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悬臂
皮带
输送
常见故障
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处理
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悬臂皮带输送机常见故障分析及处理,悬臂,皮带,输送,常见故障,分析,处理
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1中文翻译：【中文 4210 字】悬臂皮带输送机常见故障分析及处理伊. 基. 劳德维加克斯，代尔夫特科技大学，荷兰带式输送机作为连续散装物料的机械已广泛用于世界，发电厂，冶金工业，食品工业以及散装物料的输送，如装船机斗轮堆料机。在采购，设计，制造，安装和运行这种设备，一些新用户还不熟悉他们。从过去几年的经验和用户的观点和意见中，对这种设备常见故障原因和处理方法进行了分析和描述。1 皮带输送机皮带跑偏处理：在操作中，皮带输送机皮带跑偏是常见的故障。为了解决这种类型的故障，重点应放在安装尺寸精度和日常维护。有几种原因，应根据不同原因区别对待。1.1 托辊的设置调整：如果皮带输送机皮带在输送机中间跑偏食，需要对托辊的位置进行调整。在制造中，托辊上加工的双面安装孔是为了方便托辊的调整。对于具体的调整方法，见图 1.具体的方法是，当带是从侧面偏离时，偏离一面的托辊运动方向应向前运动，而另一方面向后移动，如图 1 所示，如果皮带是向上跑偏，托辊底部位置设置应移动至左侧并且托辊上不移动至右侧。1.2 自调心托辊的安装设置：自调心托辊的种类有许多，如：中间转轴式，四连杆式和边辊式。其原理是在水平面内利用封锁或旋转的滚轮。滚轮式有旋转或产生横向推力使皮带自动对齐以达到对皮带跑偏的调整。这是可行的，在一般情况下，使用这种方法时皮带输送机皮带整体长度较短或皮带输送机是双向操作。其原理是较短的皮带输送机易跑偏并且不易调整。因此这种方法不用于较长的带式输送机，因为自调心托辊的使用对皮带的使用有一定的影响。1.3 头部弯曲辊及滑轮的位置调整：调整头部弯曲辊及滑轮式对皮带跑偏调整的关键环节。由于一个皮带输送机中至少有 2 到 5 个滑轮，所有滑轮的安装位置必须垂直于沿带式输送机长度中心线的方向。如果偏差过大，必然会发生跑偏。调整的方法类似于托辊组。对于头轮，如果从滑轮右侧跑偏，在右侧的轴承座应当向前移动，如果带从滑轮左侧跑偏，在右侧的轴承座应当向前移动，对于相应的滑轮在左侧的轴承座也可以向后移动或在右侧的轴承座2向后移动。尾部滑轮调整方法与头部相反。至于调整方法请参阅图 2。滑轮反复调整直至皮带调整到预期位置。在调整头轮或弯曲滑轮前最好准确的安装。1.4 调整皮带涨紧装置：调整皮带涨紧装置是对皮带输送机皮带跑偏调整的重要环节。在悬吊式配重张紧装置上不的两个弯曲滑轮不仅应垂直于沿皮带的长度方向并且应与重力方向相垂直，换言之，他是确保与轴中心水平。当螺旋张紧装置或液压张紧装置使用时，两个张紧轮轴承座应同步，以确保滑轮轴线垂直于皮带的纵向方向。具体的皮带跑偏调整方法类似于滑轮的调整方法。1.5 物料的移交接收点对皮带偏差的影响：物料的移交接收点对皮带跑偏的影响很大，尤其是两条皮带输送机的投影在同一水平面重合，上层输送带和下层输送带在移交点的相对高度，通常应认真考虑。相对高度越低，材料的水平分速度分量越大，对下层输送带的横向冲击越大。另外，物料的难以集中导致皮带的横截面倾斜，最终导致皮带跑偏。如果皮带从右侧偏离，皮带就向左偏离，反之亦然。在设计过程中，两个皮带输送机相对高度的增加实际上是可能的。上料斗和下料斗的结构和尺寸，散料输送机械都受到空间的限制，应更仔细的考虑。在一般情况下，它适用于约皮带宽度 2/3 的滑道。为了减少或避免皮带跑偏，挡板强度可增加到材料为块时的强度，改变物料下跌方向和材料位置。对于带上不确定的材料如图 3.1.6 双向皮带输送机皮带跑偏的调整：双向带式输送机皮带跑偏的调整相对于单向带式输送机更加困难。在具体的调整中调整应从一个方向，然后再调整下一个方向。调整过程中，必须仔细观察皮带行进方向和皮带跑偏趋势关系。调整应该一个接一个的完成。首先重点应放在调整头部托辊和弯曲滑轮。其次的重点是放在对托辊和材料的接受点。另外应指出的是，当皮带输送机硫化接头时，载荷应沿皮带长度方向均匀分布。当引导链牵引使用时，两面的载荷应尽可能的均匀分布。2 带式输送机的物料泄漏：物料泄漏在带式输送机上是一个普遍现象。原因体现在几个方面。因此应放在加强日常维护。2.1 物料在转移点的溢出:物料泄漏主要发生在换乘点，如收料料斗，溜槽。如果皮带输送机严重超载，橡胶皮带输送机溜槽就会受到损害。在设计时，如果钢板滑道远离橡胶板，该材料将会飞出溜班。这个问题可以通过控制输送能力，加强日常维护得到解决。32.2 在运输中，物料泄漏发生在皮带凹面部分：当曲率半径较小时，皮带在凹面部分出现浮动。这时带槽的形式已发生改变，因为皮带已偏离了托辊槽角。在这种情况下，由于槽角变小导致一部分材料泄露出去。因此，早设计中，凹部分通常采用较大的曲率半径，一避免物料泄漏。如果没有在机械行驶装船机或堆取料机上，根据过渡部分设计凹部分以缩短其尾部车。物料泄漏很容易在选择皮带宽度不足的情况下出现。2.3 在皮带跑偏时物料泄漏：在皮带跑偏下物料泄漏的原因是带两边栽运行过程中高度改变了，即一边高，一边低。物料在边缘较低的一边泄漏。处理方法是调整皮带跑偏。3. 异常噪音;当皮带输送机运行时，从驱动器，头滚，弯曲滑轮和托辊中听到异常噪音。根据异常噪声可以确定设备故障。3.1 当托辊严重偏离时会发生噪声：当皮带输送机运行时，由于震动会产生异常噪声，特别是在返回卷轴。卷轴越长自重越重，噪声越大。噪声的产生主要有两种原因:一个是制造托辊的无缝钢壁厚不均匀，从而产生更大的离心力，另一种是在机加工时，两端轴承孔中心大大偏离的顶圆心，一产生更大的离心力。滚筒在使用时并没有伤害轴承，噪音是允许存在的。3.2 噪音发生在两个耦合的不同心轴：异常噪音是从两者之间的驱动马达的高速联轴器和减速器或制动轮联轴器中产生的，同时，随着电机的转动还伴随着震动。如果产生噪声，应及时调整马达或减速器的位置，以避免减速机输入轴的断裂。3.3 头轮和弯曲滑轮的异常噪音：当头部滑轮和弯曲滑轮正常运行时，噪声很低。如果早生产生于轴承座，轴承必须更换。4 减速机轴断裂：减速机轴断裂通常发生在减速机高速轴，通常故障发生在减速第一阶段轴是垂直齿轮轴作为高速轴使用。轴的断裂通常有两个主要原因。4.1 减速器高速轴设计强度不足：这个故障通常发生在轴肩。由于瞬态圆角会遭到损坏。如果圆角过小，减速机轴断裂可能会发生在很短的时间内。轴断裂后，断裂处通常会非常平整。如果此故障被发现出来，应及时更换或对减速机的设计进行修改。4.2 高速轴非轴向：当电机高速轴非轴向，减速器输入轴的径向负荷将增加，导致轴上弯矩的增加。如果轴以这样一种方式运行了很长一段时间，4轴可能会发生断裂。在安装和维修时，轴位应仔细的调整，以确保两轴对齐。在大多数情况下，电机轴断裂不可能发生，因为电机轴使用的材料是 45#钢，电机轴较粗，具有良好的应力集中。4.3 在使用两个马达时轴的断裂：双电机驱动意味着将两个电机，两个减速器安装在一个头轮上。当有较小的空间去设计或选择减速器高速轴是，轴易发生断裂。在过去的几年里，液力耦合器没有被用于皮带输送机的驱动器中，所以很容易出现故障。原因是很难保证速度同步和负载均匀分布。现在液力耦合器已被应用于大多数带式输送机，所以轴断裂不经常发生，但应该指出的是，液力联轴器在运行中不能用油来填充，因其有一对力矩作用和提高其使用寿命。5 较短的皮带使用寿命：带的使用寿命和服务模式取决于带的质量。在运行中它应确保清洁，可靠和好的操作。在回程皮带上没有任何的材料。如果以上不能得到保证，回程皮带上的材料会由头滚或滑轮进入回程皮带。由于皮带表面上的材料，皮带将会被破坏。导致覆盖在滑轮表面的硫化橡胶层损坏，降低了皮带的使用寿命。带的制造质量问题用户应给予关注。后一种带模式选择，应同样关注制造质量。带的安全检查可由国家专门机构进行质量测定。对外观进行常规检查，看是否存在龟裂，老化和在制造后超过了时间限制。上述之一发生时，不应购买。通常情况下，再很短时间内裂隙带将会被发现。6 皮带输送机凹凸部分曲率半径的影响。6.1 横截面中间部分起拱：该起拱往往在横截面凸部分出现褶皱，见图 4。