带式输送机的典型故障分析与处理#中英文翻译#外文翻译匹配

Typical failure analysis and processing of belt conveyor Lihua ZHAO,Yin LIN School of Mechanical Engineering, Northeast Dianli University, Jilin City, Jilin Province Changchun Road 169,132012,China Abstract: The paper analyzes two typical failure forms of roller and conveyor at the belt conveyor, and describes the maintenance methods of prevention and elimination failures to ensure the normal operation of belt conveyor. 1. Introduction: Belt conveyor is a commonly used equipment of continuous transport, it has a high efficiency and large conveying capacity, simpler construction, small amount of maintenance. Can be achieved at different distances, different materials transportation. It iss widely used in mining, coal handling system in thermal power plant and other projects. Belt conveyor will often occur some typical problems in the course, this paper Based on research common typical failure of belt conveyor during use, analysis the cause of failure, proposed some effective methods to solve the problem. 2. Typical faults of conveyor belt: 2.1. Conveyor belt deviation In the belt conveyor, as the conveyor belt is traction components, transmit power and motion, also is carrying components, support material load. Working more complex, so at work often happen belt deviation. Deviation is the conveyor belt during operation, the center line of belt deviation the center line of conveyor. As the conveyor belt deviation may cause between the belt edge and rack wear, cause belt edge premature damage, Ranging impact the life of conveyors, affect the throughput of materials, Weight is caused by withdrawal material, even happen stop occurrence, direct impact on production. As the conveyor belt is more important, the most expensive parts. Its price about 25%50% to the conveyor. So analysis the reasons of belt deviation, reduce and eliminate belt deviation, It is an important part of ensure belt to work, extend equipment life. Cause the belt occurs deviation because of the following factors. 2.1.1. In the device itself a. Rack rigid is poor, large deformation under load, causing the belt deviation. b. The larger error of roller outer cylindrical, caused deviation when the conveyor belt running. c. The supporting roller rotation is not flexible, causes the conveyor belt both sides stress to be uneven, causes the conveyor belt deviation. d. The parallelism error cylindrical axis and roller axis is too big, causes the conveyor belt deviation. e. Conveyor belt itself is questionable quality, thin and thick uneven, caused a shock lead running conveyor belt deviation. f. Conveyor belt manufacturing quality have defects, the length of belt both sides edge is inconsistent, cause running conveyor belt deviation. g. Not parallel with belt connector, connection error is too big, cause belt deviation. 2.1.2. Installation adjustment a. Drive, change roller axis and conveyor centerline vertical error is too big, make conveyor and horizontal line have a bigr inclination, cause belt deviation. b. Roller axis and conveyor centerline vertical error is big, will cause belt deviation also. c. The connection strength between rack and ground is not enough, the rack unstable, causing belt deviation. d. The feeding plate of discharge trough and improperly located, both sides of the conveyor belt uneven force cause belt deviation. 2.1.3. With maintenance a. The cleaning performance of sweeper is poor, make the roller cylindrical diameter local increases. b. Feeding mouth location is wrong, so that the material partial load on the conveyor belt, cause belt deviation. c. Poor maintenance and improper adjustment, resulting in the conveyor belt deviation. d. For the steel cord belt, as the manufacture of steel cord is uneven force, so that a deviation occurs in the operation, or a strong difference of belt, large elongation under load, causing the vibration, the belt will deviation. e. Also, the vibration of running conveyor belt system can cause the deviation. f. In addition, when conveying some viscous material, make the roller, etc. bonding materials, make the cylindrical diameter of roller part increases, causing belt deviation. 