Views: 0 Author: Site Editor Publish Time: 2025-05-07 Origin: Site
Conveyor, each unit consists of 8 rollers, each unit can be used independently or connected to multiple units for easy installation;
The conveyor can expand and contract freely, and the ratio of the longest to the shortest state of a unit can reach three times.
Firstly, let's explain the composition of the belt conveyor system: The belt conveyor is the most important equipment for conveying and loading and unloading bulk materials, which can be widely used in industrial fields such as mining, metallurgy, building materials, chemical industry, electricity, food processing, etc. The extensive application of leather machines can be seen in coal mines, metal mines, steel enterprises, ports, cement plants, and other places. Transportation machinery can not only complete the transportation of bulk materials, but also transport bulk materials. However, there will be significant differences in its design and application depending on the location of use, working environment, and type of transported materials;
Modern conveyor systems have higher requirements for dust prevention. Therefore, sprinkler dust collection devices are installed at each transfer point, and windproof covers or plates are installed along the belt conveyor. The system is composed of a single machine. For operators and repairers working in the entire system, they need to not only focus on the single machine they are in charge of, but also understand the interconnections between the systems. Single machines are composed of many components. Only by doing a good job in daily maintenance of each component to keep it in good working condition can the safe operation of the equipment be ensured;
We generally use different forms of belt conveyors based on their usage locations, working environments, technical performance, and types of conveyed materials to meet various operating conditions. In addition to the commonly used general belt conveyors, there are also various new types of special belt conveyors with new structures. Representative ones include: large angle belt conveyors, deep groove belt conveyors, and belt press conveyors, tubular belt conveyors, air cushion belt conveyors, flat turning belt conveyors, linear friction conveyors, and wavy edge conveyor belt conveyors. There are also multiple classification methods for refinement. The following is an introduction:
Classified by purpose, there are universal mobile conveyors, underground selection conveyors, open-pit mining fixed conveyors, special structural conveyors, movable conveyors, loader specific transfer function conveyors, large angle conveyors, etc. Generally speaking, short distance in plant conveyors can complete horizontal, upward or downward transportation. Reversible patterned belt conveyors can be used for bidirectional material transportation. Cantilever machines are usually installed on stackers and can rotate to achieve soil discharge or fabric distribution. Elevated machines supported by gantry cranes are usually used in conjunction with other bulk material processing equipment, such as in hydropower construction. Standard intermediate frames can be configured, which are set on sleepers for easy relocation;
Classified by the type of transported materials, there are belt conveyors used for general loose materials, hard materials, and single piece materials. Classified by the position of the rubber conveyor belt bearing section, there are three types: the belt bearing section above, the bearing section below, and the bidirectional conveyor with both bearing sections above and below. The bidirectional conveyor can respectively transport materials in the upper and lower branches, but in order to maintain the contact surface of the materials, the rubber belt needs to be regularly flipped.
belt conveyor
The commonly used belt conveyors can be divided into: ordinary canvas core belt conveyor, steel rope core high-strength belt conveyor, fully explosion-proof downward belt conveyor, flame-retardant belt conveyor, dual speed dual transport belt conveyor, reversible mobile belt conveyor, cold resistant belt conveyor, and so on.
The belt conveyor is mainly composed of a frame, a conveyor belt, belt rollers, a tensioning device, a transmission device, etc.
GX type tubular screw conveyor
(1) Working principle of GX type tube conveyor: GX type screw conveyor uses a rotating screw to move the conveyed material along a fixed casing for conveying work. The head and tail bearings move outside the casing, and the suspension bearing adopts sliding bearings with dust-proof sealing devices. The bearing shell is generally made of powder metallurgy, and the conveying cement adopts felt bearing shells. The suspension shaft and screw shaft are connected by sliding blocks.
(2) GX type tubular screw conveyor product overview: GX type screw conveyor, commonly known as winch, is a widely used conveying equipment in the mineral, feed, grain and oil, and construction industries. From the perspective of material displacement direction, screw conveyors are divided into two types: horizontal screw conveyor and vertical screw conveyor, mainly used for horizontal conveying and vertical lifting of various loose materials such as powder, particle, and small block.
(3) Application scope of GX type tubular screw conveyor: The screw conveyor is the main unit for mechanized transportation in various departments of industry and agriculture, which can reduce labor intensity and improve work efficiency in transportation work. It has a wide range of applications. Suitable for various industries such as building materials, chemicals, electricity, metallurgy, coal, grain, etc., suitable for horizontal or inclined transportation of powdery, granular, and small block materials such as coal, ash, slag, cement, grain, etc.
(4) The main features of GX type tubular screw conveyor are:
1. High load-bearing capacity, safe and reliable.
2. Strong adaptability, easy installation and maintenance, and long service life.
3. The whole machine has a small volume, high speed, and ensures fast and uniform conveying.
4. The discharge end is equipped with a cleaning device, which has low overall noise, strong adaptability, and flexible layout of the inlet and outlet positions.
5. Good sealing performance, the shell is made of seamless steel pipe, and the ends are connected to each other with flanges to form a whole, with good rigidity.