带重叠后进入头滚和弯曲滑轮，使皮带皮带损伤加重。通常起拱的主要原因是，重叠后，中部横截面单位长度拉应力值与外部存在差异，是皮带下滑到中间形成起拱或重叠。单位长度的拉力值的大小与凸节的曲率半径和托辊槽角有关。槽角越大，凸曲率半径越小和越不易起拱和重叠。当皮带输送机槽角等于 40 度以上时，在直线段运行时起拱和重叠发生在头部或尾部槽。此时槽角应减少或过渡段长度增加，从而使皮带槽角过度。对于在凸节皮带输送机，在凸部分的实际曲率半径应尽可能的增加，轧辊槽角减小，使输送能力得到满足。6.2 带的凸部分在平辊与网页辊之间发生故障：带的凸部分在平辊与网页辊之间发生故障，通常是由块体材料引起的。可移动输送机械如：船舶装载机，堆取料机。带故障很容易出现在设备挑梁根部的位置。这是发生在它5所对应的凸部分。凸过度段的曲率半径所需大小不能轻易满足，因为它几何条件的限制。带的凸部分在平辊与网页辊之间发生故障只有在悬臂带的根部通过一个或两个托辊之间的时候，形成了集凸部分。该问题解决方法是，凸部分由原一个或两个托辊组改为由四或五个托辊组。例如，皮带输送机是水平排列在其后面，悬臂是定在 12 度以下 ，凸段设在 12 度角 。如果有五个托辊组用于这个地方的角度变化，皮带经六次压弯达到向下 12 度角。皮带一次压弯 2 度。改造后，带的凸部分在平辊与网页辊之间的故障不再发生。四连杆或后续行动框架设计，可用于用来改变角度的基本轧辊。6.3 在启动时，凹部分带的跳动和偏转受风的影响：如果在带式输送机启动时带上没有任何材料，带的凹部分在有风的天气就会偏移。因此，最好是在凹部分提供压辊，以免被退回或被风吹偏离。7 皮带的打滑7.1 在悬吊式配重张紧装置下皮带输送机皮带的打滑：当带是在与悬吊式配重拉紧装置下打滑，它可以通过增加平衡块，直到带不能打滑来解决。然而，平衡重量不宜过多，以避免他们遭受不必要的过大的拉力带，从而在皮带使用寿命降低。 7.2 皮带输送带在用螺钉拉紧装置或液压张紧装置的情况下打滑：皮带输送机在用螺钉张紧装置或液压张紧装置时，可以通过调整张紧行程来增加拉力。在这个时候，然而，带张紧不够或带永久变形时，可以削减一部分带。小结：皮带输送机是通用机械设备。他们已经被用户使用多年。然而，带式输送机维护必须定期进行。由于对文章长度的限制，实在是很难在一篇文章中包含所有的内容。具有操作和维修经验带式输送机可以逐步积累了日常工作。我们希望，这一文将对带式输送机的用户很有帮助。1Common Fault Analysis For Belt Conveyer Ir. G. Lodewijks, Delft University of Technology, The NetherlandsBelt conveyers as continuous bulk material conveying machinery have been widely used in the world, electric power plants, metallurgical industry and foodstuff industry as well as in bulk material conveying machinery such as ship loader and bucket-wheel stacker-reclaimer. In the purchase, design, manufacture, erection and operation of this kind of equipment, some of new users are not familiar with them. Common fault causes and their handling methods of this kind of equipment are analyzed and described herein as a matter of experience in the past years and from the point of view of users.1. Handling of belt deviation of belt conveyer: The belt deviation of belt conveyer during operation is the most common fault. To handle this type of fault, emphasis should be placed on the dimensional accuracy of erection and the routine maintenance. There are several kinds of causes. The differential treatment should be made according to the different causes.1.1 Adjustment of carrying roller set: If the belt of belt conveyer is deviated in the middle of the whole belt conveyer, the position of carrying roller set is adjusted. During the manufacture, the mounting holes on both sides of carrying roller set are machined to slots for the convenience of adjustment. For the specific adjusting methods, see Fig. 1. The specific method is that when the belt is deviated from the side, that side of carrying roller set should be moved forwards the direction of travel, or the other side moved backward the direction of travel. If the belt is deviated from the upper direction as shown in Fig. 1, the bottom position of carrying roller set should be moved to the left side and the upper position of carrying roller set is moved to the right side.21.2 Installation of self-aligning carrying roller set: There are many types of self-aligning carrying roller sets such as intermediate rotating shaft type, four-link type and edging roll type. The principle is that by utilizing blocking or rotating the rollers in the direction of horizontal plane, the rollers are blocked by rotating or the lateral thrust is produce to make the belt be automatically aligned so as to attain the object of adjustment of belt deviation. It is feasible, in general, to use this method when the whole length of belt of belt conveyer is shorter or the belt conveyer is operated in the bidirection. The causes are that the shorter belt conveyer is easier to