刮板输送机设计【Q=600t-h V=1m-s L=150m】
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Q=600t-h V=1m-s L=150m
刮板输送机设计【Q=600t-h
V=1m-s
L=150m】
输送
设计
600
150
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河南理工大学万方科技学院本科毕业设计（论文）中期检查表指导教师： 高爱华 职称： 副教授 所在院（系）： 机械与动力工程系 教研室（研究室）：机械教研室 题 目刮板输送机设计学生姓名王志云专业班级机制08-2班 学号0828070100一、选题质量：（主要从以下四个方面填写：1、选题是否符合专业培养目标，能否体现综合训练要求；2、题目难易程度；3、题目工作量；4、题目与生产、科研、经济、社会、文化及实验室建设等实际的结合程度）1、我所选的题目为刮板输送机设计，内容涉及刮板输送机的总体布置、材料选择以及一些机械零件的设计计算与校核，与所学专业课程联系紧密，符合机械设计专业的培养目标。在设计过程中，需要综合运用所学知识，并查阅相关文献，能够充分锻炼和培养分析问题和解决问题能力，体现综合训练的要求。2、设计任务难易程度和工作量适中，符合本科毕业设计要求。3、刮板输送机是煤矿综采工作面不可或缺的输送机械，与煤矿生产紧密相关，在实际的应用中比较广泛，在设计过程中，对机器的零件的设计和计算是对以往所学知识的总结和应用，所以所选题目刮板输送机设计在生产、科研、经济等方面与实际的结合都比较紧密。二、开题报告完成情况：我根据将来的工作选择了刮板输送机设计作为设计题目，根据自己在各方面资料的收集和整理，从实际工作环境出发，确定了明确的课题设计方向；已经开始对课题进行设计计算，设计过程已经快速地展开，确定了工作的内容和方法；同时，完成了对相关资料的查阅，对课题有了总体的分析。最后结合自身的实际情况和设计的时间安排完成了开题报告。三、阶段性成果：1、前期阶段主要是对有关于刮板输送机的各方面的文献和资料进行搜集，通过对所搜集的资料的学习，明确了国内外研究情况，了解了国内外刮板输送机技术的差距。2、通过对刮板输送机的了解，进行了详细的技术分析，确定出刮板输送机的总体方案。 3、中期阶段主要是依据有关刮板输送机设计的文献和参考资料，从上面找到一些关于刮板输送机的信息，对其主要零部件以及结构有了大致的了解，已有了大概的设计方法，并开始了一些基本的结构设计。四、存在主要问题：1、这次设计对我来说是个巨大挑战，以前在矿上见到过刮板和刮板链，却没有接触过这方面的设计知识，设计工作不知道要计算哪些内容。 2、局部结构设计思路不清晰，对刮板输送机紧链器和机头段的结构不太清楚，系统性不强，在整体结构及零部件结构上存在一定问题。 3、获得资料不够充分，缺少参考文献，在选用零件和确定结构工艺参数时缺少经验和参考，设计过程中关于自己所设计的有些方面内容不是太明确，导致了的设计进度缓慢。五、指导教师对学生在毕业实习中，劳动、学习纪律及毕业设计（论文）进展等方面的评语指导教师： （签名） 年 月 日河南理工大学万方科技学院本科毕业设计（论文）开题报告题目名称刮板输送机设计学生姓名王志云专业班级08机械制造2班学号0828070100一、 选题的目的和意义： 刮板输送机是一种有挠性牵引机构的连续运输机械，是为采煤工作面和采区巷道运煤的机械它的牵引机构是刮板链，承载装置是中部槽，刮板链安装在中部槽的槽面。中部槽沿运输路线全线铺设，刮板链绕经机头、机尾的链轮接成封闭形置于中部槽中，与滚筒采煤机和输送机推移装置配套，实现落煤、装煤、运煤及推移输送机械化。沿输送机全长都可向溜槽中装煤，装入中部槽中的煤被刮板链拖拉，在中部槽内滑行到卸载端卸下。刮板输送机在煤矿是使用量大、消耗多的重要设备。多年来，我国制造的刮板输送机有几十种型号。一般的刮板输送机能在25以下的条件使用。刮板输送机在使用中要受拉、压、弯曲、冲击摩擦和腐蚀等多种作用，因此，必须有足够的强度、刚度、耐磨和耐腐蚀性。由于它的运输方式是物料和刮板链都在槽内滑行，因此运行阻力和磨损都很大。但是，在采煤工作面运煤，目前还没有更好的机械可代替，只能从结构上、强度上和制造工艺上不断研究，使它更加完善、耐用。毕业设计是对大学期间所学知识的检验与综合运用，由于毕业后会去煤矿工作，选刮板输送机作为设计题目也与将来的工作有一定的联系，通过此次设计使自己对矿山运输机械有更深刻的认识，同时使我的设计、计算和绘图能力以及使用专业文献的能力得到全面的训练。二、 国内外研究综述：刮板输送机作为煤炭运输的主要运输设备，在煤炭生产中起着非常重要的作用。目前，我国刮板输送机的总体设计、制造水平已接近国外同类机型,但与国外相比仍有不少差距。对此，加快研制高可靠性的超重型大功率刮板输送机刻不容缓。一、国外刮板输送机发展概况自世界上第一台刮板输送机诞生以来，经历了半个多世纪的不断研究、试验、改进,刮板输送机已成为煤矿运输的主要设备。目前世界上生产刮板输送机的国家主要有德国、美国、英国、澳大利亚、日本等,机型从轻型、中型到重型、超重型，装机功率已发展到3700kW。保护形式有:弹性联轴器、限矩型液力耦合器、双速电机、调速型液力耦合器、软启动(CST可控传动装置、阀控调速型液力耦合器、交流电机变频调速技术三种软启动装置)等等。二、我国刮板输送机发展现状我国综采机械化的应用始于20世纪70年代末，经过20多年的发展,目前我国中、小功率刮板输送机已具备成型技术，并有成熟的制造能力,完全能够满足国内市场的需求。大功率刮板输送机通过成套引进国外的装备和技术，成功地进行了国产化研制工作,并相继推出了一些产品。20世纪80年代以来，国内外刮板输送机都在向大运量、长运距、大功率、高强度、长寿命与高可靠性方向发展。目前，国外综采最大的工作面刮板输送机，去运量已达6000t/h，装机功率4800kW，运距450m。国内自主研发的刮板输送机运量已达3500t/h，装机功率3700kW，运距300m。随着神东等大型煤炭基地400m工作面的出现，国产刮板输送机将朝着更大型的方向发展。但是运量、运距和功率的增大受到诸多因素的限制。首先，中部槽的高度不宜太高，否则会影响装煤效果。其次，输送机的长度也不宜太长，会降低推进速度。然后最主要的影响因素还在于关键元部件的技术性能和寿命。所以，在刮板输送机向大型化发展的同时，高性能元部件的研发将成为今后刮板输送机的发展重点，软启动技术、工况检测、运行状态控制等机电一体化技术的运用将成为今后刮板输送机发展的重要标志。刮板输送机在煤矿的生产与建设中的发展，大致经历了三个阶段。第一阶段在30-40年代，是可拆卸的刮板输送机，它在工作面内只能直线铺设，随工作面的推进，需人工拆卸、搬移、组装。刮板链是板式，多为单链，如V型、SGD-11型、SGD-20型等小功率轻型刮板输送机。第二阶段是40年代前期由德国制造出可弯曲刮板输送机，它与采煤机、金属支架配合实现了机械化采煤。这种刮板输送机适应底板不平凹凸不平和水平弯曲等条件，移设时不需拆卸，并且运煤量也有所增大，如当时的型号SGW-44型刮板输送机就是这个阶段的代表产品。