定量给料机维护手册(中英对照版).doc

Yamato 定量给料机操作维护手册 Operation & Maintenance Manual for the Constant Feed Weigher定量给料机(CFW)操作维护手册Operation & Maintenance Manual for the Constant Feed Weigher (CFW)(GM BSC S02)上海大和衡器有限公司Shanghai Yamato Scale Co., Ltd. Copyright Shanghai Yamato Ltd.2007概述Introduction上海大和衡器有限公司生产制作的定量给料机、定量皮带秤、皮带秤在现代工业中应用范围非常广泛，尤其在水泥、电力、钢铁、化工、造纸、化肥工业等等地方更是起着非常重要的作用。The Constant Feed Weigher, Constant Belt Weigher and CS produced by Shanghai Yamato Scale Co., Ltd. have a very broad application scope in the modern industry and especially play a very important role in cement, electric power, chemical engineering, paper making and fertilizer industry. 上海大和衡器有限公司生产制作的定量给料机采用重量传感器检测到物料的单位长度的瞬时重量信号，同时速度传感器检测到速度脉冲信号。通过控制系统将重量信号与速度信号进行乘积运算，从而求得物料的真实流量（输送量）。控制系统将物料的真实流量和用户设定的输送量（设定量）进行逐次比较，其差值信号反馈给变频器，用于调节输送胶带速度，从而保证物料的真实流量和设定量相一致。The Constant Feed Weigher produced by Shanghai Yamato Scale Co., Ltd. adopts the load cell to inspect the instantaneous weight signals of the material in a unit length and at the same time the speed detector to inspect the speed pulse signals. The weight signals and speed signals are conducted with the product calculation by the control system so as to attain the materials real flux (feeding amount). The control system progressively compares the materials real flux and the feeding amount (the set amount) set by the user and then the signals of difference value are fed back to the inverter in order to adjust the rubber belt feeding speed and guarantee the materials real flux is consistent to the set amount. 本手册描述的性能、尺寸、外观、配置、操作等为上海大和衡器有限公司通用标准，可能与您所购的产品有所不同。不同部分应参照订货合同的技术协议附件为依据。本手册所载内容，因产品的改进，会有未经预告的变更，届时请谅解。The performance, dimension, appearance, configuration and operation described in this Manual belong to the current standards from Shanghai Yamato Scale Co., Ltd., which may be a little different from your purchased products. The different parts shall refer to the annexes of the technical agreement on order contract. The content stipulated in this Manual may be modified upon no notice for the improvement of the products so then please be understanding! .安全预防Safety Precautions 需实行正确操作和定期检修,以保证定量给料机安全运行。谨请在完全读完本手册并且了解了定量给料机后,操作和保养该设备。完全理解了定量给料机结构和安全操作的意义，才能预防人员伤亡事故的发生，才能避免设备的毁损。It is necessary to carry out correct operation and periodical repair in order to guarantee the Constant Feed Weigher safe operates. After completely reading this Manual and get a full knowledge of the Constant Feed Weigher, then operate and maintain this equipment. To get a full knowledge of the Constant Feed Weighers structure and safe operations meaning can prevent casualties and accidents from occurring and avoid the equipment from damaging. 从另一方面来说，安全工作就是防止设备故障和正确操作，有效维护，以致设备能发挥它的最高性能。In the other hand, safe operation is to prevent the equipment from breaking down and carry on correct operation and realize effective maintenance so that the equipment can exert its own highest performance. 标志的含意：Meaning of the signs:在设备运行时，在标志附近范围内较危险，如果没有做到安全操作，可能引起伤亡事故和设备的毁坏。必须绝对遵守安全操作规范，避免出现危险的情形。 When the equipment is running, it is very dangerous around the sign range. If safe operation fails, it may result in casualties and accidents and the damaging of the equipment. It is necessary to absolutely abide by the rules of safe operation in order to avoid the occurrence of dangerous events. 在设备运行时，在标志附近范围内较危险，必须注意到工作环境的危险性，以避免出现伤亡事故。