带式输送机安装工艺指导书.docx
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带式输送机安装工艺指导书.docx
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带式输送机安装工艺指导书
带式输送机安装工艺指导书
工艺名称
Processname
工艺要求
Processrequest
公差
Tolerance
质量问题
QualityQuestion
解决办法
Solution
地基
Foundation
按照带式输送机的安装尺寸,核实安装基础是否符合要求,测量安装基础是否在同一水平面上(指横向)
Accordingtotheinstallationsizeofthebeltconveyor,Verifyinstallationbaseisinlinewiththerequirements,Whethermeasuringinstallationbasedonthesamehorizontalplane(Referstothehorizontal)
水平面公差
1/1000
Leveloftolerance1/1000
地基水平
FoundationLevel
可用垫片调整到水平为止
Availableshimadjustmentatthelevel
带式输送机安装中心线
Thecenterlineofthebeltconveyorinstallation
按总装图的安装尺寸要求,将其尺寸复制到地基上,划完线后,再由工程质检进行检验确认
Accordingtotherequirementsofassemblydiagramofinstallationdimension,Itssizeiscopiedtothefoundation,Afterdrawtheline,Confirmedbythetestengineeringqualityinspectionagain
滚筒及托辊轴线对输送机机架中心线的垂直度2/1000,两相邻托辊对角线≤3mm
Pulleyandrollerlinetothecenterlineoftheconveyorframeverticaldegree2/1000,Twoadjacentrollersdiagonal≤3mm
先将头尾架划好中心,再用软线弹出带式输送机的中心线,根据中心线两侧分画中间架及支脚线
Centerheadtailrackrowfirst,Popupthecenterlineofbeltconveyorwithasoftlineagain,Accordingtothecenterlineonbothsidesofthepictureframeandthelegline
头尾架
Headandtailframe
在经检验合格后的安装中心线上,进行头尾架的安装所用工具千坠、水平尺、差尺,主要测量头、尾架、滚筒座是否在同一水平面上(要求
1/1000),尔后测出滚筒轴线对输送机中心线的垂直度(要求2/1000)
Intheinspectionqualifiedaftertheinstallationofthecenterline,Theheadandtailrackinstallationtoolsusedforthousandpendant,spiritlevel,ruler,mainlymeasuringheadandtailframe,pulleyisinthesamehorizontalplane(request1/1000),Thenmeasuretheverticalityofcylinderaxisofthecenterlineoftheconveyor(request2/1000)
水平公差1/1000
垂直公差2/1000
Theleveloftolerance
1/1000
Theverticaltolerance
2/1000
地基不平,头尾架变形
Thefoundationuneven,
Headtotailframedeformation
①地基不平可用垫片进行调整;②机架变形可调整机架
(1)thefoundationunevengasketavailabletoadjust
(2)theframedeformationadjustableframe
支腿
landingleg
首先检测支腿是否变形,方法是测量两立柱的对角线,观测两立柱是否在同一平面上,确认无质量问题后,按地脚线进行安装,安装后确保支腿两侧立柱的直线度在任意25m长度内,公差为5mm,输送机长度≤100m,直线度10mm>100-300m,直线度30mm以内
ThefirstDetectingwhetherthelegtransformation,Methodsarethetwopillarofdiagonalmeasurement,Ifobservedtwocolumnsonthesameplane,Afterconfirmedwithnoqualityproblem,Accordingtotheanchorlineinstallation,Afterinstallationtoensurethatthelegoneithersideofthecolumnthestraightnessinarbitrarylengthof25m,toleranceof5mm,Conveyorlength100morless,straightness10mm>100-300m,Straightnessof30mm
对角线≤4,在任意25m直线度5mm≤100m直线度10mm,>100-300m直线度30mm以内
Diagonal≤4,Inany25mstraightness5mmorless100mstraightnessis10mm,>100-300-mstraightnesswithin30mm
地基不平,支腿变形
Thefoundationuneven,
Headtotailframedeformation
①用垫片调整地脚;②修正支腿或变换
(1)withthegaskettoadjusttheanchor
(2)correctionoflegorchange
中间架
MiddleFrame
按图确定好下料点位置,首先安装与其对应的中间架,尔后按中间架排号进行安装,边安装边测量孔的对角线≤4mm,
安装完后必须经质检人员签字合格后方可进行下一步工序
Accordingtothefigurefineblankingpointlocationisdetermined,
