移动式耙斗清污机使用说明书-英文.doc

移动型垂直耙斗式拦污栅清污机 使用说明书Travelling trash rack &rake operational manualYCB移动型垂直耙斗式拦污栅清污机Travelling trash rack &rake使 用 说 明 书Usage specification目录/List一、 用途与性能/Purpose and performance-111、用途与性能/Purpose and performance -112、使用条件/Usage condition-1二、 系列型号与主要技术参数-1Series model and main technical parameters-121、型号说明/Model explain-122、主要技术参数/Main technical parameters -2三、 结构与功能和工作原理-3Structure & function and work principle-331、结构与功能/ Structure & function -332、工作原理/Work principle -7四、 安装与调试/Installation and debug-8五、 操作/Operation-14 清污机操作可参考电气使用说明书-14 Please refer to the electric instruction-14六、 使用与维护/Usage and maintenance -14I Purpose and performance11 Purpose and performanceThe traveling trash rack& rake machine is the trash remover for water supply and drainage system of irrigation works and water and electricity project, power plant, metallurgy, chemical and municipal projects. It removes weed, leaf, trash and animal skeleton on the rake; it replaces manual trash removal, reduces labor strength and meets working requirements of the following purifying water quality and water pump. The trash rack& rake machine is used for clearing trash on the multi-hole grid. Water level difference measurement device is set for each hole to reflect trash addition on the grid. Sound and light signals are used to notify the staff on-duty in the pump cabinet and make the machine to the hole for sending signal and remove the trash on the grid. The machine is featured in multi-hole, flexible, less floor, light weight and investment and etc. Operating cabinet is set for the machine to make the operator work in a safe, comfortable and wide environment. The operator completes traveling, trash removal and etc. by simple and effective electric control device. 12 Usage conditionFor the machine can remove large trash in water, therefore, grid for the machine shall be set at the upper reaches of the filtration net for series connection use. If there is large trash in flow (maximum dimension over 400mm), a grid with larger screen shall be set at the upper reaches of the grid to ensure normal operation. II Series model and main technical parameters21 Model explainY C B Nominal width of grid (mm)Vertical rakeTraveling22 Main technical parametersMain Technical Parameter Sheet Of Traveling Vertical Rack& Rake Machine Sheet INo.Description Model unit Y C B150020002500300035004000450050001Nominal width of the rack holemm150020002500300035004000450050002Rack lift m10 15 20 25 303Traveling gauge of trash machinem1.6 2.34Rail modelP 24（Light type）5Traveling rate of machinem/min36Lifting rate of the rakem/min67Flow rate passing the gridm/s0.8 0.98Designed water level difference of the rackmmLight model 1000 Middle model 1500 Heavy model 20009Calibrated water level difference of the rackmmLight model 1500 Middle model 2000 Heavy model 250010Water level difference of startingmmLight model 300 Middle model 450 Heavy model 60011Space of grid of the rackmm25 10012Depth of rake tooth into the grid stripmm2013Distance from the bottom to surface of the rakemm300 50014Rack volumem30.40.50.60.81.01.21.41.615Permissible load of rack(Including deadweight）T0.81.01.21.62.02.42.83.416Power of main motorkw46.57.5III Structure & function and work principle31 Structure & functionThe machine consist of: 1. Drive unit； 2 Lift unit；3 Electric control； 4 Rake assembly；5 Grid bar1 Drive unitThe traveling unit is the traveling structure of the traveling trash rack& rake machine. Rail is placed on the ground, and it is connected to the pressing plate, bolt and the foundation embedded parts. The traveling unit includes traveling motor, cycloid needle wheel reducer, short travel bush brake, transmission shaft, traveling drive wheel, traveling driven wheel, bearing and angle bearing seat, rail clamp and etc. The rail clamp is made up of motor, worm wheel and worm reducer, screw, rail clamping device and etc. 2.Winding unitThe winding unit is the executing unit for completing trash removal for the traveling trash rack& rake machine. The main components are fixed on the platform frame of the traveling unit. The winding unit includes motor, cycloid needle wheel reducer, short travel bush brake, the secondary reducer is opening gear transmission, steel wire rope cylinder, cylinder shaft, steel wire rope and guide pulley. 3.Operating unitMain control components of the operating unit are mainly distributed in the distribution box and the driving cabinet. The operating unit is divided into automatic and manual control. The automatic control refers to operation of the winding unit, namely, up and down of the rake and the trash removal process are regulated by the set program to ensure accuracy and safety; to facilitate maintenance and adjustment, the automatic control can be locked and manual control is available. Manual control is used for both the traveling unit and the rail clamp. when the traveling unit is working, the winding unit is out of power; when the winding unit is working, the traveling unit is out of power to avoid mis-operation.Up and down of the rake and the trash removal process is the comprehensive reflect of the trash removal capability. Control component of the operating unit and the rake coordinate closely to meet accurate rake operation and safe operation of the travelling trash rack& rake machine. Buttons and display instrument of the operating unit are set on the operation bench of the operation cabinet. See the figures below. 4. RakeThe rake is made up of body, traveling wheel, rake bottom, crankshaft connecting rod and etc. Up and down of the rake and trash removal is the whole process of the traveling trash rack& rake machine. 