2.2. Measures to prevent the belt deviation 2.2.1. Due to equipment in the manufacture of conveyor belt causes the deviation, primarily through improved design, manufacture precision to prevent and reduce the occurrence of conveyor belt deviation. 2.2.2. For installation adjust improper and daily use causes deviation, mainly the following aspects should be considered: Conveyor belt in drive roller or on rear rollers deviation, usually by adjusting the position of the roller bearing ways to eliminate, usually by adjusting the position of the roller bearing ways to eliminate. a. The longitudinal centerline of the roller rotation axis and conveyor is not perpendicular, resulting in the conveyor belt one side loose and the other tight, belt move from the tight side to the loose side, Occurs deviation phenomenon. Should be adjusted bearing position of the tighten deviation side. Make horizontal pull of belt equal, eliminate deviation. When tail roller is spiral tensioning, the reasons of tail deviation may be due to the top tight power of tensioning device both sides screw rod are not equal, resulting in caused by imbalance. b. Cylinder axis is not horizontal, at both ends bearing of the height difference is cause another reason of head or tail deviation. At this point, at both ends roller bearing should add and subtract shims way to leveling roller axis ,to eliminate conveyor belt deviation. c. Roller surface adhesion material, equivalent to increasing the roller local rdiameter, will cause the conveyor belt deviation, should strengthen empty segment cleaning of conveyor belt to reduce the adhesive material or dust accumulation on the conveyor belt. In addition, the conveyor belt between the nose and tail parts deviation, called central or local deviation. Such deviation reasons is more complex, it is with the conveyor belt along device exposure to a relationship. Need a detailed analysis for specific issues. Using the following methods can resolve these issues. A. Load or no-load branch roller axis with the conveyor belt running centerline is not perpendicular, causing tape at the roller deviation. Deviation ends should adjustment to the conveyor belt running direction. At this time often need to adjust the adjacent groups of rollers in order to achieve the purpose of eliminating deviation, adjusting deviation angle should not be too big. B. Conveyor belt joint with the tape centerline (trumpet) is not perpendicular, to cause the deviation, Should improved installation connection accuracy to eliminate deviation. C. If material loaded on the conveyor belt is straight; make the material block and weight distribution along bandwidth direction distribution serious inequality, cause deviation, through adjustment blanking tube and skirt plate location method to be eliminated. D. Recently, it was suggested that the method of application film for transfer partial conveyor belt, because of high manufacturing costs and some technical problems not well solved, makes this method very difficult to promote the use. 3. The typical failure of roller: 3.1. Operation is not flexible Each belt conveyor have lot number rollers, installation shown in Picture 1, their work status directly affects the conveyor is working. According to the actual work of conveyor, roller in the conveyor system can be classified four kinds according their efect, trough roller, parallel roller, buffer roller and self-aligning