Firstinstallationanditscorrespondingtothemiddleoftheframe,Thenaccordingtothenumeralmiddleframeforinstallation,Installwhilemeasuringholediagonal4mmorless,Aftertheinstallationmustbedonebythequalityinspectionpersonnelqualifiedrearcancarriesonthenextworkingprocedure
两侧中间架水平度2/1000,安装托辊横梁孔的对角线公差≤4mm
Onbothsidesofthemiddle2/1000levelness,Installidlerbeamholediagonaltoleranceof4mmorless
两中间架不在同一水平面上,对角线超差
Twothemiddleframeisnotinthesamehorizontalplane,diagonalerror
应认真调整、测量,
注:
这是对输送机跑偏与否起到关键性的工艺
Shouldbecarefullyadjusted,measurement
Note:
Thisiskeytechnologyintermsofconveyorrunningdeviationornot
滚筒
pulley
头尾滚筒的安装要求转动灵活,垂直度要符合2/1000的公差要求
Therequestofinstallationaboutheadandreturnpulleyisflexiblerotation
水平度1/1000
Levelness1/1000
垂直度2/1000
Vertical2/1000
①滚筒转动不灵活;
Pulley’srotationisnotflexible②垂直度超差
Verticalbeyondtolerance
①滚筒两侧瓦合用垫片进行调整到转动灵活为止;Adjustbothsidesofpulley’stilecombinationwashertoflexiblerotation②检查划线是否有误,Checkthedashwhetherhavemistake用调整螺栓进行调整beadjustedbyadjustingthescrew
托辊横梁及托辊conveyframeandroller
认真查阅总装配图,注意缓冲托辊、前倾横梁及过渡横梁、调心托辊横梁的安装位置(两边的调心托辊先不上)
Carefullyreviewthegeneralassemblydrawing,Noticetheinstallationlocationofimpactrollers,forwardbeamsandexcessivebeam,sphericalrollerbeams(sphericalrollersbothsidecan’tinstallfirstly)
输送带
Conveyorbelt
输送带安装前必须严格检查转动件转动是否灵活可靠,确认无问题后,可安装输送带,输送带的吊装严禁用带锐角的工具或钢丝绳直接接触带来吊运,可用>80mm直径的圆管等穿入带心进行吊装,输送带接头贴接采用硫化贴接,需专业技术人员完成
Conveyormustbestrictlycheckedbeforeinstallationtoconfirmturningwhetherflexibleandreliable.Installationconveyorsafterconfirmed.TransportingconveyorbeltsuseWithsharptoolsordirectcontactwithwireropeisforbidden.Liftingcanusepenetrationwithahearttube(pipediameter>80mm).Connectorofconveyorbeltusethenpastesulfidebyprofessionalworkers.
带边撕裂
Bandedgetear
吊装工具不对,更换工具
Liftingtoolsiswrong,changetools
跑偏开关、拉绳开关
Deviationswitch,Ropeswitch
输送带安装完毕后,在试运行前必须安装好跑偏开关及拉绳开关,否则禁止试车运行
Afterinstallingconveyorbelts,andBeforecommissioning,deviationswitchandropeswitchmustbeinstalledsuccessful.orcommissioningisforbidden
驱动装置
Drivemeans
驱动装置安装时与传动滚筒对接,其两联轴器的标志一定对齐(此件为柱销联轴器)安装同心度≤0.7mm,安装完后按设备要求加足润滑油
Installbuffdriveanddrivepulley,thelogoftwocouplingsmustalignment.(Thispieceispincoupling)Installationconcentricity≤0.7mm,AddLubricatingoilasequipmentrequestafterinstallation.
同心度≤0.7mm
Concentricity≤0.7mm
转动时颤动或两相邻的轴承发热
Rotationfibrillationortwoadjacentbearingsheating
重新调整驱动装置位置,上下不同心可在驱动架下垫片,解决前后不同心,可移动驱动装置解决,以达到理想效果为止
Re-adjustthepositionofdrivemeans.DrivingunderthegasketintheframewhileDowndifferentheart,MobiledriveunittoslaveBeforeandafterdifferentheart.Theaimistoachievethedesiredeffect
Plough
unloader犁式卸料器
在下料口处安装犁式卸料器,安装后要进行调整,①胶板探出刮板10-15mm,②刮板要与输送带调至无间隙为止,在试运行前,把犁头抬起以减小开车阻力
Installploughunloaderatfeedopening,afterinstalling,adjustit.①rubberboardislongerthanscraper,about10-15mm.②Scraperandconveyorbeltshouldbeadjustedwithnogap,beforecommissioning,liftthepoughtoreducedrivingresistance.
试运行
Commissioning
运行前准备工作:
preparationbeforeoperating
一、检查驱动装置各润滑处所注入的润滑油牌号、数量是否符合要求;
㈠Checkthedrivingdevicelubricationpoint,theinjectedoilgradeandquantitytomeettherequirements.
