ROPE HAULAGE

Types of Rope Haulage

1)Direct rope haulage
a)Single drum direct rope haulage
b)Double drum direct rope haulage
2)Main & tail rope haulage
3)Endless rope haulage
a)Under rope endless rope haulage
b)Over rope endless rope haulage
4)Gravity rope haulage

1)Direct Rope Haulage

a)Single Drums Direct Rope Haulage: This is simplest
system of rope haulage. It consists of one track, one rope
& one drum which are connected to a motor through
gears. One end of the rope is connected with the train of
tubs on the track & another end of the rope is connected
to the drum. When the drum rotates situated at the top of
the incline, the loaded tubs moves upwards. But for the
downward journey of the empty tubs it does not require
any power because a tub moves downward due to their
own weight. The system can be on inclines steeper than 1
in 12 & the speed of the haulage is 8 – 12 kmph.
Advantages of Single Drum Direct Rope Haulage
1)Simple in operation.
2)Only one brake is required.
3)Extension is easy.
4)Branched roads can also be served, if gradient is
suitable.
5)Can be used in narrow roads.
Disadvantages of Single Drum Direct Rope Haulage
1)High power demands for upper journey of loaded tubs.
2)Efficient breaking system required for downward
journey.
3)High speed haulage demands more maintenance of
track.
4)Cannot be used for less incline roadways.
5)A derailment is associated with heavy damages.
6)Due to high speed more dust, more wear & tear.

b)Double Drum Direct Rope Haulage: It consists of two

drums, two ropes & two tracks but only one driving motor.
One end of each rope is connected with two drums &
another end of rope is connected with the set of tubs. In
such a way that when one set of tub is at incline top, the
other set is at incline bottom. The two drums are
connected with each other. When drum rotates, the rope
coils on one drum & uncoils from another drum. It can be
used if inclination is more than 1 in 12. The speed of the
system is 8 to 12 kmph.
Advantages of Double Drum Direct Rope Haulage
1)Higher output.
2)Less power demand.
3)Branched roads can also be served, if gradient is
suitable.
Disadvantages of Double Drum Direct Rope Haulage
1)Wider roads required.
2)Efficient breaking system required for downward
journey.
3)High speed haulage demands more maintenance of
track.
4)Cannot be used for less incline roadways.
5)A derailment is associated with heavy damages.
6)Due to high speed more dust, more wear & tear.

2)Main & Tail Rope Haulage: In this system the haulage

engine provided with two separate drums, one for main
rope which hauls the loaded tubs up the gradient & one for
tail rope which hauls the empty tubs down the gradient.
When one drum is in gear, the other drum revolves freely
but controlled. The main rope is approximately equal to
the length of the incline & tail rope is twice this length. The
system can be used if the gradient is unsuitable for the
use of direct rope haulage. Its speed is 15 – 18 kmph.
Advantages of Main & Tail Rope Haulage
1)Can be used on less inclined & undulating roadways.
2)Branch roadways can be served.
3)Only one track is required.
4)Less number of tubs is required.
Disadvantages of Main & Tail Rope Haulage
1)Due to high speed more dust, more wear & tear, more
maintenance.
2)Derailment causes high damage due to high speed.
3)More power is required than the endless rope haulage.