be deviated and it is not easily adjusted. Therefore, this method is not used for the longer belt conveyers because use of self-aligning carrying roller sets can have certain influence on the service life of belt.1.3 Adjustment of positions of head roll and bend pulley: Adjustment of head roll and bend pulley is a key link of adjustment of belt deviation. Since there are at least 2 to 5 pulleys in one belt conveyer, the mounting position of all the pulleys must be perpendicular to the central line along the length of belt conveyer. If the deviation is too large, the belt deviation occurs of necessity. The adjusting method is similar to that of carrying roller set. For head pulleys, if the belt is deviated from the right side of pulley, the bearing block at the right side should be moved forward and if the belt is deviated from the left side of pulley, the bearing block at the right side should be moved forward. For corresponding pulleys, the bearing block at the left side can be also moved backward or the bearing block at the right side moved backward. The adjusting method of tail pulleys is just opposite from that of head pulleys. For the adjusting method, see 3Fig. 2. The pulleys are repeatedly adjusted till the belt is adjusted to the expected position. It is preferable to make the mounting position accurate before adjustment of head rolls or bend pulleys.1.4 Adjustment of belt tensioning device: Adjustment of belt tensioning device is a very important link of adjustment of belt deviation of belt conveyer. Two bend pulleys on the top of counterweighted tensioning device should be not only perpendicular to the direction of the belt along length but also to the gravity vertical, i.e. it is ensured that the shaft center line is horizontal. When the screw tensioning device or hydraulic tensioning device is used, two bearing blocks of tensioning pulley should be synchronously translated so as to ensure that the axial line of pulley is perpendicular to the longitudinal direction of belt. The specific adjusting method of belt deviation is similar to the adjusting method of pulleys.1.5 Influence of material receiving position at the transfer point on the belt deviation: The material receiving position at the transfer point has a great influence on the belt deviation, especially when the projection of two belt conveyers in the horizontal plane. The relative height of the upper belt conveyer and lower belt conveyer at the transfer point should be normally taken into consideration. The lower the relative height the greater the horizontal velocity component of material and also the greater the lateral impact on the lower layer of belt. In addition, the material is difficult to center so as to make the material at the cross section of belt be skew and finally lead to belt deviation. If the material is deviated from the right side, the belt will be deviated from the left side, vice versa. In the course of design, the relative height of two belt conveyers is increased as practically as possible. The form and dimension of the upper hopper and the lower hopper, chute etc. of bulk material mobile conveying machinery which are limited by space should be more carefully taken into consideration. In general, it is applicable for the width of chute being about 2/3 of that of belt. In order to reduce or avoid the belt from being deviated, the baffles can be increased to block the material and change the falling direction and position of material. For the uncentering of material on the belt, see Fig. 3.41.6 Adjustment of belt deviation