(5) Various manufacturing methods of GX type tubular screw conveyor:
part | Manufacturing code | Expressing Content |
Spiral type | S | A solid helical surface spiral with a pitch equal to 0.8 times the diameter |
D | Equipped with a helical belt, with a pitch equal to the diameter | |
Hand pushed discharge outlet with toothed strip discharge outlet | Left installation | Looking from the spiral head section to the tail section, the pull plate is pulled to the left |
Right installation | Looking from the spiral head section to the tail section, the pull plate is pulled to the right | |
Installation type of driving device | Left installation | Looking forward from the motor, the low-speed shaft of the reducer is on the left side of the motor shaft |
Right installation | Looking forward from the motor, the low-speed shaft of the reducer is on the right side of the motor shaft |
Conveyor machinery can be divided into: bulk material conveying machinery (such as belt conveyors, screw conveyors, bucket elevators, large angle conveyors, etc.) and logistics conveying machinery (such as assembly lines, assembly line equipment, conveyor lines, suspended conveyor lines, elevators, pneumatic elevators, rack and pinion elevators, scissor elevators, elevators, roller conveyors, elevators) according to their intended use.
(1) Belt conveyor
A belt conveyor is composed of a driving device, a tensioning device, a middle frame of the conveyor belt, and a support roller. The conveyor belt is used as a traction and load-bearing component to continuously transport fragmented materials or finished products.
Belt conveyor is a mechanical device driven by friction to transport materials continuously. By applying it, materials can be transported along a certain conveyor line, forming a material conveying process from the initial feeding point to the final unloading point. It can transport both fragmented materials and individual items. In addition to pure material transportation, it can also be coordinated with the requirements of the production processes in various industrial enterprises to form a rhythmic flow operation transportation line. So belt conveyors are widely used in various modern industrial enterprises.
Belt conveyors are widely used in underground tunnels, surface transportation systems, open-pit mining sites, and beneficiation plants in mines. It is used for horizontal or inclined transportation.
A universal belt conveyor consists of a conveyor belt, idlers, rollers,and driving, braking, tensioning, reversing, loading, unloading, cleaning, and other devices.
① conveyor
There are two commonly used types: rubber bands and plastic bands. Rubber bands are suitable for working environments with temperatures between -15 ° C and 40 ° C. The material temperature should not exceed 50 ° C. The inclination angle for conveying loose particles upwards is 12 ° to 24 °. For large angle conveyors, patterned rubber belts can be used. Plastic tape has the advantages of being resistant to oil, acid, alkali, etc., but it has poor adaptability to climate and is prone to slipping and aging. Bandwidth is the main technical parameter of belt conveyors.
② Carrying idler
Single drum (tape wrapping angle of 210 °~230 °), double drum (wrapping angle up to 350 °), and multi drum (used for high power). There are groove shaped rollers, flat rollers, self-aligning rollers, and buffering rollers. Groove shaped rollers (composed of 2-5 rollers) support and carry branches for conveying bulk materials; The self-aligning roller is used to adjust the lateral position of the belt to avoid deviation; Buffer rollers are installed at the receiving area to reduce the impact of materials on the belt.
③ roller
Divided into driving drum and reversing drum. The driving drum is the main component for transmitting power.
④ Tightening device
Its function is to achieve the necessary tension on the conveyor belt to prevent slipping on the drive drum, and to ensure that the deflection of the conveyor belt between the rollers is within the specified range.
Belt advantage: Firstly, it operates reliably. Belt conveyors are used in many important production units that require continuous operation, such as coal transportation in power plants, bulk material transportation in steel and cement plants, and ship loading and unloading in ports. If the machine is shut down in these situations, the losses are enormous. When necessary, the belt conveyor can work continuously from shift to shift.
Belt conveyors have low power consumption. Due to the almost no relative movement between the material and the conveyor belt, it not only reduces the running resistance (about 1/3-1/5 of the scraper conveyor), but also has low wear and breakage on the cargo, resulting in high productivity. All of these are beneficial for reducing production costs.
The conveyor line of the belt conveyor has strong adaptability and flexibility. The length of the line is determined according to the needs. It can be as short as a few meters and as long as 10km or more. It can be installed in small tunnels or set up above ground traffic chaos and dangerous areas.
According to the requirements of the process flow, belt conveyors can flexibly receive materials from one or more points, and can also unload materials to multiple points or sections. When feeding materials onto the conveyor belt at several points at the same time (such as the conveyor under the coal bunker in a coal preparation plant) or feeding materials to the conveyor belt through a uniform feeding device at any point along the length direction of the belt conveyor, the belt conveyor becomes the main conveyor line.
Belt conveyors can retrieve materials from the tunnels below the coal storage piles and mix different materials from each pile when needed. The material can be easily unloaded from the head of the conveyor, or it can be unloaded at any point along the length of the conveyor belt through a plow unloader or a mobile unloader.
Main technical parameters of belt conveyor
Tape width (mm) | Conveying length (m) Power (kw) | Conveyor speed (m/s) | Conveying capacity (t/h) | ||
500 | ≤12 3 | 20-30 4-5.5 | 20-30 5.5-7.5 | 1.3-1.6 | 78-191 |
650 | ≤12 4 | 12-20 5.5 | 20-30 7.5-11 | 1.3-1.6 | 131-323 |
800 | ≤6 4 | 6-15 5.5 | 15-30 7.5-15 | 1.3-1.6 | 278-546 |
1000 | ≤10 5.5 | 10-20 7.5-11 | 20-40 11-12 | 1.3-2.0 | 435-853 |
1200 | ≤10 7.5 | 10-20 11 | 20-40 15-30 | 1.3-2.0 | 655-1284 |
(2) Spiral conveyor
Spiral conveyor, commonly known as auger, is suitable for horizontal conveying, inclined conveying, vertical conveying and other forms of granular or powdery materials. The conveying distance varies depending on the deformity, generally ranging from 2 meters to 70 meters.
