胶带跑偏原因及纠正措施

1 胶带跑偏原因及纠正措施 一 导致皮带跑偏的主要因素 1 胶带的结构 类型和工作条件 机架地基出现不均匀沉降 风霜雨雪的影响 2 由驱动和张紧装置所传递的功率和张力大小 3 胶带接头对准程度 4 非承载面存在灰尘和水 5 加载方向和落料点是否对中 二 各种跑偏原因及对策措施 1 所有胶带在机架的某一部位向一侧跑偏 One or more idlers immediately preceding trouble point not at right angles to the direction of belt travel 一个或多个拖辊在前述故障点上延胶带运动方向角 度不正 Advance in the direction of belt travel the end of the idler to which the belt has shifted Square idlers 首先延着胶带 运动方向 对胶带跑偏的哪一侧托辊进行方形校正 Conveyor frame or structure crooked 皮带机架弯曲 Stretch string along edge to determine extent and make correction 沿机架边缘拉一条直线来判断弯曲程度 然 后进行校正 One or more idler stands not centered under belt 一个或多个拖 辊不正 Center them Same as above 校正拖辊 Sticking idlers 拖辊粘滞 Clean and lubricate 清理和润滑拖辊 Belt runs off terminal pulley Check terminal pulley assignment Check alignments of idlers approaching terminal pulley Build up of material on idlers 物料粘结在拖辊表面 Clean them Install cleaning device 清洗掉物料 安装 清理设备 Structure not level and belt tends to shift to low side 机架不平导 致皮带向较低一侧偏移 Level structure 调平机架 2 胶带的某一段沿整机向一侧跑偏 Belt not joined squarely 皮带接头不正 Square ends resplice 调正接头 Bowed belt 皮带弯卷 Tension it or replace 张紧皮带或更换 3 胶带在较长距离一段机架位置向一侧跑偏 Load being placed on belt off center 落料点偏离皮带中心 2 Adjust chute and loading conditions so as to place load in the center of belt 调整溜槽或落料点使物料落在皮带中心 Conveyor frame or structure crooked 皮带机架弯曲 Straighten it 调直机架 4 胶带无规律跑偏 Belt too stiff to train 皮带太硬无法调整 Use self aligning idlers Increase tension conforms to crowns Use more flexible belt on replacement 采用自调 偏拖辊 增大牵引力 用柔韧性好的皮带替换 Tilt troughing idlers forward but not over 2 degrees Use more troughable belt 槽形拖辊向前翘起 但不超过 2 度 需用更多的 槽形拖辊 Combination of causes listed under Paragraphs 2 and 3 Correct loading first Other causes can then be identified and corrected 首先调整落料点 然后再考虑其它办法 三 整机纠偏顺序 The basic and primary rule of tracking a conveyor belt is simply THE BELT MOVES TOWARD THAT END OF THE ROLL IT CONTACTS FIRST 检查胶带首要的 基本的原 则是 胶带朝与托辊最先接触的一端运动 The NORMAL SEQUENCE of training is to start with the return run working toward the tail pulley following with top run in the direction of belt travel Start with the belt empty After tracking is completed run the belt with a full load and re check tracking 检查胶带的 正常顺序是先从下皮带开始 向机尾处检查 随后延皮带运行方向检查上皮带 先空载检 查 之后再带载检查 TRACKING ADJUSTMENT is done while the belt is running and should be spread over some length of the conveyor preceding the region of trouble Permit the belt to run for several minutes and at least three full belt revolutions after idler has been adjusted to determine if additional adjustment is required If the belt has over corrected it should be restored by moving back the same idler and not be shifting additional idlers or rollers 应 在皮带运行时对前述故障区域进行调整 在拖辊调整后如还需进行额外调整 皮带应先运 行至少三圈 如果皮带调整过头 需要及时对所调过的拖辊进行恢复 不能调整其它拖辊 或辊筒 Conveyor troughing idlers are offered in a wide variety of styles Troughing angles include 20 35 45 The stands are primarily two 2 types and vary with each manufacturer 皮带槽形托辊 有多种类型 槽角有 20 35 和 45 常用的主要有 两种 随制造商不同而变化 3 enlarge 1 1 1 Straight over 90 This stand has no tilt and is designed for the conveyor belts to run in both directions It has no real assist in belt tracking 1 直角托辊架 90 这种托辊架与机架垂直 不 向前倾 适用于双向运行皮带 在皮带调整方面没有多大 作用 2 Tilted 2 In the direction of belt travel Conveyor belts are to run in this direction only The 2 tilt offers good results in conveyor belt tracking 2 带倾角托辊架 在皮带运行方向上 皮带只能在倾 斜方向运行 这种 2 的倾角在皮带运行时产生良好的效 果 enlarge 2 2 Straight stands can be tilted 2 forward by placing a 1 8 thick washer under the back side of idler stand indicated by