进入60年代由于液压支架的出现，为了适应综采的需要，刮板输送机发展到了第三阶段，研制出大功率铠装咳弯曲重型刮板输送机，如SGD-630/75型、SGD-630/180型等就是属于这个阶段的产品。目前，随着采煤工作面生产能力的不断增大，刮板输送机主要发展趋势： 1、大运输量。国外先进采煤国家已经发展到小时运输能力高达1500t（80年代）3500t（90年代）的刮板输送机。 2、长运输距离。为了减少采区阶段煤柱的损失量，加大工作面的长度，刮板输送机的长度已经达到335米以上。 3、大功率电动机。电动机的功率已发展到单速电机达525kW，双速电机500/250kW。 4、寿命长。由于使用大直径圆环链，增加了刮板链的强度，延长了刮板输送机的寿命，整机过煤量高达600万吨以上。三、 毕业设计（论文）所用的主要技术与方法：1、明确系统设计要求；2、分析系统工况，确定主要参数；3、采用先进的设计方法如优化设计等，从网络、书籍、论文等方面查找相关内容，在脑中构思，然后通过理论计算，最后验证理论分析，从而完成设计任务；4、在绘图过程中运用计算机绘图（包括AutoCAD绘图）；5、在外型设计中充分考虑其工作环境，运用了人机工程学方法，以使人机环系统协调，相互适应。确保输送工作的高效、安全可靠以及经济的运转、防止和杜绝事故的发生，减少噪音、环保节能；6、利用计算机绘制三维图，工程图；7、编写设计计算说明书。四、主要参考文献与资料获得情况：1 于学谦，矿山运输机械 徐州：中国矿业大学出版社，20032 许洪基，现代机械传动手册 北京：机械工业出版社，19953 吴相宪，实用机械设计手册 徐州：中国矿业大学出版社，20014 成大先，机械设计手册 北京：化学工业出版社，20045 程志红，唐大放，机械设计 南京:东南大学出版社, 20066 洪晓华，矿井运输提升 徐州：中国矿业大学出版社，20057 程居山，矿山机械 徐州：中国矿业大学出版社，19978 谢锡纯、李晓豁，矿山机械与设备 徐州：中国矿业大学出版社，2000五、 毕业设计（论文）进度安排（按周说明）第16周 毕业实习，收集资料，完成开题报告。第710周 完成实习报告，总体方案设计，初步完成设计计算，外文翻译。第1113周 完成总装图和零件图的绘制和设计说明书。第1415周 修改和完善，准备毕业答辩。六、指导教师审批意见(对选题的可行性、研究方法、进度安排作出评价,对是否开题作出决定)指导教师： （签名）年 月 日 英文原文Analysis and Precautions of Chain BreakageFailure of Scraper Conveyors1. ForewordScraper conveyor the fault, the failure to bound rupture the most prominent, and deal with the time spent by the labor intensity and also the largest. Maintenance often found that the chain of serious wear, the end of a chain of non-normal damage and a pit, and other phenomena. This paper analyses the reasons for the failure occurred, by preventive measures.2. analysisAccording to statistics, in the normal production of fully mechanized coal face, scraper conveyor chain conveyor failure time about the failure of more than 40 percent of the time. Ring linked bound rupture major fault caused by the following aspects(1) improper installation1) in the double-stranded different lengths. Under normal circumstances, single 200 kW power both in the use of double-stranded form, the new procurement scraper conveyor chain at the initial stage when there is no inconsistency in the length of the chain problem, because after the use of conveyor-bending level was advancing, through the chain A longer period of time after use,In the lateral (side-wall coal face) relative elongation of the chain, concentrated load, the heavy start-up occurred when bound rupture vulnerable. When the conveyor face again the next installation, assembly chain may be confusing, if short-chain installed in the lateral and medial in the long-chain equipment, conveyor work will result in biting sprocket chain, with a loose chain Sprocket was bitten and seriously so that when the chain pull off.2) chain link seam down. For the double-stranded conveyor at the time of installation in the Central Weld legislation must be progressive, to reduce wear Weld, extended chain link life; chain link Weld and reduce the friction and wear of the plate. However, in actual use, since the chain link wrong equipment, chain link seam down, and the frequent occurrence bound rupture fault.3) the use of short-scraper. As manufacturing quality problems