3)Endless Rope Haulage: This system consists of double

track, one driving pulley & one return pulley. An endless
rope passes from the driving pulley which is situated at the
inby end & back again to the driving pulley. One track is
used for loaded tubs & another track is used for empty
tubs. Rope moves in one direction only with the speed of
3-7 kmph. Only one train of tubs is attached to the rope at
a time but some times a set of tubs can be attached to the
rope. The system is used where the gradient is less,
generally less than 1:12 or where the ground is undulating.
A squirrel cage motor is commonly employed.
a)Under Rope Endless Rope Haulage: If the rope
passes below the tubs, it is known as under rope endless
rope haulage. In this system there is more wear & tear to
this rope but also there is an advantage that there is more
direct pull on the tubs.
b)Over Rope Endless Rope Haulage: If the rope passes
over the tubs, it is known as over rope endless rope
haulage. In this system rope is unaffected by wet floor &
liable to wear & tear. The rope is at better working height
& a system is generally used for undulating roadways.
Advantages of Endless Haulage
1)Because of slow speed, less wear & tear to the tub
wheel & track.
2)Less maintenance is required.
3)Accidents do not cause much damage.
4)Less motor power required.
5)Continuous flow of mineral or coal is attained.
Disadvantages of Endless Haulage
1)It requires wider roads.
2)Not suitable for Steeper gradient.
3)Load on the rope is large hence a rope of large cross
section require.
4)Large number of tubs & clips are required.
5)It cannot serve a branch road.
6)Extension is not simple.
7)Minor injuries to hands & feet are common.
Driving Pulley or Surge Wheel
Types of Driving Pulley & Surge Wheel
1)Clifton pulley.
2)V-grooved pulley.
3)Fouler’s pulley.
1)Clifton Pulley: This pulley has tapered throat lining of
renewable cast iron or soft steel segment having a taper of
about 1 in 8. These segments are bolting to the rim to
protect the main pulley from wear. The rope is coiled
several times (3 ½ - 4 ½) around the pulley & it enters the
pulley at larger diameter & leave the pulley at smaller
diameter. This pulley is commonly used in mines in
endless haulages.
2)V-Grooved Pulley: This pulley consists of two
segments made of renewable cast iron or soft steel. These
segments are bolted to the main pulley in ‘V’ shape. The
rope takes only a half turned around the pulley & takes the
necessary grip by becoming wedged between the two
inclined segments. The grip on the rope is directly
proportional to the tension in the rope.
3)Fouler’s Pulley: It consist of number of bell shaped
pivoted segments made of renewable cast iron or soft
steel. These segments are pivoted to the main pulley as
shown in figure, the pressure of the rope on bottom of the
segment towards each other so that they grip the rope in
proportion to its tension.

Types of Clips
1)Screw clip.
2)Small-man clip.
3)Cam clip.
4)Goose neck clip.
5)Lashing chain.
1)Screw Clip: It consists of two jaws i.e. lower jaw &
upper jaw. When the distance between two jaws is enough
to accommodate the rope, the moving rope is placed in
between the jaws & the handle operated which reduces
the distance between the two jaws. Hence the two jaw
grips the load rope, due to this grip as well as tub starts
moving with the rope because the clip is connected to the
tub & through a rod or lever.
2)Small-Man Clip: It consists of two side plates loosely
held together by a bolt which has a spring which keeps the
two plates apart. A hand lever pivoted at ‘P’ & carries a
wedge at its upper end. When the hand lever is
depressed, the wedge enters between the two plates to
grip the rope. The clip can be detached automatically from
the rope by fixing a trite bar to the sleeper which raises the
hand lever to release the rope.
3)Cam Clip: It consist of a plate having its one edge bent
over to form a groove into which the rope is pressed a
gripped by a lever which is pivoted & other end of the lever
is connected to the tub to a chain. The pull on the chain
turns the lever to grip the rope. The grip on the rope is
proportional to the load.
4)Goose Neck Clip: It consist of an ‘S’ shaped hook
loosely into the holders mounted on the end of the tub as
shown. When the rope is placed in position in the hook at
either end or at both end of the tub, the hook turns through
about 300 & grips the rope. The grip on the rope is
proportional to the tension in the rope. But this grip bends
the rope which reduces the rope’s life.
5)Lashing Chain: It consists of a chain 2.5 to 3.0 meter
long with a hook at each end. One hook is attached to the
tub & other end of the chain is coiled 3 to 4 times around
the rope & the hook is linked to the chain. On undulating
roads chain should be used at both the ends. Generally in
this case a set of tubs is attached with the rope at a time.

Tensioning Arrangement for Endless Rope Haulage

For the proper working of endless rope haulage a uniform
tension should be maintained in the endless rope. The
common practice to ensure proper rope tension is to pan
the rope half turned around the pulley mounted on the
tension which is placed on the rope. Heavy weights are
attached to the boggy through chain & wire rope. This way
the weight always acts downwards. Hence a uniform
tension in the rope is always maintained.
The correct place for the tension boggy if the slope is most
likely to occur. Generally the tension boggy is kept at the
bottom end of the haulage.