arrows Remember this conveyor only runs in one direction 如图中箭头所示 通过在托辊后安装一个 1 8 厚的垫圈 使托辊架向前倾 斜 2 注意 这种皮带只能向一个方向运行 Many times on reversing conveyors the belt runs great in one direction only to run off when reversed Question What are you using If you are using tilted stands they are good for one direction only 大多数情况下 配置这种托辊的皮带在 单一方向上运行的很好 只是在皮带反转时才出现问题 有什么问题吗 你们用的是什么托辊 如果你们正在使用 倾斜托辊架 它们只会在一个方向运行 On reversing conveyors where tilted stands are already in service and giving problems you can neutralize the tilt by placing a 1 8 thick washer under the front side of the idler stand opposite the side indicated by arrows Now with the tilted stands neutralized you can run your conveyor belt either direction 在双向运转皮带上如果安装了这种倾 斜托辊并且出现问题 如图所示 可在托辊架倾斜的反方 向上安置一个 1 8 厚的垫圈来调整 现在随着托辊架倾 角的改变 皮带可以进行双向运行了 4 enlarge 3 3 The only part of the troughing idler that hs any training effect on the conveyor belt is the center roll indicated by the arrow Re read this statement 如图中箭头所示 槽形托辊组成中对皮带运行有实质影 响的唯一部分就是中心托辊 仔细阅读这一部分内容 enlarge 4 4 The rollers indicated by the arrows form the trough in the conveyor belt either 20 35 or 45 They offer load support but do not have any training effect on the conveyor belt 如图中箭头所示 两侧托辊的倾角有 20 35 或 45 它们起支撑作用 但对皮带运行无实质影响 enlarge 5 5 This example accounts for the largest single cause of conveyor belt tracking problems You will note that the conveyor belt does not contact the center roll of the troughing idler which is the only part of the trouging idler that has any training effect on the conveyor belt You can turn this troughing idler until you are blue in the face and you will see no results 本例说明了在皮带运行过程中发生的大量重复性问题的原 因 你会注意到皮带不接触中心托辊 而我们说中心托辊 是对皮带运行产生实质影响的部分 你可以调节托辊却没 有任何结果 即使调到你脸色发蓝也是如此 How many times have you heard this saying My conveyor runs great empty but when I put a load on it the belt goes crazy Well let s look at our example indicated by the arrow There is no cneter roll contact until you put a load on the conveyor belt At this time the weight of the load makes the conveyor belt contact the center rolls which are turned in all directions Now the training effect takes place and the conveyor belt does what it is told to do by the center roll of the troughing idler 你听过多少次这样的说法了 皮带空载时运行很好 但一旦带载后 就会出现很多问题 是的 如图中箭头 所示 让我们看看例子 在皮带未带载之前 中心的托辊 没有与皮带接触 一旦带载后物料的重量使皮带与中心托 5 辊接触 在此之前 中心托辊可以任意旋转 现在实质性 的影响发生了 皮带会延着中心托辊设定的路线运行 enlarge 6 6 This example shows the correct conveyor belt contact with the center roll of the troughing idler the conveyor belt should not just barely touch the center rolls but should touch hard enough to flatten the conveyor belt over the whole rolls face 本例显示了皮带与中心托辊的正确接触方式 在带载之前 皮带几乎不与中心托辊接触 但在带载之后 皮带中心平 展 几乎与中心托辊紧紧贴在一起 It may be necessary to shim roller frames several inches to contact center rolls Concave curves in conveyors have the tendency to lift the conveyor belts out of the curves and the troughing idlers resulting in Big Problems 也许将中心托辊垫高几英寸来使皮带与中心接触是必需 的 这样形成的凹曲线在运行中有使皮带脱离槽形托辊和 机架形成的轨迹 结果造成大问题 enlarge 7 7 Which way do we turn or adjust idlers to move conveyor belts to a corrective position The easiest way to remember is to think of the troughing idler or flat rolls as being the handlebard on a bicycle Look at the conveyor belt in the direction of belt travel and steer the idlers in the same way as bicycle handlebars until you move the conveyor belt to the desired position The training efort is caused by the friction force of the scruffing action of the conveyor belt as it passes over the cocked idler 调整托辊或皮带应采用哪种方法呢 最简单的办法就是 把槽形托辊或平行托辊想像成自行车车把 延皮带运行方 