roller; according to the loads case can be divided two kinds, no-load roller and bearing roller. Trough roller use bearing branches of materials, play a supporting role and increased throughput role. Parallel roller is a long-shaped roller, for no-load branch of conveyor, to play a supporting role of no-load branch tape; buffer roller is trough roller too. Flexible support trough roller be installed on conveyor load branch, Installed in the material office. Reduce the impact of material for conveyor belt, protect the tape and support bearing. Generally based on the elastic support were divided into rubber ring and spring plate; the role of self-aligning roller is a certain degree of automatic adjustment of conveyor belt deviation, To avoid excessive wear of belt and materials scattered. In the load and no-load branch are equipped with a number of self-aligning roller. The self-aligning principle shown in Fig. 2. Manufacture installation quality of roller directly affect the life and running resistance of conveyor belt. roller repair and replacement costs are also an important part of conveyor belt operating expenses. The roller operation quality for conveyor of the running resistance, power consumption, roller and belt life, maintenance workload and cost of transportation has a significant impact. Therefore, analysis method to extend the service life of rollers, also an important contents to ensure stable operation of belt conveyor, practical significance in engineering. Trough roller of belt conveyor systems used on material bearing branch, play supporting role and increased throughput role. Parallel roller is a long-shaped roller, for no-load branch of conveyor, to play a supporting role of no-load branch tape; buffer roller is trough roller too. Flexible support trough roller be installed on conveyor load branch, Installed in the material office. Reduce the impact of material for conveyor belt, protect the tape and support bearing. The role of self-aligning roller is a certain degree of automatic adjustment of conveyor belt deviation, To avoid excessive wear of belt and materials scattered. In the load and no-load branch are equipped with a number of self-aligning roller. If roller appear rotating not flexible or not turning phenomenon. The drag coefficient of roller operation by rolling into a slide, value was ten times to increase. The results will result in increased running resistance of belt conveyors, electric power consumption increases. As the roller rotation is not flexible, the friction between roller and conveyor belt by rolling friction into sliding friction, make the friction increase between the two, shorten the equipment life . Therefore, we must often replace a large number of idlers, conveyor belt, resulting in increased equipment maintenance, operating costs increased. Many factors for affect the flexibility of running rollers and life span, summarized in the following areas: a. Manufacturing quality of roller Roller manufacturing problems mainly in the bearing stiffness is not enough, it is difficult to ensure precision of roller assembly, thereby constraining the flexibility of running roller. b. Sealed lubrication and the use of maintenance Main factors of affect roller rotation not flexible include sealing and bearing lubrication problem. As the work environment of belt is more severe. Generally speaking, the dust are great on used site. The seal form of bearing have a great influence on the running flexibility for rollers. If sealed not well, Dirt is easy into bearing to cause the roller rotation is not flexible, In addition, bearing grease if using the general calcium base grease is easy to change color to dry, can not play a very good lubricant role. 3.2. Solutions a. In the roller manufacturing processes guarantee the accuracy