4)Gravity Rope Haulage: This is haulage without motor

or any external source of power. It is used when load is to
be transported from up hill to down the gradient. It consists
of brake path on one side & is way pulley. It is located at
the top of the incline roadway. The one end of the single
rope is attached to the loaded tub & the other end is
attached to the empty tubs while passing over the jib
pulley. When the loaded tubs moves down the gradient at
sometimes empty tubs moves up the gradient. The brake
strap is provided with brake path & is connected to a lever.
When the lever is depressed the braking effect on the jib
pulley is produced.

Essential Requirements of a Haulage Track

1)Rail should be of an adequate weight & cross section.
2)Sleepers used should be of single track construction.
3)Rail should be jointed by fish plates, bolts & to the
sleepers by log spikes.
4)Track should be well.
5)Change in gradient should be made by vertical curves.
6)Curve should be of large radius.
7)At curves the other rail is super elevated.
8)Cross gradient should be there for good system of
drainage.
9)There should be careful alignment before & after
ballasted.

Safety Devices
1)Backstay or Drag: These are used behind an
ascending set of tubs as a safe guard against a broken
rope or coupling. It is very strong & made up of steel of rail
section. If the tub coupling or rope breaks, the ascending
tub starts moving backward. At the pointed end of the drag
gets fixed in the ground or sleeper to derail the tubs. It is
used in direct rope haulage.
2)Back Catch or Monkey Catch: It comprises a piece of
wood or rail placed in such a way that one end is always
high enough to catch the axle of the backward run away
tub. When the tubs move in moving in correct direction, its
axle presses the elevated end of the back catch so that it
can cross the back catch. In this safety device movement
of tubs is possible because only in one direction. It is used
in endless rope haulage.
3)Spring Catch: It consists of a wooden block at one end
& pressed sideways over the rail at the other end by a
spring as shown in figure. The tub moving in proper
direction pushes aside the wooden block & passes over it,
but due to spring the wooden block at once returns to its
original position to arrest a backward run away tub. It is
used in endless rope haulage.
4)Age Croft Device: It is some what similar to a monkey
catch. But their designs to arrest forward run away
automatically. When the tub is moving in the direction from
B to A as shown in figure the front axle of the tub
depresses the higher end ‘A’ of the pivoted bar AB & so
raises the forked end ‘B’ to axle height. If the tub is moving
at normal speed the ‘B’ end drops before the back axle
reaches it. If the tub is moving very fast, the back axle of
the tub is caught by the end ‘B’ & the tub is held in
position. It is used in endless rope haulage.
5)Jazz Rails: In this safety device, the straight rail track is
giving a very slight curve & again made straight. In some
cases the track is bent at both sides & then made straight.
At normal speed the tubs can easily cross it in either
direction. But the uncontrolled tubs gets a high speed
hence they cannot cross the jazz rails. Hence the
derailment takes place. It is used in all types of haulage.
6)Stop Block: They are made in difficult forms & are used
to stop or derail a moving tub on a track. Generally a
wooden block which is pivoted to the sleeper at one end is
kept across the track to derail the unwanted tubs. The
track can be cleared by positioning the wooden block
inclined with the track. It is used in direct rope haulage &
main & tail rope haulage.
7)Run Away Switch: This switch is normally kept open by
a spring. When a lever handle is operated by an operator,
the switch gets closed. And tubs can pass over it
otherwise the tub derails when they pass over the
runaway switch. It is used with direct rope haulage & main
& tail rope haulage.
8)Runaway Switch & Stop Block: This safety device is
situated at the incline mouth of direct or main & tail rope
haulage.In this safety device the stop block & the run
away switch are so interconnected that at any time one of
them is working. The distance between stop block & run
away switch should be more than the train length (train
length + 4.5 meter). The stop block & the primary switch
are connected by a lever. When the lever is operated to
clear the track from the stop block the run away switch is
open. But as soon as the tubs crosses stop block the lever
is again operated to close the run away switch & at the
same time it is on the stop block.
9)Drop Warrick: This safety device consists of a strong
girder which is pivoted at the roof level through an eye bolt
& pin. The pin is operated through a long wire attached to
the swinging lever which is to be operated by the tubs, on
the up hill side when the tubs are moving in downward
direction. The control movement of tub does no exert in a
pull or the wire but in case the tub running uncontrolled. It
extracts a high pull on the wire through the lever which is
turned. Drop the pivoted girder between tracks to arrest
the forward runaway of the tubs. It is used with direct rope
haulage, main & tail rope haulage & endless rope haulage.
10)Manholes: Height should be more than 1.8 meter,
depth should be more than 1.2 meter & width should be
more than 0.7 to 1 meter. When person are allowed to
work or pass through an incline, when the haulage is in
motion, the manholes are made along the roadways sot
that person travelling can take shelter in the manholes.
The interval between two manholes should not be more 10
meters, but if the gradient is less than 1:6 the interval may
be up to 20 meter. If the roadways are less than 1.8 meter
in height the manhole should be made up of full height of
the roadway it is used in direct, main & tail & endless rope
haulages.