Transportation principle: The rotating spiral blades push the material and transport it on the spiral conveyor. The force that prevents the material from rotating together with the blades of the screw conveyor is the weight of the material itself and the frictional resistance of the screw conveyor housing to the material.
Structural features: Spiral blades are welded onto the rotating shaft of the screw conveyor, and the blade surface types include solid surface type, belt surface type, blade surface type, etc. depending on the conveyed material. The screw shaft of the screw conveyor has a thrust bearing at the end of the material movement direction to provide axial reaction force to the screw along with the material. When the machine is long, an intermediate suspension bearing should be added.
A double screw conveyor is a screw conveyor with two rotating shafts welded with rotating blades. Simply put, it is the organic combination of two screw conveyors to form a screw conveyor.
The rotation direction of the rotating shaft of the screw conveyor determines the direction of material transportation, but generally, the rotating blades of the screw conveyor are designed based on single item transportation during design. When conveying in reverse, it will greatly reduce the service life of the conveyor.
(3) Bucket elevator
A bucket elevator is a continuous conveying machinery that vertically lifts materials using a series of hoppers uniformly attached to an endless traction component.
The bucket elevator has significant advantages such as large conveying capacity, high lifting height, stable and reliable operation, and long service life. Its main performance and parameters comply with JB3926-85 "Vertical Bucket Elevator" (which is equivalent to referring to international standards and advanced foreign standards), and the traction ring chain complies with MT36-80 "High Strength Ring Chain for Mining". This elevator issuitable for conveying powdery, granular, and small block materials without abrasion or with low abrasion, such as coal, cement, stones, sand, clay, ores, etc. Due to the traction mechanism of the elevator being a circular chain, it is allowed to transport materials with higher temperatures (material temperature not exceeding 250 ℃). The maximum conveying height can generally reach 40 meters.
Working principle of bucket elevator: The bucket elevator has a simple structure and smooth operation. It can be used for digging and loading, mixed or gravity unloading. The bucket elevator rim adopts a combination sprocket, which is easy to replace. The sprocket rim has a long service life after special treatment. If a gravity automatic tensioning device is used in the lower part, it can maintain a constant tension, avoid slipping or chain detachment. At the same time, when the hopper encounters resistance, it has a certain tolerance to effectively protect the moving parts. The material temperature does not exceed 250 ℃.
Logistics conveying machinery
Conveyor types: high inclination conveyor, waveform edge conveyor, edge partition conveyor, mobile conveyor, mobile conveyor, horizontal mobile conveyor, and high inclination belt conveyor. Conveyor is a supporting equipment for colored tile machinery, widely used.
(1) Stainless steel mesh belt conveyor
1. The frame of this model can be made of stainless steel or aluminum profiles. Chain plates can be selected with corresponding materials and widths as needed. Refer to the selection of conveying products - flat chain.
2. By selecting different forms of flat chains, various functions such as flat conveying, flat turning, lifting and lowering can be achieved.
3. The motor can be set under or above the rack as needed.
4. The speed adjustment can be selected as variable frequency speed regulation or a continuously variable speed reduction motor.
5. The conveyor can be equipped with side baffles and control station units installed on both sides to achieve automation during the conveying process.
6. When inquiring, please provide detailed information on the name, size, and requirements of the conveying material, as well as the material, size, speed, and conveying capacity of the machine. [5]
(2) Introduction to scraper conveyor assembly line (advantages and disadvantages):
A conveyor that uses a scraper chain to transport bulk materials in a trough is called a scraper conveyor. According to the arrangement and structure of the scraper conveyor chute, it can be divided into two types: parallel and overlapping. According to the number and arrangement of chains, it can be divided into four types: single chain, double side chain, double center chain, and triple chain.
The adjacent middle grooves of a scraper conveyor that can be bent to a limited extent in the horizontal and vertical planes are called a bendable scraper conveyor. The working face conveyor with a 90 degree bend at the intersection of the working face and the transport roadway is called a "corner scraper conveyor".
In the current coal mining face, the role of the scraper conveyor is not only to transport coal and materials, but also to serve as the operating track of the coal mining machine, making it an indispensable main equipment in modern coal mining technology. If the scraper conveyor can maintain continuous operation, production can proceed normally. Otherwise, the entire coal mining face will be in a state of shutdown, causing the entire production to be interrupted.
The main structure and components of various types of scraper conveyors are basically the same, consisting of three parts: the head, middle, and tail.
In addition, there are auxiliary components such as hydraulic jacks for pushing conveyors and chain tighteners for tightening chains. The head of the machine is composed of a head frame, an electric motor, a hydraulic coupling, a reducer, and a sprocket. The middle part is composed of transition groove, middle groove, chain, scraper and other components. The tail of the machine is a device for returning the scraper chain. The tail of a heavy-duty scraper conveyor, like the head, is also equipped with a power transmission device, which is distinguished by its installation position as the upper head and lower head.
Main advantages of scraper conveyor:
1. Solid structure. Can withstand external forces such as impact, collision, smashing, and pressure from coal, gangue, or other materials.