向看着皮带 就像驾驶自行车一样驾驶着托辊 将皮带移 动到你想要到的方向 移动形成的摩擦力对皮带进行了调 整 这时可忽略托辊的存在 This example shows a troughing idler with the conveyor belt running to the far right The correct adjustment would be driving the side of the troughing idler forward as indicated by the arrow Small adjustments should be made and the conveyor belt should make two 2 revolutions before more adjustments are made 6 enlarge 8 8 本例显示了皮带向右侧跑偏的情形 正确的调整方法是 将托辊架向图中箭头所指方向移动 调整时幅度要小 此 时在更多调整之前皮带可能会产生两种结果 enlarge 9 9 This example shows a troughing idler with the conveyor belt running to the left The correct adjustment would be driving the side of the troughing idler forward as indicated by the arrow 本例显示了皮带向左侧跑偏的情形 正确的调整方法是 将托辊架向图中箭头所指方向移动 enlarge 10 10 This example shows two 2 flat return rolls with conveyor belt running far right top roll and conveyor belt running far left bottom roll The correct adjustments would be driving the end of the flat return roll forward as indicated 本例显示了两种平行回程托辊向右 机头 和向左 机 尾 跑偏的情形 正确的调整方法是延箭头所指移动托辊 一端 enlarge 11 11 This example shows a tail pulley with the conveyor belt running to the far left The correct adjustment would be to move the side indicated by the arrow For training purposes the tail pulley belongs to the return side or bottom side of the conveyor 本例显示了皮带运行过程中机尾滚筒向左跑偏的情形 正 确的调整方法是延图中箭头所指方向进行调整 为了训练 目的 将机尾滚筒看作皮带的回程部分或皮带下部 Note The tail pulley should never be used in an effort to train the conveyor belt the tail pulley should be left square The last return roll coming to the tail pulley and the first troughing idler on the top side of the conveyor determine how the conveyor belt runs or centers on the tail pulley 注意 在皮带调试时 一般不需要调整机尾滚筒 机尾 滚筒是用来保持机架成方形的 靠近机尾滚筒的第一个回 程托辊和靠近机头滚筒的第一个上托辊决定皮带的运行及 机尾滚筒的中心 7 enlarge 12 12 This example shows a tail pulley with the conveyor belt running to the far right The correct adjustment would be to move the side indicated by the arrow 本例显示了机尾滚筒处皮带向右跑偏的情形 正确的调 整方法是按图中箭头所示进行调整 enlarge 13 13 This example shows head pulley with conveyor belt running to far right The correct adjustment would be to move the side indicated by the arrow For training purposes thte head pulley belongs to the top side or carrying side of the conveyor 本例显示了机头滚筒处皮带向右跑偏的情形 正确的调 整方法是按图中箭头所示进行调整 机头滚筒属于皮带顶 部或带载侧 enlarge 14 14 This example shows a head pulley with the conveyor belt running to the far left The correct adjustment would be to move the side indicated by the arrow 本例显示了机头滚筒处皮带向右跑偏的情形 正确的调 整方法是按图中箭头所示进行调整 enlarge 15 15 The centering of the conveyor belt as it passes over the tail pulley and the centering of the load on the conveyor belt as it passes under the loading point are the two most important factors in assuring a straight running conveyor belt 决定皮带运行平直的两个最重要的因素是 当皮带通过机 尾滚筒时的中心以及当皮带带载时带载点的中心位置 enlarge This example shows conveyor belt running centered on the conveyor troughing idlers but the loading chute is off center to the right of the conveyor belt The result is the conveyor belt will start moving to the left 本例显示了皮带延中心运行 但当落料点偏离了皮带的 中心时情形 这种情形的结果是皮带将向左跑偏 8 16 16 enlarge 17 17 This example shows the conveyor belt finally tracking off to the left side of the conveyor spilling material the entire length of the conveyor 本例显示了皮带严重向左跑偏后的情形 物料延皮带全长 洒落 The correction would be to relocate the chute to the center of the conveyor belt or baffle and divert the flow to the center 改正的措施是将入料溜槽修正到皮带中心或者移动皮带 的中心 enlarge 18 18 This example shows the approximate amount of sag on return rollers required for good tracking Sag is regulated by the amount of weight placed on a counterweight take up or the