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Corrimal Colliery Incline
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 Posted: Fri Nov 4th, 2016 10:16 am
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oztrainz
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Hi all,
Now onto the next saga - the brakehouse. First up a quick discussion of the haulage rope and their management at the top end of the prototype Corrimal Colliery incline

On the prototype the brakehouse, the rope came in through the front wall of the brakehouse to the top of the drum from the top of the Empties Incline, wrapped around the drum several times and then exited low through the front wall from the bottom. The drum under the rope was wrapped with hardwood segments. The rope actually slipped sideways as the drum turned to get the rope from where it came in through the front wall to where it went back out and headed downhill. 22 loaded skips headed downhill is enough grunt to slip the rope sideways.

On either side of the rope drum was a 7' diameter brake drum with 6" wide water cooled Aussie hardwood brake pads. These brake pads were absorbing 40 HP when the incline was running. Speed was governed by a ball-type governor and the incline operator had a way to drop the brakes on hard for an emergency stop.

There were two wires on a fence that ran the length of the incline. If these were twisted together, it rang a bell in the brakehouse that was the emergency stop alarm. The incline was not to be restarted while the bell was ringing.

L: I had thought of mounting a 10" fire alarm bell under the layout to simulate this when the model incline is not running. Perhaps no?? :bg:

So now onto the model brakehouse that made its first appearance as a placeholder beyond the tresle

with simple doors and window shapes drawn on a blob of scrap foam

At the lower track level, it is starting to get congested

That big foam blob to the left is the mock-up of where the brakehouse will be going in.
Next up the brakehouse foundations.



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John Garaty
Unanderra in oz
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 Posted: Sat Nov 5th, 2016 12:16 am
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oztrainz
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Hi all again,
Why use a placeholder for the brakehouse? We need to work out where the rope runs go. 
 
Remember the ropes?? The Corrimal Colliery is a model of a self-acting continuous rope incline after all - isn't it? The incline ropes are one of the key things that distinguish this layout as an incline. So I need to work out where the ropes are to go on the model. Perhaps I'd better give the top-end some thought before I scenic myself into a corner that I can't get out of. 
 
Here's where it gets tricky, because we have varied the angle between the tracks to fit an offset T-shape I can't put the brakehouse where it actually was as shown below 

 
The top-end tracks on the model actually look like this

The brakehouse has to fit to the right where the blue line crosses over the red line but before the curve on the red line leading to the dead-end in order to get the rope runs close to straight as possible (after all we might be able to get the ropes moving eventually so perhaps designing as few kinks as possible into the rope "circuit" might be a good idea).  
 
As mentioned in my last post, the original brakehouse had a slightly tapered drum around which 4 1/2 turns of the 3.5" circumference Lang's Lay steel haulage rope passed. Now there is a world of difference in the performance of the rope around the top drum between the gravity drive of the prototype where the rope slips on the drum and a motor dive for a model that requires that the rope can't be allowed to slip on the top drum if the drum is to drive the model haulage ropes.

So far getting a rope drive that is small enough, powerful enough to move up to 8 metres (9 yards approx)
of continuous model haulage rope, tensioning that model haulage rope so that it will drive aw well as not tangling or interfere with the skips, AND, synchronising the rope speed to the under track chain has proved to be an insoluble problem after months of attempts. So the incline ropes are non-operational.  

On to construction - What we actually have here is a 3 level structure - with the baseboard at the lowest level, then the Fulls track and the Empties track passing over that on the trestle bridge. The brake house is at the immediate left of the picture, and lives somewhere in between the 2 upper levels 

:L: If I use separate non-operational ropes for the full and empties inclines. I'll need a hole in the baseboard to pass the ropes through - I can keep a light tension on them by hanging some kind of a weight on the end of each rope under baseboard level. With some clever design the hole is uphill and away from the chain paths for the incline. :2t:
 
First off I need to put a "floor" in for the Fulls Incline

A few bits of cardboard a cardboard tube and a few dobs of hot glue and we're done. The "rollers" to support the rope also now start to make an appearance. These are non-operational(just like the incline haulage ropes) but are designed to be easily swapped out should it look like the ropes might be got moving at some later date.

The brakehouse on the model is higher relative to this track than on the prototype. So the rope will come out of the front of the brake house and then step down to the Fulls incline by this ingenious pulley and bracket arrangement that just fits between the front of the brakehouse and the trestle bridge supports.