2. Can adapt to the needs of uneven and curved bottom plates in coal mining faces, and can withstand vertical or horizontal bending.
3. The body is short and easy to install.
4. Can also serve as a track for the operation of coal mining machines.
5. Can run in reverse for easy handling of bottom chain accidents.
6. Can serve as a pivot point for the front section of a hydraulic support.
Disadvantages:
1. The no-load power consumption is relatively high, accounting for about 30% of the total power.
2. Not suitable for long-distance transportation.
3. Easy to cause chain drop and jump accidents.
4. Consuming more steel. The cost is high.
(3) Roller conveyor
Roller conveyors can transport finished items with a flat bottom, such as plates, bars, pipes, profiles, pallets, box containers, and various workpieces, along a horizontal or small inclination angle. For non flat bottomed and flexible items, pallets can be used for conveying. It has the characteristics of simple structure, reliable operation, convenient maintenance, economy, and energy saving. The most prominent feature is that it can be well connected and matched with the production process, and has diverse functions.
Roller shaft form table:
Shaft diameter Ø d | Axle load kg/m | Axis form | ||||
8 | 0.395 | 10 | 8×15 | |||
10 | 0.617 | 6×10 | 8×10 | 10 | 10×15 | 8×15 |
12 | 0.888 | 8×15 | 10×10 | 10 | 12×15 | 10×15 |
Two perforation processes for conveyor baffles
(1) Blast drilling: The material is subjected to continuous laser irradiation to form a pit in the center, and then the molten material is quickly removed by an oxygen flow coaxial with the laser beam to form a hole. The size of the general hole is related to the thickness of the plate, and the average diameter of the blasting perforation is half of the plate thickness. Therefore, for thicker plates, the blasting perforation hole diameter is larger and not round, and it is not suitable for use on parts with higher requirements (such as oil sieve tube), and can only be used on waste materials. In addition, due to the same oxygen pressure used for perforation as during cutting, there is a larger splash.
(2) Pulse drilling: High peak power pulsed laser is used to melt or vaporize a small amount of material, and air or nitrogen is commonly used as auxiliary gas to reduce the expansion of the hole due to exothermic oxidation. The gas pressure is lower than the oxygen pressure during cutting. Each pulse laser only produces small particle jets that gradually penetrate deeper, so the perforation time for thick plates takes a few seconds.
Once the perforation is completed, immediately replace the auxiliary gas with oxygen for cutting. This way, the perforation diameter is smaller and the perforation quality is better than that of blasting perforation. The laser used for this should not only have a high output power; The time and spatial characteristics of the light beam are more important, so generally transverse flow CO2 lasers cannot meet the requirements of laser cutting. In addition, pulse perforation requires a reliable gas path control system to achieve switching of gas types and pressures, as well as control of perforation time.
Welding method of welding rod arc welding for conveyor support
Scratching method - First align the welding rod with the welding piece, then gently scratch the welding rod on the surface of the welding piece like a matchstick to ignite the arc, and then quickly lift the welding rod by 2-4mm and let it burn steadily,
Knocking method - Align the end of the welding rod with the weldment, then bend your wrist downwards to lightly touch the weldment. Quickly lift the welding rod by 2-4mm, ignite the arc, and place your wrist flat to keep the arc burning steadily. This arc ignition method is mainly used in production because it does not scratch the surface of the workpiece and is not limited by the size or shape of the workpiece surface. But the operation is not easy to master, and proficiency needs to be improved.
When starting an arc, the following precautions should be taken:
1) The arc starting point should be free of oil stains and water rust to prevent the formation of pores and slag inclusions.
2) The lifting speed of the welding rod after contact with the workpiece should be appropriate. If it is too fast, it will be difficult to initiate the arc, and if it is too slow, the welding rod and workpiece will stick together, causing a short circuit.
(2) Shipping strips
Strip transportation is the most important step in the welding process, which directly affects the appearance and internal quality of the weld seam. After the arc is ignited, the welding rod generally has three basic movements: gradually advancing towards the molten pool, gradually moving along the welding direction, and swinging laterally.
The welding rod is gradually fed towards the molten pool - not only to add metal to the molten pool, but also to maintain a certain arc length after the welding rod melts, so the speed of feeding the welding rod should be the same as the speed of melting the welding rod. Otherwise, arcing or sticking to the welded component may occur.
The welding rod moves along the welding direction - gradually forming a weld bead as the welding rod continues to melt. If the movement speed of the welding rod is too slow, the weld bead will be too high, too wide, and the shape will be uneven, and burning through phenomenon will occur when welding thin plates; If the movement speed of the welding rod is too fast, the welding rod and the workpiece will melt unevenly, the weld bead will be narrow, and even incomplete penetration may occur. When moving the welding rod, it should form an angle of 70-80 degrees with the forward direction to push the molten metal and slag backwards. Otherwise, the slag will flow towards the front of the arc, causing defects such as slag inclusion.
Characteristics and Industry Applications of Chain Plate Conveyor Lines
Chain plate material: carbon steel, stainless steel, thermoplastic chain. Different widths and shapes of chain plates can be selected according to the needs of your product to meet the requirements of flat conveying, flat turning, lifting, lowering, etc.
(3) Characteristics of Chain Plate Line
1. The conveying surface of the chain plate conveyor is flat and smooth, with low friction, and the transition of materials between the conveying lines is smooth. It can transport various materials such as glass bottles, PET bottles, and cans, as well as various bags and suitcases.