LOCOMOTIVES
Types of Locomotive Haulages are
1)Diesel locomotive
2)Electric locomotive/over head wire locomotive/trolley
wire locomotive
3)Electric battery locomotive
4)Compressed air locomotive

Main Parts of Locomotives

1)Chasis: Chesis is rigid frame work of steel section.
2)Driving wheels, axles, springs & brake blocks etc.
mounted below the Chasis.
3)A power Unit: it may be a diesel engine, an electric
motor, a battery or compressed air.
4)Operator’s Cabin: Having control panel with brakes,
operating system, horn etc.
5)Lights at both ends.
6)A screw brake for emergency.
7)For large size locomotives an air compression for power
brakes.

Limitations/Applicability of Locomotives
1)Generally the gradient should be less than 1:100 but it
can be used up to a gradient of 1:25.
2)Where track is in settled ground.
3)Where roads/galleries are reasonably wide & high.
4)Where transport distance is large.
5)Where production is high.
6)In the intake airways where the air velocity is high
enough to keep the fire damp percentage below the
danger limit.

Locomotive Haulage: In case of rope haulage the power

to move the load is available from external fixed motor to
the haulage. While in case of locomotive haulage the
driving unit i.e. locomotive is coupled to a train due to
which more safety can be attained. The locomotives are
very flexible in nature & they can be used for men
transport also.

1)Diesel Locomotive: Diesel locomotive are commonly

used in number of mines. Their weight varies from 3 tonne
to 15 tonne & power from 50kw to 75kw. The power unit is
a diesel engine. The locomotives used in underground
coalmines have a power unit in a flame proof enclosure as
a safe guard against ignition of fire damp. In coal mines
the diesel locomotives are not allowed where the
percentage of inflammable gases is more than 1.25% in
the general body of air. Hence these are generally used in
intake roadways. The exhaust of the diesel engine
includes oxygen, nitrogen, carbon dioxide & small
quantities of oxides of sulphur & nitrogen & other
aldehydes which smell badly & causes irritation of the
nose, throat & eyes. To remove these oxides & aldehydes
the locomotives are fitted with exhaust conditioner.
Exhaust Conditioner & Flame Trap: The exhaust gases
from the engine strikes on the surface of the water in the
chamber A. This traps hot particles & washes out the
sulphur oxides & aldehydes. The gases then rise through
a flame proof slag wool which is kept moist by water &
thereafter pass through second chamber. Similar chamber
B, where gases are further cooled & filtered before
passing through the flame trap. A flame arrester consists
of a removable stainless steel plates 1/2mm apart. Finally
gases are mixed with about 30 to 40 times their volume of
fresh air before entering in the atmosphere. In chamber A,
a water level indicator is installed in such a way that if
water level falls below certain level, the brakes are applied
automatically. The exhaust conditioner should be replaced
by a clean set after every 24 hours.
Advantages of Diesel Locomotives
1)Cheaper
2)Completely self controlled
Disadvantages of Diesel Locomotives
1)Danger of fire in handling the diesel.
2)production of poisonous gasses
3)Adds heats to the atmosphere.
4)More maintenance required.
5)More employees required.
2)Electric Locomotives: The electric locomotive is
equipped with an electric motor which draws the current
from the overhead wires through a pantograph or through
a long pole which is kept pressed against the overhead
conductor by spring tension. The DC supply to overhead
wires is 250 volts. These locomotives may be used in
degree I gassy mines. The overhead wires are suspended
through insulators over the track at a height more than 2
meter.
Advantages of Electric Locomotives
1)More reliable
2)Light weight
3)Less maintenance
4)Good control
5)Small size
6)No exhaust gases
Disadvantages of Electric Locomotives
1)High initial investment
2)Danger of shock & fire
3)Derailment is major problem