5. Rack The rack is the device for stopping the trash. Space of the grid is determined according to trash, water quality requirements, possible circumstances and importance. The rail for rake up and down is set on the rack, which facilitates rake operation and reconstruction of old factories. The rack can be divided into many sections as required to meet the requirements of hoisting height. The rack is installed vertically, which is featured in less floor area and investment, convenient installation and maintenance and meet reconstruction requirements of the old factories. Quality of the rack is determined by water quality and customers requirements, with common steel or stainless steel employed and corrosion resistance measures employ coating or anode protection. 32 Working principle Schematic diagram of the traveling trash rack& rake machine of model YCB is described below: （1）Working principle of the traveling trash rack& rake machine:There are three conditions for the rake: trash clearing in up condition, removing trash in the rake and trash removed in down condition. The rake moves downwards from the trash unloading point, the rake bottom is opening until the lower stop point, the rake bottom is closed and tooth on the rake bottom is inserted into the rack grid, then the rake lifts up and it enters trash clearing condition, the rake lifts up along the rail, the rack tooth performs trash clearing and removes the trash into the rake until the upper end point. Then it is pushed to the upper point of the trash collection hopper, open the rake bottom to unload the trash to complete one cycle. （2）Coordination of rake action and electric components: Up and down and trash unload of the rake is controlled by cylinder and steel wire rope of the winding unit. Positive and negative rotation of the cylinder is controlled by the limit switch and electric component of the travel control device. When the rake moves downwards from the trash unloading position, the cylinder in the winding unit rotates positively, when the rake moves to the lower end point, the limit switch of the travel control device acts, and cuts off power supply of the motor of the winding unit, and one delay relay is connected. After several seconds delay, it re-connects power supply of the motor to make the motor rotate negatively. Steel wire rope cylinder for controlling rake bottom rotates firstly, tightens the steel wire rope and closes the rake bottom to make the rake tooth enter the grid. Through torque transmitted between blocks of the steel wire rope cylinder to make synchronized rotation of the steel wire rope cylinders for controlling rake up and down and rake bottom opening and closing, the rake enters trash clearing and lifts up along the grid; when it moves to the upper end point, the limit switch in the travel control device acts and cuts off power supply of motor of the winding unit; meanwhile, get through the delay relay A, after several seconds delay, it re-connects power supply of the motor, meanwhile, another delay relay B is connected, at this time, the steel wire rope cylinder for controlling rake bottom opening and closing acts to open the bottom and unload the trash. The relay B acts, cuts off power supply of the motor, and the time relay C is connected. After delay, re-connect power supply of the motor and the electric-driven pushing rod retrieves. Extension of the pushing rod is controlled by another time relay. After the rake completes one cycle, it can stop at the hole or continue to work according to trash conditions. （3）Coordination of the traveling unit and electric control: When the traveling trash rack& rake machine is ready at the hole, the operator operates or the water level difference signal controls. Inductance plate is installed on the rail, which inducts with proximity switch on the side of the frame to cut off power supply of the traveling motor to stop the machine. The proximity switch may be short circuit to realize moving of the machine between holes. Manual and electric controls are used for the rail clamp. When the rail clamp is released, the traveling unit is powered on and power consumption equipment of the winding platform is powered off; when the rail clamp is clamped, power consumption equipment of the winding platform is powered on and the traveling unit is powered off. （4）Electric control device:Control cabinet of the traveling trash rack& rake machine is set in the operation cabinet. The operation switches and buttons are set on the panel of the control cabinet. Power, working status, hole aiming and indicator light indications are set on the panel. In case of overload with, cut off power supply with sound and light alarm. To facilitate operation and maintenance, fan and electric heater are provided, with sound lighting and wide vision to ensure the operator works in sound environment. The circuit is made up of the followings: 1 Safety circuit 2 Rake control loop and pushing rod control circuit; 3 Traveling control circuit of the big machine; 4 Control clamp of the rail clamp; 5 Overload alarm circuit. （5）Safe operation device:Many measures are employed on safe operation of the traveling trash rack& rake machine. (1) On overload protection, the manufacturer preset over-current protection device in the electric components. The setting current is 1.25 times of the rated current. During normal operation, if the current exceeds the setting value, the power will be cut off with light and sound alarm. At this time, cut off the power supply, check and remove the trouble and get through the power supply. (2) Super high limit switches are provided at the upper part of the rake. In case of failure, the rake is high and when it collides the limit switch, it cuts off the power supply. At this time, cut off the general power supply and check the limit switch of the travel control device, then get through the power supply.