2. Chain plates are made of materials such as stainless steel and engineering plastics, with a wide variety of specifications and varieties. They can be selected according to the requirements of the conveying materials and processes, and can meet the different needs of various industries.
3. Chain plate conveyors can generally be washed directly with water or soaked directly in water. The equipment is easy to clean and can meet the hygiene requirements of the food and beverage industry.
4. Flexible equipment layout. Horizontal, inclined, and curved conveying can be completed on one conveyor line.
5. The equipment has a simple structure, runs smoothly, and is easy to maintain.
6. The width of the direct transmission chain plate is 63.5, 82.5, 101.6, 114.3, 152.4, 190.5, 254, 304.8; The width of the turning chain plate is 82.5, 114.3, 152.4, 190.5, 304.8, and it is widely used for automatic conveying, distribution, and packaging of food, canned goods, drugs, beverages, cosmetics and washing products, paper products, seasonings, dairy industry, tobacco, etc.
Rubber conveyor belts are measured in square meters. When customizing, both length and square meters should be specified simultaneously.
(1) Method for expressing the specification and length of adhesive tape
Bandwidth (millimeters) x number of fabric layers x [upper adhesive thickness (millimeters)+lower adhesive thickness (millimeters)] x tape length (meters)
(2) The square meter conversion method for tape can be used
Square meters=tape width (meters) x [number of fabric layers+(upper adhesive thickness (millimeters)+lower adhesive thickness (millimeters))/1.5] x length (meters)
Generally, the main parameters are determined based on the requirements of the material handling system, various conditions of the material loading and unloading location, relevant production processes, and the characteristics of the materials.
① Conveying capacity: The conveying capacity of a conveyor refers to the amount of material conveyed per unit time. When transporting bulk materials, calculate based on the mass or volume of the material transported per hour; When transporting finished items, calculate based on the number of items transported per hour.
② Conveyor speed: Increasing the conveyor speed can improve the conveying capacity. When using a conveyor belt as a traction element and the conveying length is large, the conveying speed gradually increases. However, high-speed belt conveyors need to pay attention to vibration, noise, and issues such as starting and braking. For conveyors that use chains as traction components, the conveying speed should not be too high to prevent an increase in power load. The conveying speed of the conveyor that performs process operations simultaneously should be determined according to the production process requirements.
③ Component dimensions: the component dimensions of the conveyor include conveyor belt width, Flat noodles width, hopper volume, pipe diameter, container size, etc. The dimensions of these components directly affect the conveying capacity of the conveyor.
④ Conveyor length and inclination angle: The length and inclination angle of the conveyor line directly affect the total resistance and required power of the conveyor.
1 Fixed conveyors should be installed on a fixed foundation according to the prescribed installation method. Before the official operation of the mobile conveyor, the wheels should be wedged with triangular wooden wedges or braked with brakes. To prevent movement during work, when multiple conveyors are operating in parallel, there should be a one meter passage between machines and between machines and walls.
2 Before using the conveyor, it is necessary to check whether each operating part, tape buckle, and bearing device are normal, and whether the protective equipment is complete. The tension of the tape must be adjusted to a proper degree before starting.
3 The belt conveyor should be started with no load. Only after normal operation can the material be fed in. It is prohibited to feed before driving.
4 When several conveyors are running in series, they should be started sequentially from the discharge end. Only after all are operating normally can the material be fed in.
5 When the tape deviates during operation, it should be stopped for adjustment and not forced to be used to avoid wear on the edges and increased load.
6 The working environment and the temperature of the delivered materials shall not exceed 50 ℃ and shall not be lower than -10 ℃. Do not transport materials containing acidic or alkaline oils and organic solvents.
7 Pedestrians or passengers are prohibited on the conveyor belt.
8 Before parking, the feeding must be stopped first, and the parking can only be done after all the materials stored on the belt have been unloaded.
9 The conveyor motor must have good insulation. Do not pull or drag the cables of the mobile conveyor randomly. The electric motor should be reliably grounded.
10 It is strictly prohibited to pull the belt by hand when it slips, in order to avoid accidents.
(1) After the installation of each device, carefully debug the conveyor to meet the requirements of the drawing.
(2) Add corresponding lubricating oil to each reducer and moving parts.
(3) After installing the conveyor to meet the requirements, each individual device is manually tested and combined to debug the conveyor to meet the operational requirements.
(4) Debug the electrical part of the conveyor. Including the debugging of conventional electrical wiring and actions, to ensure that the equipment has good performance and achieves the designed functions and states.
One of the most common faults during the operation of a belt conveyor is belt deviation. There are various reasons for deviation, mainly due to low installation accuracy and poor daily maintenance. During the installation process, the head and tail rollers, as well as the middle support roller, should be placed on the same centerline as much as possible and parallel to each other to ensure that the conveyor belt does not deviate or deviates less. In addition, the strap joint should be correct, and the circumference on both sides should be the same.
If there is deviation during use, the following checks should be conducted to determine the cause and make adjustments. The parts that need to be checked frequently for conveyor belt deviation and the corresponding treatment methods are:
(1) Check the non coincidence between the transverse centerline of the roller and the longitudinal centerline of the belt conveyor. If the non coincidence value exceeds 3mm, it should be adjusted using the elongated mounting holes on both sides of the roller group. The specific method is to determine which side the conveyor belt is biased towards, which side of the roller group moves forward in the direction of the conveyor belt, or which side moves backward.
