QDZ750型汽车袋装水泥装车机说明书.doc

qdz-750型汽车袋装水泥装车机qdz-750 automobile sacked cement loading machine使用说明书instructions唐山智能电子有限公司tangshan zhineng electronics co., ltd.目 录contents1 用途1usage12 主要技术参数1important technical indices13 主要结构及特点1main structure and characteristic14 安装1installation15 使用及保养10maintenance106 轴承及易损件表11bearing and vulnerable parts table117 附图12attached figure12qdz-750型汽车袋装水泥装车机润滑点图oil site map of qdz-750 automobile sacked cement loading machine产品执行标准：q/zn 03-2005装车机gb/t 1804-2000一般公差 线性尺寸的未注公差gb 4208 外壳防护等级的分类gb/t 4942.1-2006旋转电机整体结构的防护等级（ip代码）-分级gb/t 6414-1999铸件尺寸公差与机械加工余量gb/t 13306 标牌jc/t402水泥机械涂漆防锈技术条件jc/t 532建材机械钢焊接件通用技术条件production executive criteria:q/zn 03-2005loading machinegb/t 1804-2000 general tolerance, the linear dimensional tolerance not noted.gb4208 classification of out cover protection grade gb/t 4942.1-2006 protection grade of the massive structure of the rotating motor (ip code) gb/t 6414-1999 cast dimensional tolerance and machine-finish allowancegb/t 13306 signjc/t402 antirust engineering factors of cement machinery paint jc/t 532 general engineering factors of welded steel pieces of building material machine 唐山智能电子有限公司tangshan zhineng electronics co., ltd.河北省唐山市高新技术开发区荣华道7号no 7 ronghua road hi-tech developingzone tangshan hebei电话（tel）真（fax）址（web site）：邮箱（email）：1 用途 purposeqdz-750型汽车袋装水泥装车机是我公司为适应市场需要而开发的新产品。它主要用于将包装机下面的输送带输送出来的袋装水泥，通过该机直接输送到汽车斗上。这种直接输送到汽车斗上的装车方法，可以节省装车的劳动力，提高装车的效率，减少搬运、装卸过程中所造成的破袋现象。the qdz-750 automobile sacked cement loading machine is the new product of our company to adapt to the market requirement development. it is mainly used to transport the sacked cement which is transported by the conveyer belt to the automobile fights. this method can save labor force, enhance the efficiency, and avoid broken bag phenomenon which caused by transporting, loading and unloading. 2 主要技术参数 main technical parameter1.装车能力：2400袋/h 1. loading ability：2400bags/h 2.带速：0.8m/s2. belt speed：0.8m/s3.机架行走速度：0.21m/s3. rack walking speed：0.21m/s4.皮带运行驱动减速机：bwd4-5-29；功率：4kw4. speed reducer driven by the belt motion：bwd4-5-29；power：4kw5.机架行走驱动减速机：xwd2.2-5-59；功率：2.2kw5. speed reducer driven by the rack walking：xwd2.2-5-59；power：2.2kw6.带宽：650mm6. belt width：650mm7.电动葫芦：cd12-6d；功率：3kw；起重量：2t；起升高度：6m；起升速度：8m/min7. electric block：cd12-6d；power：3kw； carrying ability：2t；raising height：6m；raising speed：8m/min8.机重：4t8. machine weight：4t9.外形尺寸：1955019001570mm9. external dimension：1955019001570mm3 主要结构及特点 main structure and characteristic汽车袋装水泥装车机是由水平皮带机、倾斜皮带机、电控柜、动力传动等部分组成。该机共有3个动力：the automobile sacked cement loading machine is composed of horizontal belt machine, inclined belt machine, electrically controlled cabinet, power drive and so on. this machine has 3 powers altogether:1.装车机的行走驱动电机，功率为2.2kw，其水平行走速度为0.21m/s.1. the walking of the loading machine drives the motor, power 2.2kw, and its average walking speed is 0.21m/s.2.输送皮带驱动电机，功率为4kw,带速为0.8m/s. 2. the transporting belt drives the motor, power 4kw, and the belt speed is 0.8m/s.3.倾斜皮带机上、下升降动力，采用功率3kw，起重量2t的电动葫芦。3. the power for moving up and down of the inclined belt machine is 3kw, the carrying ability is 2t.水平皮带机与倾斜皮带机的皮带驱动共用一台电机驱动。可以使两个输送皮带同步、带速一致。整机的行走由固定在水平皮带机架下面的减速机通过链条传动带动车轮转动来实现前后行走。倾斜皮带机通过电葫芦提升，摆动角度大，能适应大、中、小型运输车的装车高度。该机设计合理结构简单紧凑，使用维护方便。the horizontal belt machine and the inclined belt machine share the same motor-driven; it can make the two belts work synchronously. the walking of the overall is realized by the wheel rotation which driven by the chain drive of the speed reducer fixed under the horizontal belt machine. the inclined belt machine adapts the height of large-scale, medium and small-scale transport vehicle through the lift of the trolley hoist. the machine is reasonable designed, easy to use and maintain.4 安装 installation1.