result is less main frame deflection and consequently reduced pinion/rack misalignment).

• 4 travel wheel system with 3 fixed wheels and 1 self-adjusting (sprung) wheel to accommodate travel rail vertical deviation.

• Compact Arm counterbalance raising/lowering system to reduce hydraulic cylinder pressures.

• Arm to wagon coupler design to ensure efficient pulling load transfer to wagon coupler.

• Overhead onboard electrical cable routing system for efficient and rapid electrical installation.

• Full structural analysis (via Ansys FEA) of both loading arm and main train mover body.