必须绝对遵守安全操作规范，避免出现危险的情形。 When the equipment is running, it is very dangerous around the sign range. More attention should be paid to the danger of the working environment so as to avoid the occurrence of casualties and accidents. It is necessary to absolutely abide by the rules of safe operation in order to avoid the occurrence of dangerous events.在操作时必须小心谨慎，如果没有预防措施，可能引起现伤亡事故的发生。必须绝对遵守安全操作规范，避免出现危险的情形。 It must be careful when operating the equipment. If there are no precaution measures, it may result in casualties and accidents. It is necessary to absolutely abide by the rules of safe operation in order to avoid the occurrence of dangerous events.必须正确操作，有效维护，以致设备能发挥它的最高性能。同时需绝对遵守安全操作规范，避免出现事故苗头。It is necessary to carry on correct operation and effective maintenance so that the equipment can exert it own highest performance. At the same time, it is necessary to absolutely abide by the rules of safe operation in order to avoid the occurrence of incipient tendency of the accidents. 必须完全了解设备的特性，才能保证设备正常工作和能发挥它的最高性能。It is necessary to get a full knowledge of the equipments traits so as to ensure that the equipment normally operates and exerts its own highest performance. 目录Contents 概述- 1 -Introduction- 1 -安全预防- 2 -Safety Precautions- 2 -1. 称量原理- 5 -1. Weighing Principle- 5 -2. 结构 - 5 -2. Structure- 10 -3.定量给料机起动前的准备工作- 15 -3. Preparing work before the starting of the Constant Feed Weigher- 15 -4.远程（中央）操作过程- 15 -4. Remote (center) operating process- 15 -5.现场（本地）操作过程- 16 -5. Spot (local) operation process- 16 -6. 定量给料机停机处理要求- 16 -6. Handling requirements toward the stopping of the Constant Feed Weigher- 16 -7. 定量给料机运行时的调节- 16 -7. Adjustment of the running Constant Feed Weigher- 16 -8. 零点和量程调准 -23-8. Adjustment of zero point and range- 23 -9. 故障排除- 26 -9. Fault eliminating- 26 -10. 定量给料机的点检项目- 30 -10. Point inspection toward the Constant Feed Weigher- 30 -11. 更换输送带的过程- 39 -11. Process of changing the conveyer belt- 39 -12.检锤的安装- 43 -12. Installation of the inspecting hammer- 43 -1. 称量原理1. Weighing Principle 1- 1.连续的称重的原理1-1. Principle of continuous weighing 给料机的输送量由下列方程式表示：The feeding amount of the feeding machine is expressed by the following equation: Q：输送量 (重量范围 0t1) (kg)Q：Feeding amount (the weight ranges from 0t1) (kg)q：瞬时输送量 (kg/min)q: Instantaneous feeding amount (kg/min)W：物料的单位长度重量 (kg/m) (载荷密度)W: Materials weight in a unit length (kg/m) (load density)V：皮带速率 (m/min)V: Belt speed (m/min)设输送带的运行长度为l，输送带的速度为v，输送带运行时间为t, 那么：It is set that the running length of the conveyer belt is to be 1 and the running time of the conveyer belt is t, then: l=vt因此在输送带运行了 t1时间后，输送带的运行长度为l1=vt1，那么，输送量可用下列方程式表示：Therefore, after the conveyer belt runs for t1, the running length of the conveyer belt is l1=vt1 and the feeding amount can be expressed by the following equation:上式表明，定量给料机的输送量为A，B，C三点所包围的面积。如图Fig.1 1所示。The above equation indicates that the feeding amount of the batching feeding machine is the encircled area of Point A, Point B and Point C, shown as Fig.1 1. W单位长度重量W = f(1)CLFig.1 - 1AB W = f (1) : 在任选的单位运行长度 l 上的载荷密度W = f (1): Load density on the random unit running length 1Wdl : 在微小运行距离(dl)上的输送量Wdl: Feeding amount on the minimum running distance (d1)上述表明：要获得输送量，需通过称量传感器检测到物料的单位长度的瞬时重量信号，同时速度传感器检测到速度脉冲信号。通过控制仪表将重量信号与速度信号进行乘积运算，从而求得输送量。