开箱检查：按装箱单核对随机配件是否齐全，检查各零部件在运输和搬运过程中有无损坏。1. inspection after opening the box: check whether the matching parts are all there according to the packing list, and whether there is damage during the transportation and in the transporting process.2.在欲安装装车机的楼层上按附图中的轨距要求（两轨道中心距1210mm；轨道上面标高 +5.00m）固定两根p18轻轨，供装车机在轨道上往返行走；两轨道要求相互平行不得有弯曲，并且两轨道上平面在同一水平面内，轨道水平布置不得有坡度。如图1所示在每根轨道两端应加焊限位挡铁，以防止接近开关失效时装车机跑出轨道。2. on the floor where a loading machine will be installed, two p18 light tracks (the orbital center distance between the two are 1210mm, and the orbital elevation +5.00m ) on which the loading machine goes back and forth are fixed according to the attached figure. the two tracks are required to be paralleled without curve, and the top surfaces of the two tracks are required in the state of water level without any slope. as shown in figure 1, a spacing blocking steel should be welded at each side of the tracks, which can prevent the loading machine from running off the tracks. 限位挡铁 spacing blocking steel 轨道 track图1：限位挡铁焊接示意图figure ：the welded map of the spacing blocking steel3.装车机机架的组装如图2所示：以水平皮带机架的组装为例。斜皮带机与水平皮带机机架结构相似。发货时机架已经分段组装好，安装环形皮带时需要将一侧的大梁解体，套上环形皮带后再将恻梁组装好。安装托辊时要求托辊轴线与大梁的侧面垂直并且各托辊轴线以及滚筒轴线相互平行，用手拨动托辊应转动灵活。图示为水平皮带机一段机架的组装，各段之间通过销轴和螺栓连接。3. loading machine racks are assembled as shown in figure 2: take the horizontal belt rack assembly as an example. the rack structure of slanting belt machine and the horizontal belt machine are similar. the rack has been assembled well before delivering. when installing the loop belt, one side summer beam should be disintegrated, and then reassembled after putting on the loop belt. when installing the supporting roller, the roller axis and the side of the summer beam should be vertical, and the roller axis and cylinder axis should be paralleled. the supporting roller should rotate nimbly when moving with hand. the graph shows a section of the rack assembly of horizontal belt machine; sections are connected by pin bearings and bolts.主车附梁 attached beam of the machine; 主车底架 base frame of the main body of the machine; 托辊 carrier roller;横梁 crossing beam 托辊支撑板 supporting board of the carrier roller. 图2：机架组装示意图figure ：track assembly map4.水平皮带传动部分的组装如图3所示：联轴器组装时要使减速机轴与滚筒轴轴线同心，并在两个半联轴器之间留12mm间隙。4. the assembly of horizontal belt transmission part is shown as in figure 3: when assembling the shaft coupling, the speed reducer axis and the drum shaft axis should be concentric, and the gap between two half shaft couplings should be kept for 12mm.图3：水平皮带传动部分组装示意图610987625431121figure ：assembly map of horizontal belt transmission part序号图号名称数量备注1摆线减速机12qdz750-1-18a挡板23qdz750-1-17a半联轴器a14qdz750-1-20a尼龙柱销65qdz750-1-19a半联轴器16带座轴承27qdz750-1-25a传动滚筒18qdz750-1-07a主车附梁29qdz750-1-31a链轮压盖110qdz750-1-30a主动大链轮111qdz750-1-21a减速机托架1orderfigure numbernamequantitynotes1cycloid reducer bwd13-29-412qdz750-1-18aback plate23qdz750-1-17asemi- coupling a14qdz750-1-20anylon dowel pin65qdz750-1-19asemi-coupling b16stock bearing ucfu31127qdz750-1-25atransmission roller18qdz750-1-07aattached beam of the machine29qdz750-1-31asprocket gland110qdz750-1-30adrive sprocket111qdz750-1-21aspeed reducer bracket138575643215.斜皮带传动部分的组装如图4所示：传动滚筒轴安装轴承和从动链轮时，不允许直接锤击，以防损坏。5. the assembly of slanting belt transmission part is shown in figure 4: when bearing and driven sprocket are installed on the transmission roller spindle, direct hammer should be avoided to prevent the damage.图4：斜皮带传动部分组装示意图figure ：assembly map of the slanting transmission part序号图号名称数量备注1qdz750-1-31a链轮压盖12qdz750-3-12a从动链轮13带座轴承24qdz750-3-02a左连接梁15qdz750-3-11a支撑套26qdz750-3-02a/03a输送梁27qdz750-3-01a传动滚筒18qdz750-3-03a右连接梁1orderfigure numbername quantity notes 1qdz750-1-31asprocket gland12qdz750-3-12adriven sprocket13stock bearing 24qdz750-3-02aleft connecting beam15qdz750-3-11asupporting cover26qdz750-3-02a/03atransporting beam27qdz750-3-01atransmission cylinder18qdz750-3-03aright connecting beam16.