(2) Check the deviation values of the two planes for installing the bearing seats on the head and tail frames. If the deviation between two planes is greater than 1mm, they should be adjusted to be in the same plane. The adjustment method for the head drum is: if the conveyor belt deviates to the right side of the drum, the bearing seat on the right side of the drum should move forward or the bearing seat on the left side should move backward; If the conveyor belt deviates to the left of the drum, the bearing seat on the left side of the drum should move forward or the bearing seat on the right side should move backward. The adjustment method of the tail drum is exactly opposite to that of the head drum.
(3) Check the position of the material on the conveyor belt. If the material is not centered on the cross-section of the conveyor belt, it will cause the conveyor belt to deviate.
If the material deviates to the right, the belt will deviate to the left, and vice versa. When using, materials should be centered as much as possible. To reduce or avoid the deviation of such conveyor belts, material blocking plates can be added to change the direction and position of the materials.
Conveyors have been subjected to the impact of materials, ores, coal blocks, and even metals for a long time, resulting in friction and severe impact wear, the most common of which are the impact wear of the coal chute and the guide plate. When the particles of some materials are relatively fine, they may accumulate due to production processes, installation angles, material humidity, and other reasons.
Once the equipment experiences impact wear, the traditional solution is to replace it with a metal material with relatively high welding hardness, such as manganese steel plate. Some also use wear-resistant lining plates made of riveted PE or other materials for protection, but once the anchor bolts wear out, it will cause the lining plates to fall off, block the feeding channel, and be difficult to clear, affecting the normal production of the enterprise. Regarding the above-mentioned conveyor faults, Western countries often use polymer composite materials for treatment, among which the most mature application is the Meijiahua technology system. Its superior adhesion performance and super wear resistance safely solve the problem of frequent metal wear, ensuring the normal production of enterprise equipment. Moreover, the unique ceramic material and special surface strengthening agent in the material make its wear resistance and physical impact resistance superior to any steel or even surpassing ceramic tiles in the harshest dry grinding environment. The material's incompatibility with coal is also an ideal material for preventing coal accumulation.
The common faults and troubleshooting methods of this machine are as follows:
1. Common malfunction: The motor cannot start or immediately slows down after starting.
Fault cause analysis: Line A fault; B voltage drops; C contactor malfunction; Operate continuously within 1.5 seconds.
Solution: Check the circuit; Check the voltage; Check overloaded electrical appliances; Reduce the number of operations.
2. Common faults: Electric motor overheating;
Fault cause analysis: Due to overloading, excessive length, or conveyor belt jamming, the operating resistance increases, causing the motor to operate under overload; Due to poor lubrication conditions in the transmission system, the power of the electric motor increases; Dust accumulates in the air inlet or radial heat sink of the electric motor fan, deteriorating the heat dissipation conditions.
Solution: Measure the power of the motor, identify the cause of overload operation, and provide targeted treatment; Timely supplement lubrication for each transmission part; Remove dust.
3. Common malfunction: When fully loaded, the hydraulic coupling cannot transmit the rated torque
Fault cause analysis: Insufficient oil volume in the hydraulic coupling.
Solution: Refueling (When driving with dual motors, it is necessary to measure the two motors with an ammeter. Investigate the oil filling amount to make the power tend to be consistent.)
5. Common fault: Overheating of reducer
Fault cause analysis: Too much or too little oil in the reducer; The oil has been used for too long; Deterioration of lubrication conditions leads to bearing damage.
Solution: Inject oil according to the prescribed amount; Clean the interior, replace oil or bearings in a timely manner, and improve lubrication conditions.
6. Common malfunction: Conveyor belt deviation
Fault cause analysis: The rack and drum were not adjusted to be straight; The axis of the roller is not perpendicular to the centerline of the conveyor belt; The joint of the conveyor belt is not perpendicular to the centerline, and the edge of the conveyor belt is S-shaped; The loading point is not in the center of the conveyor belt (unbalanced load).
Solution: Adjust the rack or drum to keep it straight; Use the roller to adjust the position and correct the deviation of the conveyor belt; Remake the joint to ensure it is perpendicular to the center of the conveyor belt; Adjust the position of the coal drop point.
7. Common faults: aging and tearing of conveyor belt
Fault cause analysis: Friction between the conveyor belt and the frame leads to edge pulling and cracking; The interference between the conveyor belt and the fixed hard object causes tearing; Poor storage and excessive tension; Laying too short results in bending times exceeding the limit, leading to premature aging.
Solution: Adjust in a timely manner to avoid long-term deviation of the conveyor belt; Prevent the conveyor belt from hanging onto fixed components or falling into metal structural components; Store according to the requirements for conveyor belt storage; Try to avoid using short distance paving as much as possible.
8. Common malfunction: broken strap
Fault cause analysis: The material of the belt is not suitable, and it becomes hard and brittle when exposed to water or cold; The strength of the conveyor belt deteriorates due to long-term use; The quality of the conveyor belt joints is poor, and local cracks have not been repaired or remade in a timely manner.
Solution: Use materials with stable mechanical and physical properties to make the core; Timely replace damaged or aged conveyor belts; Regularly observe the joints and promptly address any issues found.