 
Viewed from the other side...with the brake house place holder roughly in position 

And Mount Chux has disappeared under its first coat of paint  

Next up, replacing the brakehouse placeholder,



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John Garaty
Unanderra in oz
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 Posted: Wed Nov 23rd, 2016 11:58 am
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oztrainz
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Hi all again,

And now on  to the saga of the brake-house at the top of the incline.
In the beginning there was a brake drum that was mounted to a stryrene floor over a hole

 
It then grew a back wall that had been used somewhere else previously

 
As mentioned previously, the bottom of the drum is up in the air with respect to the Fulls Incline so we need some pulleys to lift the haulage rope to the correct level. Here they are again 

 
Now if these pulleys are painted a suitable gungy grey, this whole set up hides in amongst the other stuff near the trestle carrying the Empties Incline over the top 

 
Here's the view from the top of the Empties Incline looking towards the brake drum showing the pulley that kicks the rope out under the rail to the right

 
At this time the brakehouse still needed side walls a front wall and a roof, but in order to be able to thread the brake drum, the roof and front wall had to be removable.


So the front wall ended up looking like this after a baby powder surface treatment to simulate old concrete  

 
with the lower level vertical slit for the Fulls Incline rope at the left, then the higher level vertical slit for the Empties Incline rope and the horizontal viewing slot for the operator and finally the door at the right.
 
The operator lurks inside

 
The interior still needs to be painted and detailed, but at least we now have a brake house that looks like this from the side 

 
and from the back

This view now looks a lot different from this earlier view when the trestle went in


It is surprising how much a few bits of cardboard, a few stirrer sticks fabricated into retaining walls and some stones can change things.

So when the haulage cables are run out we end up with something like this at the Top End of the Incline


There's something wrong in this photo - I'm not sure if anyone can pick it
 
That will do for this post - It's long enough, maybe even too long ;)



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John Garaty
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 Posted: Wed Nov 23rd, 2016 09:03 pm
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Alwin
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John, not sure if it is the answer but it looks like the cable on the fulls incline is pushing to the underside of the rail.

Alwin

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 Posted: Wed Nov 23rd, 2016 10:29 pm
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oztrainz
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Hi Alwin and all,
The following 2 photos might help explain things about how we get the haulage rope away from the rails at the top and bottom of the hill

The first photo shows the Empties Incline, brakehouse and haulage cable




The second photo is a tight crop of the previous photo where the cable comes out from between the rails


This photo shows the smaller offset pulley in between the rails and the larger pulley outside the rails that aims the cable at the brakehouse. The rope path is designed to pass just underneath the foot of the rail. The smaller pulley and haulage rope support pulleys along the incline are all designed to be lower than rail height so that they don't interfere with the skips' couplings, axle boxes and magnets passing over them. It's a tight fit with clearances of less than 2 mm.

The lower-level Fulls Incline is bit more complicated in that the pulley outside of the rails is offset further away from the rail to line up with the pulleys that lift the level of the rope and feed the haulage rope from the brakehouse.

This is a non-reversible, continuous-rope incline. So the prototype rope movement was from grade on the higher-level Empties Incline to the brakehouse and then back to the top of the Fulls incline, then down the hill to the tipple, where the rope was tensioned and then turned around under the tipple deck for the run back up the hill.

I hope that this helps to clear things up,



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John Garaty
Unanderra in oz
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 Posted: Wed Nov 23rd, 2016 10:31 pm
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Rod Hutchinson
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Fascinating engineering John.



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 Posted: Thu Nov 24th, 2016 02:53 am
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Robert Comerford
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Well done ...as usual John
regards
Bob Comerford

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 Posted: Thu Nov 24th, 2016 11:05 am
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slateworks
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John, every time I look at this there seems to be another few acres of ground coverage. It's all coming together superbly and I'm learning more and more about the real life operations as the build progresses. Great stuff.



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 Posted: Tue Jan 31st, 2017 12:57 am
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oztrainz
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Hi all,
time for an almost "real time" photo of significance - 
P1230327a by oztrainz, on Flickr

There is still a lot of the saga involved in getting to "here" that is yet to appear on this thread yet.  



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John Garaty
Unanderra in oz
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 Posted: Tue Jan 31st, 2017 04:07 am
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Si.
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Hi John :wave:


That's one of the most radical photos I've ever seen Posted on Freerails ;) ...


...perhaps even on THE NET :shocked:


:moose:


Si.


" It's coal Jim, but not as we know it "


:bg:



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