行走驱动部分的组装如图5所示：6. assembly of walking driving part as shown in figure 5: 图5：行走驱动部分组装示意图figure ：assembly map of walking driving part序号图号名称数量备注1摆线减速机12qdz750-1-26a行走小链轮13qdz750-1-27a减速机压盖14qdz750-1-29a车轮压盖25qdz750-1-13a行走车轮26qdz750-1-22a行走大链轮17轴承座28qdz750-1-23a车轮轴19qdz750-1-03a行走减速机座1orderfigure numbername quantity notes 1cycloid reducer12qdz750-1-26awalking small sprocket13qdz750-1-27aspeed reducer gland14qdz750-1-29awheel gland25qdz750-1-13awalking wheel26qdz750-1-22awalking big sprocket 17bearing bracket28qdz750-1-23awheel shaft19qdz750-1-03awalking speed reducer seat17.将装车机各部分都组装好后，环形皮带也安装好以后再进行整体组装。用与斜皮带机相连的左右连接梁，前端通过梁连接板与行走副车连接，后端通过销轴与水平皮带机相连（如图6所示）。各滚筒安装完后，没装环形皮带以前用手拨动应转动灵活。安装车轮罩时要将带有豁口的车轮罩装在头尾车轮处。链轮安装时主动链轮和从动链轮的轮齿几何中心平面应重合，链条松紧要适度，链条松边垂度按48mm调整。环形皮带的松紧要适当，通过改向滚筒两侧的丝杠进行调节。7. integral assembly begins after the installment of all loading machine parts and loop belt. the front end the left and right connecting beam connected with the slanting belt machine is used. the front end is connected with the attached walking machine through the beam connecting board. the rear end is connected with paralleled belt machine through pin bearing. (as shown in figure 6) after rollers installment, the rollers should rotate nimbly when moving it with hands before the loop belts installment. when installing the wheel cover, the cover with opening should be installed on the front and then end wheel. when installing the sprocket, the geometric center plane of the drive sprocket and the driven sprocket should be superposed. the chain wheel elasticity should be moderate and the side chain should be adjusted to about 4-8mm. the elasticity of loop belt also should be moderate. it is adjusted through the levers on each side of the cylinder.梁连接板girder joint plate 连接销轴jointpin roll图6：整机的组装示意图figure ：assembly map of overall 8.电葫芦的安装：电葫芦安装在行走副车头部的两槽钢之间，电动葫芦安装牢靠。电动葫芦上下升降限位开关调整位置适当；8. the installation of the trolley hoist: the trolley hoist should be installed firmly between the two channel steels of the attached walking machine. the up and down limit switch of the trolley hoist should be adjusted suitably. 9.本机的前后行走限位通过接近开关控制，如图7所示将接近开关安装在头部车轮罩的外侧，并在装车机行走的前后极限位置在铁轨上各焊接一个接近开关感应板。9. the forward and backward walking limit is controlled by the close witch. as shown in figure 7, the close switch is installed in the outer part of the forehead wheel, and the inductive board should be installed in the steel track of two ends of the limit place respectively.接近开关 close switch 接近开关感应板 close switch inductive board图7：接近开关及感应板安装示意图figure ：installation map of close switch and inductive board10.为了安全起见除了电葫芦自带的上升下降限位开关外，本机还增加了一个斜皮带上限位开关，通过行程开关控制。如图8所示，将斜皮带机提升到接近上升的极限位置，将行程开关架现场焊接在装车机头部的行走车轮的副车架上，行程开关碰板与输送吊架现场焊接好。10. to make it more safe, besides the up and down limit switch which the machine attached, a slanting belt limit switch controlled by position switch is added. as shown in figure 8, when slanting belt machine is promoted close to the up limit position, the position switch shelf is welded in the sub-frame of the head loading machines walking wheel, and the position switch and the transporting hanger should be welded well.副车架 secondary car frame 行程开关架 overall-limit switch frame行程开关 overall-limit switch 行程开关碰板 overall-limit switch collision board 输送吊架 conveying drop-hanger frame图8：上限位行程开关安装示意图figure ：installation map of up limit position switch按钮盒 button box图9：按钮盒的安装位置示意图figure ：installation position map of button box11.本机配有两根安全链，一端安装在输送吊架上，另一端安装在头部电葫芦两侧的槽钢上。在装车机周边应架设可靠的防护栏杆由厂家根据场地情况自行制作安装。