二、检查液力偶合器中注入的介质(油式水)质量、数量是否与传动功率相匹配(应加入介质量占总容积的75-80%);
二、Checkinjectedoperationmedium(oiledwater)offluidcouplingquality,quantity,whethermatchthetransmissionpower(shouldbeaddedtothetotalvolumeofoperationmediumquality75%-80%)
三、检查制动器闸瓦与制动轮间隙是否符合1.5-3mm的要求;三、Checkthebrakeshoeandbrakewheelgap,whethermeetstherequirementsof1.5-3mm.
四、检查减速器输入轴的转向,逆止器的转向是否符合要求;点动试车
四、Checkthethesteeringofthegearboxinputshaft,steeringofinvertedvalve,meetstherequirements.coldstartup.
五、检查跑偏开关、拉绳开关是否安装完毕;
五Checkthedeviationswitchandcordswitchareinstalled.
六、用手转动各传动部分的机械是否灵活,有无卡住的现象;
六Rotatethemechanicalpartofthetransmisisonisflexible,withorwithoutstuckphenomenom.
七、检查基础及各部件螺栓是否紧固,工地焊接的焊缝有无漏焊等;
七、Checkthebasisandeveryboltsarefastening,weldisweldingseamless,etc.
八、检查电气信号、电气控制保护、绝缘等是否符合电气说明书的要求,点动电机,确认电机旋转方向;
八、Checktheelectricalsignal,electricalcontrolprotection,electricalinsulation,whethermeetthedemandsofelectricalmanual,movethemotor,checkthemotorrotationdirection.
①启动电机后减速机不转动;
①Afterstartingthemotor,reducerdoesn’trotate.②整机无法启动;
②②theconveyorcan’tbeoperated.③启动后联轴器振动,轴承位发热升温超过40°C(含环境温度)③couplingvibrationstarts,bearingpositionheatingtemperaturerisingover40degrees.(includingambienttemperature)
①液力偶合器是否加够了介质数量,
①Fluidcouplingaddenoughquantityofoperationmedium
②有逆止器的带式输送机是否转向不对,②checkthebeltconveyorwithinvertedvalveisturningright.
③如联轴器振动或轴承位发热,应重新调整联轴器的同心度或轴承是否缺油。
③Ifthecouplingvibrationorbearingpositionishightemperature,re-adjusttheconcentricityofthecouplingorbearingislackofoil.
空载运行中的观察内容及设备调整
Theobservedandequipmentadjustduringnoloadoperation
试运行中,要仔细观察各部分的运转情况,发现问题及时调整:
Duringtestrun,youshouldscrutinizetheservicebehaviorofeverypart,findtheproblemandadjustit.
一、观察各运转部件有无相蹭的现象,特别是输送带点动,观察输送带是否跑偏,跑偏要及时处理,防止损伤输送带;
Observewhetheronepartrubtheotherpart,orofftracking,ifofftrackingappear,mustdisposeintimetoprotecttheconveyorbeltfrombroken.
二、输送带的跑偏超过带宽的5%应进行调整,调整好后将调心托辊安装上;
Iftheofftrackingdegreemorethan5%ofbeltwidthshouldadjust,afteradjustfinishing,installthealigningroller.
三、检查设备各运转部件,有无异常声音及异常振动;
Checkeachpartoftheequipment,whetherhaveabnormalnoiseorabnormalvibration.
四、检查减速机、液力偶合器、润滑油、轴承等处温升情况是否正常,是否有漏油现象;
Checkthetemperatureriseofreducer,fluidcoupling,lubeandbearingwhetheroilleak.
五、制动器、各种限位开关保护装置的动作是否灵敏可靠;
Checkbrakeandalllimitswitch,whetheritissensitive.
六、拉紧装置运行是否良好,有无卡死现象;
Tensiondevicerunningwell,whetherlockingornot.
七、各部分螺栓有无松动
Theboltisnotlooseness.
带跑偏
Beltofftracking
一、调整上托辊
Adjusttheuproller
二、调整下托辊
Adjustthedownroller
三、机头调整
Adjusttheheadofmachine
四、尾部调整
Adjustthetailofmachine
负载试运转
Loadtestrun
空载按上述要求完成后可进行负载试运行,以检测是否达到技术参数的设计要求,加载方式:
Youcanloadtestrunafterno-load,detectionwhethercanmeettherequirement,theuploadmethodisasfollow:
一、加载量应以小到大逐渐增加,先按20%额定加载,通过后在逐步增加倒50%、80%、100%额定负荷进行试运转,在各种负荷下的连续运转时间不得少于2小时;
Theheapcapacityshouldlittlebylittleincrease,first20%,thenincreaseto50%,80%,100%,continuousworknotlessthan2hoursunderdifferentload.
二、测量各技术参数是否符合要求
Checkwhetherthetechnicalspecificationmeettherequirement.
①托辊不转;rollerdon’trun
②落料点落料偏向一侧;Blankdeviationtooneside③胶带打滑;
Thebelt
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