(3) Both ends of the traveling unit are provided with limit switch and rubber buffer to avoid mis-operation.Both ends of rail of the traveling part are provided with trolley stop. In case of mis-operation, the limit switch acts and cuts off power supply of motor. In case of failure of limit switch, check and repair and operate the equipment. IV Installation and commissioning41 Installation 411 Preparations before installation The primary embedding is the foundation of installation and use of the traveling trash rack& rake machine, therefore, during construction of the primary embedding construction, position, exposed shape, material, foundation and etc. shall be performed according to the technology requirements. In case of change, please contact the manufacturer. 412 Secondary embedding (Rack channel)：(1) Embedding of the primary employs installation of the Phase II concrete. Before installation, check shall be done according to the drawing to remove any deformation or damage or loss caused by incorrect transportation or keeping. After check, lift up the embeddings and place them into the concrete channel. After locating, fix the hook and the bar in the primary concrete by welding. The whole body is embedded in the channel to make it in line with technical requirements and then reinforce to avoid displacement or deform in the phase II concrete pouring, the phase II concrete pouring is done. (2) Tolerance requirement of grid channel installation (See the figure): deviation of center-to-center distance of positive and negative rail of the grid channel is2mm. Permissible error of unparallel center line of the positive and negative rail of the left and right grid channels is 2mm and the height difference of the left and right grid channels may no exceed 1.5mm. 左栅槽Left grid channel 右栅槽Right grid channel (3) Tolerance requirements for installation of rail of the traveling trash rack& rake machine (See the figure)a. Tolerance of the rail gauge:2mm，a. Height difference of the top surface of the two rails is 2mm。b. Height difference of the top surface of joint of the rail c. Sides difference of joint of the rail may not exceed 1mm。d. Space of rail joint may not exceed 3mm。e. Crosswise degree of the rail may not exceed 2mm. f. Joint of two parallel rails shall be staggered and the distance of staggering is not equal to wheelbase of the wheel. g. Slope of the two rails may not exceed 2/1500 and 3mm for the whole length. 413 Installation of rack:Before installation, remove any deformation and damage caused by transportation. Number the rack and install from down to up. After it is located, connect the upper and lower pieces with bolt and make it a whole body.414 Installation of the traveling trash rack& rake machine(1) Before installation, a careful check shall be done for guide rail of the traveling trash rack& rake machine and installation can be conducted after the tolerance is confirmed. (2) Installation of the traveling trash rack& rake machine complies with the principle of down to up and big to small. Install the traveling driving wheel and driven wheel, traveling frame, drive unit, rail clamp and etc., and then install the frame, step, rail and the winding unit and the electric apparatus and other small parts are installed finally. (3):Requirements of installation tolerance of the traveling wheel of the traveling wheel of the traveling trash rack& rake machineA Tolerance of rail gauge and wheel base of the traveling wheel shall comply with the following requirements and the wheelbase tolerance shall be no more than 2mm. Relative difference of rail gauge B1 and B2 may not exceed 4mm. See the figure below. B Vertical inclination deviation of the traveling wheel may not exceed 1mm. See the figure below.C For the two traveling wheel installed on the same rail, deviation of the symmetrical vertical plane may not exceed 3mm. see the figure. D Difference of length of diagonal of the traveling wheel may not exceed 5mm, see the figure.42 Commissioning Idling trial operation has been done before leaving the factory. After assembled at the work site, to ensure safety, the followings are to be performed:(1) Preparation: after the equipment is assembled at the working site, check machine, electric and lubrication and check installation size and precision of the rail, rack and etc. (2) Check: check the equipment traveling on the rail manually. After the manual trial operation is conformed, the traveling trash rack& rake in automatic control shall be trial operated. Check the equipment traveling on the rail stably and flexibly or not; check the rail clamp works flexibly or not; check the reducer is normal or not and the brake is flexible or not. (3) Locating check: check locating of each rack hole is precise or not, and the locating error may not be more than 3mm. (4) Trash removal check: trial operation of the rake for one cycle manually. Check rake opening and closing are flexible and reliable or not; rake operation is stable or not and matching of rake tooth and rack is ideal or not; looseness of the steel wire rope is suitable or not; after checking the brake is flexible, re-check in automatic control.(