The above indicates: in order to attain the feeding amount, it is necessary to utilize the weighing transducer to inspect the instantaneous weight signals of the material in a unit length and at the same time the speed detector to inspect the speed pulse signals. The control instrument shall be applied to carry on product calculation toward the weight signals and speed signals so as to get the feeding amount. 1- 2. 称量和控制系统1-2 Weighing and Controlling System 如 Fig.1- 2的流程图所示，本设备主要分为四大单元：称重单元，皮带测速单元，积算控制仪表单元和驱动单元。Shown as the flow chart of Fig.1-2, this equipment is mainly divided into four major units: a weighing unit, a belt speed detector unit, an integrating control instrument unit and a driving unit. 称重单元，皮带测速单元，驱动单元作为输送机的部件安装在输送机上。The weighing unit, belt speed detector unit and the driving unit are installed on the feeding machine as the feeding machines components. 称重单元主要由计量托辊和两个称重传感器组成。称重传感器安装在高精度的平台上，两个传感器测量出输送带上物料的单位长度重量，然后将重量信号传送至积算控制仪表。The weighing unit is mainly composed of a measuring support roller and two weighing transducers. The weighing transducers are installed on the high-precision platform so as to measure the materials weight in a unit length on the conveyer belt and then the weight signals are transmitted to the integrating control instrument. 皮带测速单元采用编码器安装在驱动滚筒轴端，通过滚筒转动产生脉冲信号，并将脉冲信号传送至积算控制仪表。The belt speed detector unit is installed at the axial end of the driving roller by means of the coder. The rotation of the roller produces pulse signals that are then transmitted to the integrating control instrument.驱动单元的主电机根据积算控制仪表和变频器信号自动调速转动，从而使得给料机的输送量与设定的输送量一致。The main electric motor of the driving unit automatically rotates with the speed regulated according to the integrating control instrument and the signals of inverter so as to attain the feeding amount of the feeding machine consistent to the set feeding amount. 主电动机与减速箱安装一体，然后安装在给料机的驱动滚筒上。变频器根据积算控制仪表的衡定的输送量信号产生相应的频率，主电机根据不同的频率，产生不同的转速。也就是说驱动滚筒产生相应的转速。从而达到输送机的输送量衡定，即与设定的输送量一致。The main electromotor and the gear box are installed in one entity, and then installed on the driving roller of the feeding machine. The inverter produces corresponding frequency according to the signals of feeding amount scaled by the integrating control instrument, while the main electromotor produces different rotating speeds according to different frequencies. That is to say that the driving roller produces corresponding rotating speed so as to scale the feeding amount of the feeding machine, which is consistent to the set feeding amount. 积算控制仪表对传感器的称重（重量）电压信号和测速传感器的速度脉冲信号进行处理和计算。积算控制仪表通过比例关系的运算将速度脉冲信号转换成输送带每秒钟运行的长度，即输送带的速度。仪表对称重传感器（单位长度重量）和马达（皮带每秒钟运行的距离）信号进行积分，得到输送机每秒钟的输送量。每秒钟的输送量同设定的输送量进行逐次比较，其差值信号反馈给变频器，变频器产生相应的频率用于调节马达的转速（输送胶带速度），直到真实流量和设定量相一致。The integrating control instrument carries on treatment and calculation toward the weighing (weight) voltage signals of the transducer and the speed pulse signals of the speed measuring transducer and then converts the speed pulse signals into the running length of the conveyer belt per second through a proportional operation, namely the speed of the conveyer belt. The instrument conducts integral calculation toward the weighing transducer (the weight in a unit length) and the motor signals (the running distance of the conveyer belt per second) so as to attain the feeding amount of the conveyer belt per second. The feeding amount per second is successively compared with the set feeding amount and the difference signals are fed back to the inverter. The corresponding frequencies produced by the inverter are applied to adjust the motors rotating speed (speed of the conveyer belts rubber belt ) until the real feeding flux is consistent to the set feeding amount. 