of bi-directional belt conveyer: Adjustment of belt deviation of bi-directional belt conveyer is relatively more difficult than that of belt deviation of one-way belt conveyer. During the specific adjustment, the adjustment should be done from one direction, and then from the other. During adjusting, it must be carefully observed to the relationship between the travel direction of belt and the tendency of belt deviation. The adjustment should be done one by one. Firstly emphasis should be placed on adjustment of head rolls and bend pulleys. Secondly emphasis is placed on adjustment of the carrying rollers and the material receiving point. In addition, it should be noted that the load is uniformly distributed at the section of the belt along the length when the belt is at the vulcanized joints. When the leading chain is used for traction, the load at both sides should be distributed as equally as possible.2. Material spillage on belt conveyer: Material spillage on the belt conveyer is a general character. The causes are embodied in several aspects. Therefore, emphasis is placed on strengthening the routine maintenance.2.1 Material spillage at transfer point: Material spillage occurs mainly at the transfer points such as material receiving hopper and chute. If serious overload occurs on the belt conveyer, the rubber skirt plate of chute of belt conveyer can be damaged. Since the steel plate of chute is far from the rubber skirt plate in the design, the material will be flown out of the chute. The problem can be solved by controlling the conveying capacity and strengthening the routine maintenance.2.2 Material spillage at the concave section of belt during hanging: The belt at the concave section is floated when the radius of curvature is smaller. At this tome the belt in the form of trough has been changed because the belt has been deviated from the trough carrying roller set. In that case, the angle of trough becomes small so as to make part of the material be split out. Therefore, the bigger radius of curvature at the concave section is used as practically as possible in the design in order to avoid the material spillage. If the concave section is designed according to the section of transition without arc in the mechanical traveling ship loader or stacker-reclaimer in order to shorten its tail car, the material spillage may easily occur when there is less room for selection of belt width.2.3 Material spillage during the belt deviation: The material spillage occurs during the belt deviation because two edges of belt have changed in height during operation, i.e. one edge is higher and the other is lower. The material is split out from the lower edge. The handling method is to adjust the belt deviation.53. Abnormal noise: When the belt conveyer is operated, it could sound abnormally from its drive, head roll, bend pulley or carrying roller set. The failure of equipment can be determined according to the abnormal noise.3.1 Noise occurs when the carrying roller being seriously deviated: When the belt conveyer is operated, the abnormal noise could be produced and accompanied by periodic vibration, especially in the return rolls. The longer the roll and the heavier the deadweight, the higher the noise. There are mainly two causes for noise: one is that the wall thickness of seamless pipe made of carrying roller is non-uniform so as to produce the greater centrifugal force and the other is that during machining, the center of holes of bearing at both ends is greatly deviated from the center of top circle so as to produce