Twin-drum, four-rope synchronous winch: An engineering solution for precise lifting and lowering in coal washing plant dust suppression systems

I. Project Background and Industry Challenges

In the coal washing and processing industry, coal preparation plants commonly employ water spray systems to suppress dust generated during transportation. However, these spray systems require frequent height adjustments to accommodate changes in the height of the coal discharge outlet, ensuring continuous and precise coverage of the coal flow.

In practical operation, traditional lifting equipment often faces the following challenges:

• Lack of synchronisation
• Disorganised rope arrangement
• Unstable reeling and unwinding
• Safety hazards
• Low reliability during long-stroke operation

Consequently, a specially designed dual-drum, four-rope synchronous winch is required to achieve stable lifting of the spray system.

II. Client's Core Technical Requirements

The client's key requirements include:

1️⃣ Rated load: 1.5 tonnes, for hoisting two independent spray frames
2️⃣ Winch configuration: 4-rope, with motor in the centre and drums on either side
3️⃣ Motor specifications: Standard motor, 380V
4️⃣ Stroke: 15 metres
5️⃣ Speed: 5 metres per minute
6️⃣ Control Method: Wired hand-held controller, with an interface reserved in the control box for external wiring
7️⃣ Safety Configuration: Safety accessories including encoders, upper and lower limit switches, and alarms
8️⃣ Surface Colour: Orange-red

III. KLD Customised Solution

To meet the synchronised lifting requirements of the coal washing plant's water spray system, KLD designed a dual-drum, four-rope synchronous hoist system.

• The design employs a rigid synchronous shaft to connect the twin drums
• Driven by a single motor, it achieves absolute synchronisation of the four steel wires
• Equipped with European-style rope guides to ensure the steel wires remain neatly arranged throughout the long travel
• Integrated with an encoder, high/low limit switches and audible/visual alarms to provide multi-layered safety protection
• The control box features a reserved external wiring port for easy integration with on-site control systems

This solution resolves the issue of asynchronous lifting in double-deck spray racks, whilst ensuring that the steel wires do not become tangled or disordered within the 15-metre travel range.

IV. Key Technical Specifications

V. Design Highlights

✔ Structural Design: Rigid synchronous shafts connect the twin drums, ensuring absolute four-rope synchronisation through the mechanical structure
✔ Drive System: Single-motor drive, stable speed, smooth start-up and stopping
✔ Rope Management: European-style rope guides combined with precision drums effectively prevent rope tangling
✔ Control System: Operated via wired joystick; control box features reserved interfaces for easy system integration
✔ Safety Protection: Encoder provides real-time position feedback; upper and lower limit switches ensure travel protection; alarm system provides timely warnings

VI. Application Scenarios

• Lifting operations for dust suppression sprinkler systems in coal preparation plants and mines
• Synchronised lifting of large components and frameworks
• Industrial lifting platforms requiring long travel and high synchronisation control

VII. Project Benefits

This solution achieves:

• Enhanced equipment stability — completely resolves mechanical failures caused by lack of synchronisation
• Improved operational efficiency — stable and reliable lifting control ensures continuous operation
• Reduced equipment risk — comprehensive safety protection effectively prevents accidents
• Extended wire rope lifespan — optimised rope arrangement design reduces wear

VIII. Customisation Enquiries

Company: Beijing Tianheng Kairui (KLD Winch)
Website: https://kldwinch.com
Customisation Services: We provide one-to-one technical solutions and bespoke quotations; please feel free to discuss your specific requirements

IX. FAQ

Q1: Can the winch be customised?
A: Yes, we offer comprehensive customisation services covering structure, load capacity, stroke length and control methods.

Q2: How is synchronisation between the twin drums ensured?
A: We utilise a rigid synchronous shaft to connect the twin drums, ensuring they are driven by a single motor, which guarantees absolute synchronisation based on mechanical principles.

Q3: How is rope tangling prevented during long-stroke operations?
A: The equipment is fitted with a European-style rope guide, which directs the wire rope to wind neatly onto the drum, effectively preventing tangling and jamming.

Q4: In which environments is the equipment suitable for use?
A: Our standard products are suitable for conventional industrial environments. We also offer customisation to meet special requirements, such as explosion-proof or corrosion-resistant specifications.

Q5: Does KLD provide technical support?
A: We provide comprehensive technical support and consultancy services covering the entire process, from design and manufacturing to installation and commissioning.