积算控制仪表同时能够将每秒钟的输送量及时地转换成每小时的输送量用负荷率的形式显示出来。同时控制仪表具有强大的通讯功能和数据储存功能。（详细资料参见仪表说明书）At the same time the integrating control instrument can timely convert the feeding amount per second into the feeding amount per hour that then is displayed in the form of load rate. Simultaneously the control instrument is provided with a strong communication function and data storing function. (The detailed information is referred to the Instrument Specification)Speed detectorDriver MotorOperation Control instrument CFC-200Load cell Fig.1-22. 结构2. Structure1) 计量装置1) Measuring Devices采用波纹管冲氮防护传感器，型号为UB2系列。Adopt the corrugated pipe nitrogen impinging protection transducer and the model is the UB2 series- 10 - Fig.2-1Upper Supporting RollerLoad cellMeasuringSupporting RollerUpperSupporting Roller13 Fig.2-1物料的重量通过计量托辊传送到两端的传感器上。The materials weight is transmitted to the transducers at the two ends through the measuring support roller2) 输送带头部清扫器2) Head sweeper of the conveyer belt头部清扫器的主要功能是用于去除输送带上表面的物料碎粘着物，保障皮带外表面清洁。同时，保障计量性能稳定性。The main function of the head sweeper is to wipe off the material pieces and adhesions on the surface of the conveyer belt to guarantee the outer cleanliness of the conveyer belt and at the same time to guarantee the stability of measuring performance.在清扫板的两侧各安装了橡胶板，以免损伤输送胶带。清扫板采用橡胶材料制作。 A rubber plate is respectively installed at thetwo sides of the cleaning plate so as to avoiddamaging the conveyer belt. The cleaning plate is made from rubber material. Belt Interior SurfaceCleaning Board of Belt Middle Cleaner Fig 2.3 Yamato 定量给料机操作维护手册 Operation & Maintenance Manual for the Constant Feed Weigher3) 输送带中间（内部）清扫器 3) Middle (inside) sweeper of the conveyer belt中间清扫器的主要功能是用于去除输送带内表面的物料碎粘着物，保障皮带内表面清洁。同时，保障计量性能稳定性，并使得输送带不易跑偏。The main function of the middle sweeper is to wipe off the material pieces and adhesions on the surface of the conveyer belt to guarantee the outer cleanliness of the conveyer belt and at the same time guarantee the stability of measuring performance so that the conveyer belt wont run out. 清扫板采用橡胶材料制作。The sweeper board is made of rubber materials.4) 驱动滚筒（头部滚筒）4) Driving roller (the roller at the head part)在驱动滚筒外表面包橡胶，并开设人字形斜槽。这种制作方法可以提高驱动力，防止胶带打滑。The outer surface of the driving roller is wrapped with the rubber and arranged with a herringbone flume. This making method can increase the driving power and prevent the adhesive tape from slipping. Fig 2.4 Direction of Rotation Fig 2.4驱动滚筒外形为鼓形，其功能是防止胶带跑偏。The driving rollers outline is the drum shape, whose function is to prevent the rubber belt from running out. 5) 输送胶带5) Conveying rubber belt输送带型号为EP-200，聚脂帆布橡胶带。The model of the conveyer belt is EP-200 and it belongs to the polyester canvas rubber belt.6) 胶带张紧装置6) Adhesive tape tensioning device胶带张紧装置内部配置了螺母和调节杆，从而保证了胶带的恒定张力。如图Fig.2-5所示。Nuts and an adjusting rod are installed inside the rubber belt tensioning device so as to guarantee the permanent tension of the rubber belt, shown as Fig.2-5.通过调节外部的螺母可以调节张紧装置。Adjust the tensioning device by adjusting the outer nuts. Fig. 2.53.