11. there are two safety chains equipped in this machine, one end is installed in the transporting hanger, and the other end is installed in the two side channel steel of the trolley hoist. according to the site condition, the factory itself should install the guard rail around the loading machine.12.本机配有一个主电控箱和3个按钮盒。主电控箱安装在装车机头部侧面可随装车机一起前后行走。3个按钮盒其中两个（如图9所示）安装在斜皮带头部两侧，另一个按钮盒可根据厂家的实际情况安装在墙壁或其它便于操作的地方。12. this machine has a main electric controller and 3 button boxes. the main electrical controller is installed in the loading machine head side and can walk together along with the loading machine. 2 of the 3 button boxes (as shown in figure 9) are installed in the both sides of the slanting belt head, the third one may be installed on the wall or other places where is convenient to operate according to the practical condition.13.安装时应有安全措施及安全警示标志。在操作人员附近明显位置设有“设备下方严禁站人”的标示。13. security measures and security warning sign are required when installing. the sign of “no stay beneath the equipment” should be equipped in the obvious position around the operator.14.安装完成后，检查机械固定部位应紧固，各紧固件不得有松动，活动部位应灵活可靠。14. after the finishing of the installation, the machinery fixed spot should be fastened, the active spot should nimbly reliable without looseness.15.按照外部接线图，依次闭合断路器qf1、qf2、qf3、qf4、qf5，控制箱门和下按钮盒上的电源指示灯点亮。15. according to exterior wiring diagram, close the circuit breakers qf1, qf2, qf3, qf4, qf5 in turn, and then the power indicators at the control box gate and the lower button box lighten.16.按下sb5、sb6、sb13按钮，斜皮带上升，按下sb7、sb8、sb14按钮，斜皮带下降；按下sb9、sb10、sb15按钮，装车机前进；按下sb11、sb12、sb16按钮，装车机后退。以上按钮都是点动按钮，不带自锁功能。16. the slanting belt will rise when pressing sb5, sb6 buttons; the sb13 button, the slanting belt will drop when pressing down sb7, sb8, sb14 buttons; the loading machine will go advance when pressing down sb9, sb10, sb15 buttons; the loading machine will go back when pressing sb11, sb12, sb16 button. all the buttons above must be pressed by hand, without the self-locking function.17.装车机的前进、后退，斜皮带的上升，都有限位开关，当限位开关动作后，装车机动作停止。17. as for the advance and backlash of the loading machine, the rise of the slanting belt, they are all controlled with limit switch. the loading machine stops working after the movement of limit switch.18.按下sb3或sb4，装车机皮带运行，按下sb1或sb2皮带停止。18. the loading machine belt will work when pressing down sb3 or sb4, and it stops working when pressing down sb1 or the sb2.19.sb、sbs、sbs1为急停按钮，其中任意一个动作，装车机所有动作停止。19. sb, sbs, sbs1 are emergency stop buttons, and the loading machine will stop all the work when pressing anyone of them.20.电气部分正确无误后，开机试运行。观察电机转向是否正确，有无异常声响。如有异常现象应立即停机检查。待故障排除后再空载试运行。试车时要分步进行，先把皮带机驱动和机架行走单独试车后，再同时运行试车。20. after insuring the correction of the electrical part, check out whether the machine works well. observing whether the electrical machinery moves right, and whether there is any unusual sound. if there is abnormal phenomenon, the machine should be turned off immediately. after the problems are solved, the machine should run again. the test should be divided in steps to carry on, after testing the work of the belt machine drive and stander walk respectively, and then the machine test begins.5 使用及保养 uses and maintains1.详细阅读qdz-750型汽车袋装水泥装车机使用说明书、电动葫芦使用说明书及其它随机文件。1. read the “instructions of qdz-750 automobile sacked cement loading machine” “instructions of electric block” and other attached documents in details.2.每班开机前对电动葫芦进行检查，钢丝绳应按gb5972的规定进行检验和报废，钢丝绳应保持良好的润滑状态，润滑剂符合要求，并且不影响外观检查，钢丝绳出现断股或磨损时应及时更换。如未出现断股或磨损，使用6个月后必须更换新钢丝绳。2. each working shift should check the electric hoist before working. the steel wire should be checked and scraped according to the regulations in gb5972. the steel wire should be in good lubrication condition. the lubricant should conform to the requirement and should not affect the appearance test. the steel wire should be replaced i