amount of force applied to a screw take up The take up serves four needs 1 Take up maintains slack side tension on conveyor belt to prevent slipping on drive pulley 2 Compensates for variations in the belt length resulting from belt stretch or shrinkage 3 Reduces excessive sag between troughing and return rollers 4 Take up provides live storage for extra belting which can be used for resplicing 本例显示了保持皮带良好运行状态在回程皮带上所需要 的悬垂度 皮带的垂度通过安装在皮带张紧装置上一定数 量的重物来保持或通过螺旋调整装置来保持 张紧装置起 到四种作用 1 保持皮带在机头滚筒上张紧力 2 补偿皮带由于伸长或收缩产生的变化 3 减少上下托辊之间产生的额外悬垂度 4 提供皮带在安装时所需要的额外有效储存 enlarge Concave conveyors will head your list of problem conveyors This is due to the fact that the conveyor belt will lift off the troughing idlers and return rolls as indicated by the dotted lines There will be long distances of no roller contact ad lack of training 9 19 19 带凹弧曲线段皮带将是所有皮带问题中的首要问题 如图 中箭头所示 皮带与上下托辊不再接触 这样导致皮带在 较长的距离内没有托辊 The best start on solving this problem will be reducing the counter weight if possible You may also alternate return rolls over and under the conveyor belt on the return side to assure good roller contact and tracking see next example 解决这一问题的最好办法是减少张紧装置的重量 如果 可能的话 也可以将回程皮带侧的前后托辊进行替换以 确保皮带与托辊保持良好的接触 见下例 enlarge 20 20 Example shows return rolls alternated over and under conveyor belt to assure good belt contact Technique can be use concave curves where conveyor belt will lift off return rollers on return side see next example This technique may also be used on bowed conveyor belts which only contact return rolls on the very edges of the conveyor belt This type of contact makes the conveyor belt impossible to train but by neutralizing the bow the conveyor belt can be trained 本例显示将回程皮带上下托辊替换以保持皮带与托辊的 良好接触 在回程皮带侧皮带脱离托辊的地方可以采用技 术方法解决 参看下例 这种技术在弓形皮带上也有应 用 这种弓形皮带只在回程皮带的边缘才与托辊接触 这 种类型的接触使皮带有可能通过下压弓形部分来进行调节 enlarge 21 21 This example shows a conveyor belt that is under the influence of excessive counter weight Excessive weight will cause the edges of the conveor belt to curl up on the troughing idlers on the top side of the conveyor and curl down on the return rols on the bottom side of the conveyor 本例显示了增大张紧配重对皮带的影响 增加配重后将使 上皮带在槽形拖辊上向上卷曲 下皮带在下拖辊上向下卷 曲 Reduction of counter weight will relax the bowing but it may be necessary to implement the technique shown in prior example to return side 减小配重会减少卷曲 但是前例中回程皮带的状况表明 实行这种技术是必需的 10 enlarge 22 22 When reducing counter weight to relax conveyor belts in concave curves or just to get the proper sag on rollers for tracking it is imperative that the drive pulleys on the conveyor be lagged with a 60 durometer rubber material to prevent slippage of the conveyor belt on the drive pulley Water and dust act as lubricants on the drive pulley and cause tracking problems Chevron grooves in the lagging cover will assist with their removal The chevron grooved pulley above is a one directional pulley If it is installed with the chevrons running in the wrong direction or is used on a reversing conveyor tracking problems will most likely occur Water and dust will be channeled to the center of the drive pulley On reversing conveyors a diamond pattern of grooves must be used to shed material in either direction of running 当在凹弧曲线段皮带上减小配重或使皮带在运行时保持 必要的悬垂度时 机头驱动滚筒需覆盖 60 硬度的橡胶以 阻止皮带悬垂的影响 机头滚筒上的水 灰尘以及润滑剂 会导致皮带出现问题 滚筒包胶上的凹槽能避免皮带的相 对移动 机头滚筒上的包胶延单向布置 如果机头滚筒上 的包胶方向错误或应用于双向运转皮带 就很可能发生问 题 水或灰尘会进入机头滚筒上的橡胶凹槽内 在双向皮 带上要应用菱形花纹的驱动滚筒 这样可使皮带向任意方 向运送物料 enlarge 23 23 If you have reduced counter weight and conveyor belt slippage takes place on the drive pulley other steps will have to be taken To add the weight b