9. Common malfunction: slippage
Fault cause analysis: Insufficient tension of the conveyor belt and excessive load; Due to watering, the friction coefficient between the transmission drum and the conveyor belt decreases; Beyond the scope of use, inclined downward transportation
Solution: Adjust the tension again or reduce the transportation volume; Eliminate watering and increase tension; Regularly observe the joints and promptly address any issues found.
During transportation, the product should comply with the relevant regulations of the transportation department and must not come into contact with acids or alkalis. Drive devices and electrical equipment should avoid severe vibrations and impacts such as scraping, bumping, and dropping. Rainproof and moisture-proof measures should be taken during storage, and storage should be placed in a covered warehouse.
Conveying machinery and packaging machinery jointly interpret the legend of packaging
Packaging machinery and conveying machinery can be said to be essential links in the production of large-scale products. The combination of the links of conveying the product through a conveyor line to the packaging machinery before passing through packaging and then conveying it again produces molded products. It can be said to be just right.
The stainless steel conveyor adopts standardized and serialized design, which can be applied to the open conveying of materials in various industries. It has the characteristics of being lightweight, durable, structurally sound, aesthetically pleasing, and easy to use. This series of equipment can transport both bulk materials and packaged packages, bags, boxes, etc. It can be used in conjunction with automatic packaging machines or used alone to transport products. The conveying machinery is made of stainless steel as a whole, with a chain plate conveyor belt and no exposed fasteners. It has a brand new design and is beautiful and elegant; Stable and reliable conveying performance, infinite scheduling, easy to use; Used for matching high-precision equipment with good appearance requirements and high quality requirements.
(1) Start and stop
Conveyors should generally be started under no-load conditions. When installing several belt conveyors in sequence, a lockable starting device should be used to start and stop them in a certain order through the control room. In addition, to prevent sudden accidents, each conveyor should also be equipped with a local start or stop button, which can stop any one separately. In order to prevent the conveyor belt from being longitudinally torn due to certain reasons, when the length of the conveyor exceeds 30m, a stop button should be installed at certain intervals (such as 25-30m) along the entire length of the conveyor.
(2) Installation of belt conveyor
The installation of belt conveyors is generally carried out in the following stages.
1. The installation of the frame for the belt conveyor starts from the head frame, followed by the installation of each intermediate frame in sequence, and finally the installation of the tail frame. Before installing the rack, the centerline must be pulled along the entire length of the conveyor. Keeping the centerline of the conveyor in a straight line is an important condition for the normal operation of the conveyor belt. Therefore, when installing each section of the rack, it must be aligned with the centerline and leveled. The allowable error of the rack on the centerline is ± 0.1mm per meter of length. However, the error of the rack center on the entire length of the conveyor must not exceed 35mm. After all individual sections are installed and aligned, they can be connected together.
2. Installation of driving device: When installing the driving device, it is necessary to pay attention to making the transmission shaft of the belt conveyor perpendicular to the centerline of the belt conveyor, so that the center of the width of the driving drum coincides with the centerline of the conveyor, and the axis of the reducer is parallel to the transmission axis. At the same time, all shafts and rollers should be leveled. The horizontal error of the shaft is allowed to be within the range of 0.5-1.5mm according to the width of the conveyor. At the same time as installing the drive device, tensioning devices such as tail wheels can be installed. The axis of the tensioning device's drum should be perpendicular to the centerline of the belt conveyor.
3. Installation of idlers: After the installation of the frame, transmission device, and tensioning device, the idlers of the upper and lower idlers can be installed to give the conveyor belt a slowly changing bending arc. The spacing between the idlers in the bending section is 1/2 to 1/3 of the normal spacing between idlers. After the installation of the roller, it should rotate flexibly and quickly.
4. To ensure that the conveyor belt always runs on the centerline of the idler and drum, the installation of idler, frame, and drum must meet the following requirements:
1) All rollers must be arranged in rows, parallel to each other, and maintained horizontally.
2) All the rollers are arranged in rows and parallel to each other.
3) The supporting structure frame must be in a straight line and maintained horizontally. Therefore, after the installation of the drive drum and roller frame, the centerline and level of the conveyor should be finally aligned.
5. Then fix the rack on the foundation or floor slab. After the belt conveyor is fixed, feeding and unloading devices can be installed.
6. Hanging conveyor belt: When hanging the conveyor belt, first lay the conveyor belt strip on the idler roller of the unloaded section, wrap it around the drive drum, and then lay it on the idler roller of the overloaded section. The hanging strap can be used with a 0.5-1.5t hand-operated winch. When tightening the strap for connection, the roller of the tensioning device should be moved to the limit position, and the trolley and spiral tensioning device should be pulled towards the direction of the transmission device; The vertical clamping device needs to move the drum to the top. Before tightening the conveyor belt, the reducer and motor should be installed, and the inclined conveyor should be equipped with a braking device.
7. After the installation of the belt conveyor, it is necessary to conduct an idle test. In the idle test machine, attention should be paid to whether there is any deviation during the operation of the conveyor belt, the operating temperature of the driving part, the activity of the rollers during operation, the tightness of the contact between the cleaning device and the guide plate and the surface of the conveyor belt, etc. At the same time, necessary adjustments should be made until all components are normal before carrying out the load test machine. If a spiral tensioning device is used, its tightness needs to be adjusted again during the test run with load. The uneven drum causes the conveyor belt to deviate. If the installation exceeds the tolerance, the machine should be stopped and leveled; If the machining deviation of the outer diameter of the drum is too large, the outer circle of the drum needs to be reprocessed; Adhesive materials on the surface of the drum can cause the conveyor belt to deviate, and these materials should be removed regularly; Once the conveyor belt is loaded, it will deviate, and the position of the feeding port should be adjusted accordingly; The conveyor belt deviates when unloaded, but with the addition of material, it can be corrected. This phenomenon is generally caused by excessive initial tension, and appropriate adjustments can be made.