the greater centrifugal force. The rolls can continue to use in case the bearings have not been damaged and the noise is allowed to exist.3.2 Noise occurs when two shafts of coupling being not coaxial: The abnormal noise is produced from the coupling between the high-speed shaft of motor in the drive and that of reducer or from the coupling with brake wheel, it is also accompanied by the vibration that is identical with the rotational frequency of motor. If the noise is produced, the position of motor or reducer is adjusted in time in order to avoid the rupture of input shaft of reducer.3.3 Abnormal noise of bend pulley and head roll: When the bend pulleys and head rolls are operated normally, the noise is very low. If the abnormal noise is produced, the bearing, in general, may be damaged. If the cackle is produced from the bearing block, the bearing must be replaced.4. Rupture of shaft of reducer: The rupture of shaft of reducer generally occurs at the high-speed shaft of reducer. The usual fault is that the first-stage shaft of reducer is used as the high-speed shaft of vertical bevel gear shaft. There are mainly two causes for shaft rupture as follows.4.1 Inadequate design strength of high-speed shaft of reducer: This fault, in general, occurs at the shaft shoulder. Because the transient round angle exists at this place, it is subjected to fatigue damage. If the round angle is too small, the rupture of shaft of reducer can occur in the short time. After shaft rupture, the fracture is generally flush. If this fault is found out, the reducer should be replaced or the design of reducer should be modified.4.2 High-speed shaft being non-axial: When the high-speed shaft of motor is non-axial, the radial load will be increased on the input shaft of reducer so as to increase the bending moment on the shaft. If the shafts are operated in such a way for a long time, the shaft rupture could occur. During installation and maintenance, the position of shaft should be carefully adjusted in order to ensure that the two shafts are aligned. In most cases, the rupture of motor shaft can not occur, because the material used for motor shaft is #45 steel, the motor shaft is thicker and has good stress concentration.64.3 Rupture of shaft in case two motors are used: The double-motor drive means that two reducers and two motors are installed on one head roll. When there is less room for design or selection of high-speed shaft of reducer, the shaft rupture easily occurs. In the past years the hydraulic coupling was not used in the drive of belt conveyer, so the failure easily occurred. The cause was that it was difficult to ensure that the speeds were synchronous and the loads uniformly distributed. Now the hydraulic couplings have been used in most of the belt conveyers, so the shaft rupture does not frequently occur, but it should be noted that the hydraulic coupling can not be filled with excess quantity of oil during operation so as to make it have an effect on limitation of moment of force and increase the service life of hydraulic coupling.5. Shorter service life of belt: The service life of belt and the service modes are related to the quality of belt. It should be ensured that the cleaners are operated reliably and in good order when the belt is operated. There is not any material on the return belt. If the above can not be guaranteed, the material on the return belt will enters into the head roll or the bend pulley along with the return belt. The belt will be damaged due to the material on the surface of belt, resulting