requirements, For example, pressing bearing bore to achieve three precision, tube at both ends of dimensional tolerances, concentricity and ovality must meet national standards. The products have strict quality inspection to ensure that all products qualified. b. Sealed lubrication, in addition to manufacturing quality assurance, go with good lubricating materials, such as use of lithium-based grease, can improve the lubrication of bearings which extend the life of the roller is necessary. c. Bearing used to ball bearings support, plastic sealing ring labyrinth seal structure, this can ensure roller worked reasonable force, While ensuring dust effect good, resistance small, easy assembly and disassembly, easy to maintain, reduce conveyor operating costs. 4. Conclusion: Wide range applications of belt conveyors, and the work environment is generally more difficult, to keep equipment running in good working condition, extend equipment life, improve the quality of operation, reduce operating costs has been the goal of engineering and technical personnel. Analyze and resolve the impact normal operation of the main problems, to ensure the good functioning of device, it is an important work of equipment maintenance. This paper analyzes the proposed method. Helpful improve site maintenance staff levels to solve practical problems, for practical project has important significance. References: 1 yixiang Lang. Transportation machinery equipment in thermal power plant.MNortheast dianli university book; 1998.08. 2 lihua Zhao. Operation and Maintenance of Coal Handl ing Sys tem in Thermal Power Plant , J.Colliery Machine;2011,NO. 02. 3lihua Zhao. Typical failure analysis and processing of belt conveyorJ.Hoisting and Conveying Machinery;2003,NO 10. 4 lihua Zhao. The adjustment method of conveyor belt deviation J. Colliery Machine. 2001. No.05. 带式输送机的典型故障分析与处理 赵丽华 *林茵 中国吉林省，吉林市长春路 169132012 号，东北电力大学，机械工程学院 摘要 ： 本文分析了两种带式输送机失效的典型形式：托辊和输送带。并介绍了预防和消除故障的维护方法，以确保带式输送机的正常运作。 1、 介绍 ： 带式输送机 是一种常用的连续输送设备，它具有效率高、输送量大、结构简单、维修量小等特点。可以实现不同距离、不同材料的运输。它们广泛应用于矿山、火电厂输煤系统等项目。带式输送机在运作中经常出现一些典型问题，本文在带式输送机使用过程中常见的典型故障的研究基础上，分析失败的原因，并提出了一些有效的解决问题的方法。 2、带式输送机的典型故障： 2.1.输送带的跑偏： 在带式输送机 中， 输送带作为牵引组件， 它不仅 传递动力和运动，也承载组件，支持负载。工作比较复杂，所以在工作中经常发生皮带跑偏。 跑偏 是皮带输送机在运行过程中，输送带 中心线的 跑偏。由于输送带跑偏会使带之间的边缘和齿条磨损， 从而 导致带边缘的过早损坏， 其 影响 包括 影响输送带的寿命 ， 影响 材料 的通量 ，撤出材料 的重量 ，甚至发生停止 运作的现象 ，直接影响到生产。 作为输送机最重要、 最昂贵的零件 ， 它的价格 约占输送机的 25% 50%，因此皮带跑偏 的原因分析 ， 减少和消除皮带跑偏是确保带工作，延长设备使用寿命 的 一个重要部分。造成皮带跑偏 的因素有： 2.1.1.装置本身： a： 机架刚性差，大负荷下变性，造成皮带跑偏。 b：滚子外圆柱误差较大，是输送带运行时发生偏差。 c：托辊转动不灵活，是输送带两侧应力不均匀，导致输送带跑偏。 d：辊轴与圆柱轴的平行度误差太大，导致输送带跑偏。 e：输送带本身的质量问题，薄厚不均匀，造成的冲击导致运行输送带跑偏。 f：皮带输送机制造质量有缺陷，带两侧边的长度不一致，导致输送带运行时跑偏。 g：不平行的带连接器，使连接误差太大，造成皮带跑偏。 2.1.2.安装调整： a：驱动，换辊轴 和输送中心线的垂直误差太大，使输送带和水平线有一个倾斜，造成皮带跑偏。 b：辊轴与输送带中心线的垂直误差大，也会造成皮带跑偏。 c：机架与地面之间的连接强度不够，架身不稳，造成皮带跑偏。 d：送料盘的放料槽位置不当，两侧的输送带受力不均匀造成皮带跑偏。 2.1.3 维修： a：清洗性能的清洗能力差，使滚子的圆柱直径变大。 b：进料口位置错误，使材料的部分载荷作用在输送带上，导致皮带跑偏。 c：维修和调整不当，造成输送带跑偏。 d：对于钢芯输送带，如过制造时钢芯受力不均匀，则在运作中会发生跑偏，或者存在一个大的差异带，在断裂伸长率大载荷的作用下，产生振动，输送带会发生偏差。 e：输送带运行系统的震动也可引起跑偏。 f：此外，当输送一些粘性物质如粘合材料时会使托辊圆柱滚子的外径部分增大，造成皮带跑偏。 2.2 防止皮带跑偏的措施： 2.2.1 由 设备 在制造输送带时造成的偏差，主要通过改进设计方案，制造精度，以减少和防止输送带跑偏。 2.2.2 安装调整不当和日常使用造成的偏差，主要应从以下几方面考虑： 输送带在驱动辊或后方辊的偏差，通常通过调整滚子轴承的位置进行消除。 a：辊轴的纵向旋转中心线和输送带不垂直，从而使输送带的一侧松，一侧紧，带从紧边运动到松边，发生偏差现象。应调整轴承紧偏差一侧的位置，使皮带水平拉力相等，消除偏差。当尾部辊螺旋张紧，尾偏差的原因可能是顶紧力张紧装置的两侧螺杆不相等，从而造成不平衡。 b：气缸轴线不水平，在两个轴承两端的高度差是造成头部或尾部偏差的另一个原因。此时，两端的滚子轴承应采用加减垫片的方法来平衡托辊，消除皮带输送机的跑偏。 c：托辊表面的粘附材料，相当于增加了托辊的本 来直径，这将导致输送带跑偏，应加强输送带空段的清洗，以减少粘附材料或输送带上的灰尘堆积。此外，输送带之间的鼻子和尾巴部分的偏差，称为中央或局部偏差。这种偏差的原因是复杂的，它是与输送带呈接触关系。需要对特殊问题进行详细的分析。使用以下方法可以解决这些问题： A：负载或空载的分辊轴与输送带的运行中心线不垂直，造成胶带在滚筒上的偏差。偏差的两端应调整输送带的运行方向。在这个时候，为了消除偏差，往往需要调整托辊的相邻组，且调整角度的偏差不宜过大。 B：输送带接头的中心线不垂直时，所造成的偏差，应改进安装的连接精度 来消除误差。 C：如果材料在输送带上的载荷作用是竖直的，将使沿带宽方向分布的材料块的重量严重不均匀，产生偏差，通过调整下料管和主板的定位方法来消除。 D：最近，有人建议，采用应用膜的方法转变部分的输送带，因为制造成本高和没有很好的解决一些技术问题，使这种方法很难得到推广使用。