定量给料机起动前的准备工作3. Preparing work before the starting of the Constant Feed Weigher1) 请确认输送胶带位于驱动滚筒和从动滚筒的中心上。2) 请确认托辊上无任何其它粘着物，以及各部件位置正确无误。3) 请确认各个法兰连接螺栓已经被拧紧。4) 接通主电源，确认断路器工作正常，开启电源开关。.1) Please confirm the conveying rubber belt is located in the center of the driving roller and the driven roller.2) Please confirm that there is not any other adhesion on the support roller and the position of each part is correct. 3) Please confirm that each flange that is connected with the bolts is screwed down.4) Switch on the main electrical source to confirm the breaker is normally running and then start the power switch. 4.远程（中央）操作过程4. Remote (center) operating process远程（中央）操作过程如下：Remote (center) operating process is shown as follows:1) 将开关旋转切换自远程状态。2) 设定定量给料机的输送量。3) 在中央控制室启动定量给料机。1) Rotate the switch to the Remote state. 2) Set the feeding amount of the Constant Feed Weigher. 3) Start the Constant Feed Weigher in the center control room. 5.现场（本地）操作过程5. Spot (local) operation process 本地操作过程如下： Local operation process is shown as follows1) 将开关旋转切换自本地状态。2) 设定定量给料机的输送量。.3) 在现场控制柜旁启动定量给料机。 1) Rotate the switch to the Remote state. 2) Set the feeding amount of the Constant Feed Weigher. 3) Start the Constant Feed Weigher beside the control cabinet on the spot.6. 定量给料机停机处理要求6. Handling requirements toward the stopping of the Constant Feed Weigher1) 将定量给料机上残存的物料输送干净。2) 关闭定量给料机。3) 切断总电源。1) Completely convey the residual material on the Constant Feed Weigher.2) Stop the Constant Feed Weigher.3) Cut off the general power source. 7. 定量给料机运行时的调节7. Adjustment of the running Constant Feed Weigher 7- 1. 调节皮带跑偏7-1. Adjusting the belt tracking调准装置Adjusting device张紧调节杆Tension adjusting rod皮带张紧调整（调准）装置具有调节皮带跑偏和张紧输送胶带两种功能。在定量给料机后侧门的外部左右各有一个调节杆，采用搬手可以旋转调节杆。通过旋转调节杆调节皮带张力和皮带跑偏。The belt tension adjusting device is provided with the two functions of adjusting the belt from running out and tensioning the conveying rubber belt. An adjusting rod is respectively installed at the left and right sides of the outer rear lateral door of the Constant Feed Weigher and a spanner can be adopted to rotate the adjusting rod. Adjust the belt tension and belt from running out by rotating the adjusting rod. 调节方法Adjusting methods请选择合适的搬手用于旋转调节杆。每次调节时，左右调节杆的旋转方向 必定相反，而且旋转圈数必须相同。Please choose an appropriate spanner to rotate the adjusting rod. During adjusting each time, the rotating direction of the left and right adjusting rods must be opposite and the rotating circles must be the same. (1) 在调节时，须派专门人员观察调节时的输送皮带运行状况。(1) During adjusting, professional personnel must be dispatched to observe the running status of the conveying belt.(2) 如图Fig.7-1所示，当皮带往左跑偏时，顺时针旋转左侧的调节杆，同时逆时针旋转右侧的调节杆。每次调节时须微量调节。每根调节杆旋转约1/3至1/2圈。(2) Shown as Fig.7-1, when the belt runs out toward the left, rotate the left adjusting rod clockwise and at the same time rotate the right adjusting rod counterclockwise. When conducting adjustment each time, it should be slight. Each adjusting rod should be about 1/3 to 1/2 circles.(3) 反之，当皮带往右跑偏时，逆时针旋转左侧的调节杆，同时顺时针旋转右侧的调节杆。每次调节时须微量调节。每根调节杆旋转约1/3至1/2圈。(3) On the contrary, when the belt runs out toward the right side, rotate the left adjusting rod counterclockwise and at the same time rotate the right adjusting rod clockwise. When conducting adjustment each time, it should be slight. Each adjusting rod should be about 1/3 to 1/2 circles.(4) 每次调节后，需让输送胶带运行10圈以上，判别皮带跑偏现象是否得到纠正。如果