in damage of the vulcanized rubber layer on the surface of pulley, breach of the belt and decrease of the service life of belt. The manufacturing quality of belt is the problem the users relatively give attention to. After the selection of a model of belt, its manufacturing quality should be also taken into consideration. The belts can be inspected by the national specialized institution of quality determination. The appearance inspection is carried out conventionally to see whether the crazing and aging exist and the resting period is over long after manufacture. One of the above occurs, the belts should not be purchased. The fissured belt to be initially found will be, in general, damaged in a short time.6. Influence of radius of curvature at the convex-concave section of belt on belt conveyer6.1 Arch camber at the convex section of belt in the middle of cross section: The arch camber often occurs at the convex section in the middle of cross section and the belt will be pleated, see Fig. 4. After the overlapped belt enters into the bend pulley or head roll, the extent of damage of belt aggravated. The main causes for arch camber and overlapping are that the difference between the values of tensile force in a unit of length at the cross section of belt in the middle and on the outside is oversized so that the belt is slid into the middle to form the arch camber or overlapping. The magnitude of difference value of tensile force in a unit of 7length is related to the radius of curvature at the convex section and the trough angle of carrying roller. The bigger the trough angle, the smaller the radius of curvature at the convex section and the severer the arch camber and overlapping. When the trough angle of belt conveyer is equal to and more than 40 degrees, the arch camber and overlapping can occur even at the transition section of trough angle of head or tail roll which is run at the straight section. At this time the trough angle should be reduced or the length of transition section increased so as to make the trough angle of belt be transited. For the belt conveyer at the convex section, the radius of curvature at the convex section should be increased as practically as possible and the trough angle of roll reduced in the condition that the conveying capacity is met. 6.2 The belt at the convex section being seized between flat roll and web roll: The belt being seized between the flat roll and the web roll in the carrying roller set may generally occur in the bulk material mobile conveying machinery such as ship loader and stacker-reclaimer. The belt seizure may easily occur when the cantilever at the root position of cantilever beam of such equipment is pitched downward. At this time it corresponds to the convex section occurring on the belt. The size required for the radius of curvature at the convex transition section can not be easily met because it is limited by the size of geometric position. The belt being seized between the flat roll and the web roll in the carrying roller set can occur only when the belt at the root of cantilever is passed through one or two carrying roller sets to form the convex section. The method of resolution is that the convex section formed by the original one or two carrying roller sets is changed to that formed by four or five carrying roller sets. For example, the belt conveyer is horizontally arrange at its rear, the cantilever is pitched downward at the angle of 12 degrees at its fore and the convex section is changed at
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