3)Electric Battery Locomotives: The power unit of an

electric battery locomotive is a DC electric motor which
receives current from a storage battery carried in the
locomotive itself. Such locomotives are for light & medium
duties. The batteries are of lead acid type & each battery
consists of a number of 2 volt cells & their no varies from
40 to 70. The capacity of the battery to work is 8 hours &
its charging time is also 8 hour.
Advantages of Battery Locomotives
1)Less maintenance.
2)No poisonous gases.
3)No overheads wire’s problem.
4)Quite in operation.
Disadvantages of Battery Locomotives
1)Hydrogen gas is liberated.
2)Flame proofing is not possible.
3)Overheating of cell may cause sparking or fire.
4)Large cross section.
5)Expensive batteries & less life.
6)Special charging stations involve more reliable.

4)Compressed Air Locomotive: There are no

compressed air locomotives in Indian coal mines. The
source of power used in air locomotive is compressed air
cylinder, installed over the locomotive. This cylinder
supplies the required quantity of compressed air to the
locomotive. These locomotives are very safe, reliable &
very useful in hot & dip mines. Even though their working
cost is very low, they are not used in Indian coal mines
due to their high cost of installation. These locomotives
are used for light duty work only.
Advantages of Compressed Air Locomotives
1)Very safe.
2)Very reliable.
3)Less maintenance required.
4)Cooling effect on air.
Disadvantages of Compressed Air Locomotives
1)High initial cost
2)Danger of pipe leakage.
3)Efficiency is less.
Super Elevation/Cant: On a curve, centrifugal action
creates a tendency for the train to leave the track &
proceed along a line tangential to the curve. This makes
the wheel flanges very hard against the inner edge of the
outer rail, causing more wear on wheels & rails. To
counter act this; the outer rail should be raised above the
inner one. This level difference between the inner rail &
outer rail is known as super elevation.
S.E. = AV2/g.r meter.
Where,
A = gauge width in meter.
V = velocity in meter/sec.
g = acceleration due to gravity (9.8 meter/sec)
r = radius of curve in meter.

Ideal Gradient: If the Tractive force required to haul the

loaded trail down the gradient is same as it is required to
haul the empty train of the gradient with the same velocity,
this gradient is known as ideal gradient.
Let,
WL = Weight of loaded train.
WE = Weight of empty train
1 in n = Ideal gradient
m = coefficient of friction
Case I: When loaded train is moving downward
GL = WL.g.1/n
FL = WL. g.(
TF = FL – GL
TF = WL. g. (- WL.g 1/n-------------------------- (I)
Case II: When empty train is moving upward
GE = WE.g.1/n
FE = WE.g
TF = FE+GL
TF = WE.g (+ WE.g.1/n--------------------------(II)
As per the definition equation (I) = (II)
WL.g. (-WL.g.1/n = WE g + WE g 1/n
WL -WE = WE.1/n + WL.1/n
((WL-WE) = 1/n (WE+WL)
n= (WL+WE)/ ((WL-WE)

Drawbar Pull: This is that part of the Tractive force which

remains available for pulling corrected load, hence
drawbar pull can be calculated after deducting from the
total Tractive force, the Tractive force required to haul the
locomotive itself.
TF=TM Wloco = kg
TF= TM Wloco. g = N
TM= Coefficient of adhesion
Force = mass X acceleration
(TF+GL-FL=mass X acceleration.