or wear overrun by the use of the scraper, which, resulting in failure to stop production.4) rack deformation. Sprocket and rack itself allowed the rocky ledge of 5 mm, but the actual rocky ledge in excess of this value, sprocket and chain link connection is bad, a point contact, causing ring linked with the arc of Waterloo sprocket chain of non-normal wear and tear , A pit.5) nose to install high enough. When the nose to install high enough, the head drum Coal Unloader not due to the net, at the end of floating coal will be linked into the groove (that is, turn coal), an increase of the conveyor running resistance and increase the chain, the chute wear, So that the chain tension increased, bound rupture.(2) the use of improper maintenance1) sprocket transition wear. According to a point of order, 22 mm pitch of the biggest sprocket wear should be 6 mm (with the roundabout at sprocket chain-linked ring on the inspection and wheel above the distance), six months after the sprocket should use the nose, tail Sprocket to swap. However, in actual use, because of maintenance and use of cost considerations, the sprocket wear still in use, ring linked through the chain wheel when the slide because of the relative squeeze caused friction with the arc of the chain ring wear, and linked Waterloo Ring linked connection is bad, sprocket chain and ring pitch from the chain of non-aggravated the normal wear and tear.2) chain too tight or too loose. Tight at the beginning of the chain tension adjustment is too large, impact on conveyor normal work, shorten the chain of life, exacerbated by the board in the chain and wear, especially when the scratch card scraper, so that the chain elongation. When the chain-scraper, under the nose of a scraper sprocket chain piled up in the chain to interfere with, or even bite chain.3) and vertical degrees of bending gauge. Conveyor passage in the process, the level of the overrun is often due to face rugged, vertical degrees can not be fully guaranteed. Under such circumstances, the inevitable wear ring linked the increase of chain elongation increase.4) fault encountered at the engine frame. As the underground working conditions constantly changing, Shearer cut off layer, cut parting cases have occurred, then the waste water mixed with a cement-like, scraper, and the chain plate in the role of friction, wear the chain of intensified, More than normal wear and tear of coal condition, Sawtooth Central, Weld life cut short, the whole chain of life decline.5) Other damage. Electrical overload started, the running load will cause damage to link Central and bound rupture; began production in the face, cut in the bolt, metal scrap, etc. into the chute, resulting in biting card bound rupture; tight chain method is not correct , Will cause tension gauge and bound rupture(3) quality is not highCircle chain design load is about the broken scraper can withstand the tension about 10 times that in normal circumstances great safety factor, is not going to happen the bound