(3) Maintenance of belt conveyor
In order to ensure the reliable operation of the belt conveyor, the most important thing is to promptly detect and eliminate possible faults. For this purpose, operators must observe the working condition of the transport aircraft at all times and promptly handle any abnormalities found. It is important for mechanical workers to regularly inspect and check any situations or components that require attention. For example, a roller may not be very important, but a high-speed conveyor belt that transports worn materials may quickly wear through its outer shell, resulting in a blade that can seriously damage an expensive conveyor belt. Trained workers or experienced staff can promptly detect impending accidents and take preventive measures. The conveyor belt of a belt conveyor accounts for a significant proportion of the overall conveyor cost. In order to reduce the cost of replacing and repairing conveyor belts, it is necessary to attach importance to training operators and maintenance personnel on the operation and maintenance knowledge of conveyor belts.
(4) Design parameters
The parameters of the tensioning device for belt conveyors are mainly considered from the following two aspects: on the one hand, it is necessary to consider the maximum tensioning force that the tensioning device needs to meet during the starting process of the belt conveyor under normal and stable operation, based on the tension size of the conveyor belt and its safe and reliable tensioning coefficient; On the other hand, belt conveyors require a certain starting acceleration during normal start-up, and there is a certain time interval before reaching this acceleration. Therefore, it is necessary to design the time interval from the start of tensioning the conveyor belt to the normal start-up of the belt conveyor to reduce the impact on the conveyor belt during the tensioning process. Of course, the tension required for a belt conveyor varies at different stages and under different working conditions (such as starting, normal operation, and braking). Therefore, when calculating the tension, it should be considered based on the operating conditions of the belt conveyor under different working conditions, while ensuring that the conveyor belt does not slip on the driving drum. Of course, a tensioning device with reasonable parameters should meet the requirement of automatic adjustment of the tensioning force of the belt conveyor under different working conditions. This can ensure that the conveyor belt can obtain sufficient tensioning force and appropriate verticality, so that corresponding friction can be generated between the driving drum and the conveyor belt. It can also limit the conveyor belt from bearing excessive tension, thereby ensuring that the belt conveyor can work normally and stably.
The tension of the belt conveyor is transmitted through the friction between the driving drum and the conveyor belt, and in this process, it is necessary to continuously overcome the running resistance of the conveyor belt to make the belt conveyor work. The tension at each point on the conveyor belt can be calculated using the point by point method, and the tension at a certain point on the conveyor belt is equal to the sum of the tension at the previous point along the running direction of the conveyor belt and the running resistance between these two points.
The tension required for a belt conveyor is inseparable from the working conditions of the belt conveyor itself. The tension required for belt conveyors varies under different working conditions, so the designed tension device should be able to make corresponding adjustments according to specific situations.
(5) Introduction to Maintenance of Conveyor System
To prevent malfunctions, maintenance and sampling of the conveyor chain are essential:
1. Regularly provide lubricating oil;
2. Measurement of Chain Elongation (Total Elongation Measurement of Tightening Parts, Determination of Total Length and Chain Link Elongation, Measurement of Pitch);
3. Inspect the wear and deformation of the rollers and tracks.
(6) Precautions for using mesh belt conveyors in special environments
1. In high temperature environments, as we mentioned earlier, mesh belt conveyors can withstand high temperatures. Generally, mesh belt conveyors can work in an environment of 400 degrees Celsius. However, if the temperature exceeds 400 degrees Celsius, certain measures will need to be taken for the mesh belt conveyor. During the production stage of the mesh belt conveyor, in order to meet the use in high temperature environments, stainless steel mesh belts with high temperature resistance are generally selected to ensure that the service life of the mesh belt conveyor will not be affected in high temperature environments. When using a mesh belt conveyor in a high-temperature environment, it is important to choose a type that is resistant to high temperatures. During use, it should be noted that in addition to high-temperature environments, mesh belt conveyors can also generate heat during transportation. This requires us to have a certain margin of consideration for the high temperature resistance of the mesh belt when choosing a conveyor belt.
2. When using a mesh belt conveyor in a corrosive environment, attention should also be paid to the fact that the corrosive environment can damage the mesh belt, causing the various components of the mesh belt conveyor to become thinner, thereby reducing its service life. We should pay attention to certain anti-corrosion operations during use to ensure that acid and alkali will not damage the mesh belt conveyor.
3. We also introduced the importance of lubrication for mesh belt conveyors earlier. Lubrication is very necessary for mesh belt conveyors, especially large ones. During the material conveying process, serious grinding phenomena sometimes occur, which has a significant impact on the service life of the mesh belt conveyor. Grinding can directly cause wear and tear on the components of the mesh belt conveyor, thereby reducing its service life. Therefore, special attention should be paid to lubrication in the grinding environment of the mesh belt conveyor.
In other environments, such as in processes that require reducing volume or repeated processing, it is necessary for mesh belt conveyors to have excellent turning performance or improved performance.
