Rack For Electric Rope Shovel

Electric‍‌‍‍‌ Rope Shovel Racking Introduction:

The rack with electric rope shovels is a heavy forged straight-tooth rack that has been specifically designed for such uses.

By the use of a gear, the movement of the gear is altered from rotary to linear. Thus the unit is directly used in the transmission system of a rope shovel, a construction machine, or any other equipment in the mining industry.

We produce racks of high-strength alloy steel and perform different heat treatments on them so that they will be able to maintain good and stable performance even in continuous wear and high impact conditions.

The most significant advantage of forged racks over cast ones is that, forged racks have higher strength and toughness, which is very essential in an environment that is continuously heavy-loaded like mining.

We are capable of providing full services both for OEM and ODM projects. You can give us the drawings or a sample and we will figure out the size, tooth profile, material, and surface finish that fit the model of your machine.

Features of Mining Gear Racking Segments:

Durable forged blanks:

The piece of material was subjected to multiple forging processes, thus its internal structure is denser and the resistance to impact is higher than before. For this reason, forged racks have obvious advantages over cast ones, especially in mining operations where the loading is frequent and the shocks are heavy.

CNC-machined tooth profile:

The teeth are fabricated with highly accurate CNC machining, and thus the surface is smooth, the gear engagement is stable, and there are less chances of jamming and the abnormal wear of the teeth.

Material selection based on working conditions:

The five material options are 40Cr, 42CrMo, 20MnCr5, alloy steel, and high-strength wear-resistant steels.

If you give us the information about the mining environment, the working frequency, and the expected service life, we will choose the proper material with you to be sure that the rack will work efficiently under the actual conditions.

Several heat-treatment options:

We have quenching and tempering, carburizing, induction hardening, and nitriding available. All the processes have in common that they facilitate achieving a uniform hardness level and better wear resistance, thus making the gear racks an ideal match for long-term and high-frequency ‍‌‍‍‌‍‌‍‍‌‍‌‍‍‌operation.

Gear Racking for Mining Equipment

Applications‍‌‍‍‌ the Big Forged Gears Are Mainly Involved in the Following Industries:

Mining machinery: electric rope shovels, mining trucks, crushers, ball mills Construction machinery: excavators, cranes, tower cranes Metallurgy equipment: rolling mill drive systems Port machinery, heavy conveyors, slewing systems, and other large-torque transmissions

These can be used in conjunction with the likes of: P&H, CAT, Hitachi, large mining trucks (50 tons and above), large reducers, slewing mechanisms, and high-torque conveying equipment. In case you have the blueprints, we can either do a direct copy or make the products that fit the type of your machine.

Parameters:

Project	Parameter Range
Manufacturing process	Forging + CNC Finishing
Tooth profile	Straight Gear (Customizable to Drawings)
Module	M8, M10, M12, M14, M18, M20, etc.
Rack	40Cr / 42CrMo / 20MnCr5 / Alloy Steel
Tooth surface hardness	HRC 50–55 (Adjustable)
Dimensional tolerance	±0.2–0.5mm
Surface treatment	Sandblasting, Rust-preventive Oil, Galvanizing, Painting, etc.

In addition, we are capable of delivering tailor-made products for you if your application is particularly demanding in terms of strength or if it is placed in a special environment (such as areas with mud, sand, high humidity, high temperature, etc.).

Quality & Service Assurance：

Prior to the dispatch of goods: Ultrasonic testing, hardness testing, tooth profile, and lead inspection.

We do the recording of the whole shipping procedure with photographs and videos and share them with the customers who are not local.

The goods can be transported by sea, rail, or air, and the parts that weigh heavily are given a proper and safe packing.

FAQ：

Q1:‍‌‍‍‌ Could you manufacture products based on my designs or a sample that I have?

We manufacture most of the racks that are customer specific. Besides, if you provide us with a drawing, sample, or the equipment model, we will make a rack that matches your machine.

Q2: What methods are in place for quality assurance?

We only allow the shipment of the goods after the thorough inspection of every batch. The inspection here involves testing of UT/MPT, hardness, dimensions, and materials. More than that, you also receive all the reports.

Q3: What is the average lead time?

The lead time for standard sizes is normally between 25-35 days. The time for fully custom-made or large-sized racks is from 35 to 45 days. It will be a pleasure for us to put your order first if you have a project with a tight schedule.

Q4: What materials are typically used for the production of mining racks?

42CrMo and 20MnCr5 are the most common materials as they are both strong and resistant to wear. However, we can decide on the best material for you based on your mining condition.

Shipping & Packaging:

We promise the best packing of all the racks with strong, export-quality materials that not only are the perfect for protection of the goods during long transport but also against any kind of ruggedness that may occur at the ports and mines.

Standard Packaging: Heavy-duty wooden pallets or wooden cases accompanied by steel belts.

Protection: The rack is mopped with rust-preventive oil and a protective layer is put over it so that it does not get rusted during the sea voyaging or storage.

Reinforcement: The racks are not in direct contact as spacers are inserted between them thereby protecting the teeth, the sharp edges are covered with pieces of rubber or plastic for ‍‌‍‍‌protection.

Labeling: Models, batch numbers, materials, and inspection statuses are some of the information that is recorded for each package to make finding them on-site easier. Shipping Methods

Sea Freight：(mostly used for heavy spare parts) is a good way for full container or LCL shipments. ‍‌‍‍‌

Rail Transport（to Central Asia, Russia, Europe）: A good trade-off between speed and cost.

Air Freight（for urgent breakdowns）: In the case of small quantities or emergency replacements, we are able to offer fast air ‍‌‍‍‌shipments.

Multi-package consolidation: When you place orders for multiple spare parts, we are able to consolidate packages to lower the freight costs.

Also, we will send you on-site photos and packing videos before the shipment so that you can verify that everything is in order.

Our Advantages:

We have all the forging, heat-treatment, and machining lines under one roof where we operate. This is the reason for stable quality, consistent performance, and timely delivery of goods. Our engineering team can take your input in the form of drawings or old samples and give you professional recommendations. The long-term stability of our quality has been the reason why many customers dealing with mining and construction equipment continue their cooperation with us and we maintain our reorder rate at a high ‍‌‍‍‌level.