rupture. However, due to various reasons, the ring chain (Sawtooth Central) less than the quality of standards, resulting in the production chain in the ring in bound rupture3 Ring linked Circle as a scraper conveyor chain of traction, its tensile strength directly related to the reliability of. At present, Chinas largest ring linked to 42 mm 146mm compact chain, tensile strength of 2270 kN, the largest foreign ring linked to 48 mm 152mm compact chain, tensile strength of 3550 kN. With the ring linked the increasing size of the central trough of higher and higher, conveyor magnificent performance declined, the gateway if not thorough clean-up will also affect passage of conveyor. So ring linked the direction of development is to improve tensile strength and reduce the high degree of Central legislation.3.1 Materials and Technology In order to improve the roundabout chain of tensile strength, the current foreign Grade C and D-linked ring in the large-sized materials with 23 MnNiCrMo54, 23MnNiCrMo54 and 23 MnNiCrMo64 scouring steel, tensile strength limit 1600 1800 MPa. Welding Technology: the use of advanced welding equipment, welding and the use of flash returns processing technology, successfully resolved the surfacing of the process of overheating, such as a burning issue. In quality testing, the use of scanning stretch fracture fracture of cables used to pre-tension ring linked to strengthen technology, greatly enhancing the carrying capacity and fatigue.3.2 form and geometry In 1985 the first to create a company 38 mm 137mm flat chain. Flat is linked each of the chain is still ring-Central, Central was squeezed the flat ring. Flat chain link sliding work to reduce the size of the increase in the chain of slot pressure on the units and improve the legislation of the Central wear resistance; reduce its high level of the chain more easily through the sprocket, but can also reduce the capacity of power transmission and Bays of a high degree. Modern high-performance conveyor are generally involved in supporting a flat chain. Figure 5 conventional chain and a new wide-body linked flatIn 2003, the company has developed a wide-body at a flat linked, as shown in Figure 5. It is a high-intensity, low-chain, has the following characteristics: using this chain can reduce the high scraper chain, thereby reducing the central trough height, eventually reduce the use of high-mining, coal mining to meet thin. using this chain can reduce the use of power, or power in the same circumstances, increase the length of face, it will greatly reduce the workload of opening up, reducing the number of face move. this forging of wide-body flat link chain has increased the contact area, can improve the chain link at the same time reduce the intensity of the wear and helps to maintain the rigidity of chain link. Such as a flat 42 mm chain can take 2 855kW of installed power, and 50 mm wide-body flat can be linked up to 3 1000kW bear the installed power.3.3 intelligent conveyor chain As unable to accurately predict the failure of the chain, according to conventional practices are generally ahead of the replacement of the chain. In 2005 a company with a number of research institutes to study the development of a conveyor chain-detection system, as shown in Figure 6. This is a combination of integrated sensor technology of intelligent conveyor chain, it will stress the chain of real-time record, the help of micro-electronics technology devices, from computers that the chain of life remaining before the fracture. It also can detect the preloads of the chain, is conducive to life during the period in the chain to achieve the best use of state, improve safety and avoid accidents.4. bound rupture fault approach(1) off on the single-chain: a single chain on bound rupture, the first clean pile of coal on the conveyor, reversing open space will be open to the bound rupture near the tail, and then use the brake, linked resistance (or monomer Pillar), and other tools so that the chain has some margin, with links connecting the ring will be broken;(2) off the double-stranded: in the double-stranded bound rupture, the first clean conveyor on the heap of coal, materials, winch wire rope leash on the lower part of the first chain to pull the tail direction, with open space will be reversed to open the bound rupture Near the tail, and then use the brake, linked resistance (or single prop), and other tools so that the chain has some margin, with links connecting the ring will be broken, or prepared the same length of the chain will bound rupture replaced;(3) off the double-stranded: in the double-stranded bound rupture, the first clean conveyor on the heap of coal, from the estimated bound rupture open multiple skylights to find bound rupture position; materials Road winch wire rope from the tail of the first lower plate Nose to the direction of penetration, with skylights, has been sent to wire rope bound rupture, leash on the lower part of the first chain to pull the tail direction, with open space vehicles will be bound rupture Department is open to the vicinity of the tail,Recycling-oriented chain pulley will be led by the head to the tail of the board above the trough of the transition; reuse winch wire rope will lead to decapitation above the tail, and then use the brake, linked resistance (or single prop), and other tools so that the chain Have a certain margin, with links connecting the ring will be broken, or prepared the same length of the chain will bound rupture replacement.5. bound rupture fault preventive measures(1) strictly control the quality of the installation1) installation, they should point-components, according to the order to install loading transport, to prevent the components were insufficient to replace the old;2) all eyes on the face plate processing (in particular, will be cleared of scrap metal) to determine the nose, tail position, while the installation of the nose should be set aside or highly processed to meet the mounting height to prevent the installation of the wrong location Need to co-opt parts, or for unloading high enough damage to the chain;3) require the installation of the equipment, fastening bolts scraper, with the anti-chain, the scraper must be reworked;4) The installation process is prohibited frequent point vehicles, to avoid components, parts damaged.(2) to enhance equipment maintenance and management1) equipment in the operation to eliminate the use of unqualified chain link ring;2) the strict requirements of pushing wandering step over and over bending; Shearer asked the driver to control roof and floor to prevent a floor-level, to prevent conveyor overload;3) when the chain tight to prevent the chain too tight or too loose;4) the use of the old chain, such as the length of the chain should be tied up in pairs to use, if unable to find the same length of chain, the long chain can be disconnected from the two bundled into use, ranging from the length of the chain mix is prohibited, prohibited the use of breaking strength Not enough chain;5) of the periodic maintenance sentinel system, as required periodic replacement of the tail sprocket nose, to reduce the wear chain and sprocket.(3) improve the quality of technical workers, according to many years of experience, who after training in the installation of the work of the staff, efficient and reworked the low rate, the conveyor failure rate is also low. Therefore only strengthen training and improve the quality of technical workers, in order to prevent the occurrence of an abnormal failure to reduce the incidence of insecurity and improve the economic benefits of coal mine production.中文译文 刮板输送机断链故障分析及防范措施1. 前言刮板输送机出现的故障中,以断链故障最为突出,处理时所花费的时间及劳动强度也最大。检修经常会发现链条严重磨损、链条外端部有非正常损坏并出现凹坑等现象。本文分析故障发生的原因,提出防范措施。2.分析据统计,在正常生产的综采工作面,刮板输送机链条故障时间约占输送机总故障时间的40%以上。圆环链断链故障主要由以下几个方面引起:(1) 安装不当1) 中双链长短不一。一般情况下,单机功率200kW时均采用中双链形式,新采购的刮板输送机链条在初期使用时不存在链条长短不一致的问题,使用后由于输送机呈台阶形弯曲推进,链条经过较长一段时间的使用后,处于外侧(工作面煤壁侧)的链条相对伸长,集中载荷,在重载起动时极易发生断链。当该输送机在下一个工作面再次安装使用时,链条可能混乱装配,如果短链装在外侧,长链装在内侧,输送机工作时将造成外链过紧咬链轮、内链过松被链轮咬,严重时使链条拉断。2) 链环焊缝向下。对于中双链输送机在安装时立环焊缝必须向上,以减少焊缝磨损,延长链环寿命;并可减少链环焊缝对中板的摩擦磨损。但在实际使用中,由于链环错装,链环焊缝向下,而发生频繁断链故障。3) 使用短刮板。由于制造质量问题或因使用磨损超限的刮板,致使,造成故障而停止生产。4) 机架变形。链轮与机架本身允许有5mm的窜动量,但当实际窜动量超过此值,链轮与链环接触不良,出现点接触,造成圆环链圆弧段与链轮链窝的非正常磨损,出现凹坑。5) 机头安装高度不够。当机头安装高度不够时,机头滚筒由于卸煤不净,底链将浮煤拉入下槽(即回头煤) ,增加了输送机的运行阻力,增大了链条、溜槽的磨损量,使链条张力增大,断链。(2) 使用维护不当1) 链轮过渡磨损。根据规程,节距22mm的链轮最大磨损量应6mm (用圆环链平置于链轮上检查圆环链上面与轮毂的距离) ,链轮使用半年后应将机头、机尾链轮进行调换。但在实际使用中,由于考虑维修和使用成本、磨损严重的链轮仍在使用,圆环链在通过链轮时由于相对滑动摩擦与挤压而造成圆环链圆弧段磨损,链窝与圆环链接触不良、链轮与圆环链节距不等加剧了链条的非正常磨损。2) 链子过紧或过松。在紧链时初张力调整过大,影响输送机正常工作,缩短了链条的使用寿命,加剧了链条与中板的磨损量,特别是当刮板被刮卡时,使外链伸长。当刮板链过松时,在机头链轮下造成刮板链条堆积,发生与链条干涉,甚至啃咬链条。3) 弯曲度和垂直度超限。输送机在推移过程中,水平度超限是经常发生的; 由于工作面凹凸不平,垂直度也不能完全保证。在这种情况下,圆环链必然磨损增大,外链伸长加大。4) 遇到断层时拉矸石。由于井下工作条件的不断变化,采煤机割断层、割夹矸情况时有发生,此时的矸石与水相混合形成水泥状,在刮板、链条与中板摩擦作用下,链条磨损加剧,磨损量超过正常运煤工况,锯齿环、焊缝寿命减短,链条整体寿命下降。5) 其它损坏。电机过负荷启动、过负荷运行将造成链接环损坏而断链;在工作面开始生产时,切眼内的锚杆、金属废料等拉入溜槽,造成蹩卡而断链;紧链方法不正确,也会造成张紧力超限而断链。(3) 质量不高圆环链设计的破断载荷约为刮板可承受拉力的10倍左右,在正常情况下安全系数很大,是不会发生断链的。但由于种种原因,圆环链(锯齿环)的质量达不到标准,致使在生产中圆环链发生断链。3圆环链圆环链作为刮板输送机的
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