珠海1800tph链斗卸船机机改造方案Zhuhai 1800TPH chain bucket ship unloader machine transformation plan 

                                           1800t/h 链斗卸船机改造方案 1800t/h chain bucket ship unloader transformation plan

Xxxx重工有限公司 XXXX Heavy Industries Co., Ltd

2021年9月 September 2021

1800t/h 链斗卸船机改造方案 1800t/h chain bucket ship unloader transformation plan    

神华xx港 1800t/h 链斗式连续卸船机自 投入运行以来，故障不断历经数次改造，依然出现了诸如洒料、扬尘、脱链、断轴等严重影响生产的各种故障，未能完全发挥出连续卸船机节能、环保、高效的优势。有些问题是设计时考虑不周经验不足导致的，即先天的缺陷。
Since the Shenhua XX Port 1800t/h chain bucket continuous ship unloader has been put into operation, the faults have been continuously transformed several times, and there are still various faults that seriously affect production, such as sprinkling, dust, off-chain, and broken shaft, which have failed to fully play the advantages of energy saving, environmental protection and high efficiency of the continuous ship unloader. Some problems are the result of poor design and inexperience, i.e. congenital defects.

为彻底解决生产使用过程中出现的故障，对有问题的各机构、结构进行针对性的分析研究和讨论，以提高设备的效能，保证设备作业的连续性为最终目标。本公司编制此专项技术方案，让此链斗卸船机恢复原始设计的各项指标和性能，达到其额定生产率和胜任连续工作的要求，体现链斗卸船机的性价比。
In order to completely solve the faults in the process of production and use, the problematic institutions and structures are analyzed and discussed in a targeted manner, so as to improve the efficiency of the equipment and ensure the continuity of the equipment operation as the ultimate goal. The company has prepared this special technical scheme to restore the indicators and performance of the original design of the chain bucket ship unloader, meet its rated productivity and the requirements of continuous work, and reflect the cost performance of the chain bucket ship unloader.

1.给料皮带机至码头皮带机落料口 1. Feed the belt conveyor to the blanking port of the dock belt conveyor

问题：根据现场情况及实际图纸，此处有三个敞开的落料口，对于操作人员这是个安全隐患，存在人员或异物坠落至码头皮带机的风险。如下图所示：
Problem: According to the site situation and actual drawings, there are three open blanking openings, which is a safety hazard for the operator, and there is a risk of personnel or foreign objects falling into the dock belt conveyor. As shown in the figure below:

解决方案：在每个落料口处增设自动摆动的封盖装置，共3个。封盖装置有支撑轮可沿着弧形轨道运动。给料皮带机对位到哪一个，其对应的封盖打开，而另外两个封盖在复位装置的作用下自动闭合。
Solution: Add 3 automatic oscillating capping devices at each blanking opening. The capping device has support wheels that move along an arc-shaped track. The corresponding cap of the feeding belt conveyor is aligned to which one, and the other two caps are automatically closed under the action of the reset device.

2.中心溜筒与给料皮带机接口 2. The interface between the central chute and the feeding belt conveyor

问题：中心溜筒总高度约 13 米，物料在整个流动过程中无任何的缓冲装置，物料从臂架皮带机抛料点直接落到给料皮带机，极易造成给料皮带机跑偏，托辊寿命降低，落料点扬尘严重等问题。如下图所示：
Problem: The total height of the center chute is about 13 meters, the material does not have any buffer device in the whole flow process, and the material falls directly from the throwing point of the boom belt conveyor to the feeding belt conveyor, which is easy to cause the feeding belt conveyor to deviate, reduce the life of the idler, and cause serious dust at the blanking point. As shown in the figure below:    

解决方案：为了减缓物料的垂直大落差造成的冲击，筒体内设置的缓冲环节，通过“料打料”的与缓冲板相结合的方式，吸收物料的动能。给料皮带机的接料口设置防跑偏的对中装置，对中装置使用可调角度的缓冲板，将物料引导到皮带机的中心线上。以上措施可大幅度地降低物料的冲击和减少粉尘外溢。改造方案如下图所示：
Solution: In order to alleviate the impact caused by the large vertical drop of the material, the buffer link set in the cylinder absorbs the kinetic energy of the mat
erial through the combination of “material feeding” and the buffer plate. The receiving port of the feeding belt conveyor is provided with an anti-mistracking centering device, and the centering device uses an adjustable angle buffer plate to guide the material to the center line of the belt conveyor. The above measures can greatly reduce the impact of materials and reduce dust overflow. The transformation scheme is shown in the figure below:

3.臂架皮带机落料回收装置 3. Boom belt conveyor blanking recovery device    

问题：1）臂架皮带机下放的落料回收装置过短，其长度只有为皮带机总长的三分之一，致使后端落料无法回收，长期积料。2）驱动底座变形损坏。如下图所示：
Problem: 1) The blanking recovery device under the boom belt conveyor is too short, and its length is only one-third of the total length of the belt conveyor, resulting in the back-end blanking can not be recovered and the material is accumulated for a long time. 2) The driving base is deformed and damaged. As shown in the figure below:

解决方案：重新设计物料回收刮板取料机，其长度与臂架皮带机等长，采用带滚轮的套筒滚子链其标注符合GB/T8350-2003标准，依靠导轮支撑在轨道上，刮料时不发生脱链，同时轨道设置在密封罩 内 ，确保链条中无物料进入。更换臂架皮带机驱动底座。改造方案如下图所示：
Solution: Redesign the material recovery scraper reclaimer, its length is the same length as the boom belt conveyor, the sleeve roller chain with rollers is used to comply with the GB/T8350-2003 standard, relying on the guide wheel to support the track, no off-chain does not occur when scraping, and the track is set in the sealing cover to ensure that no material enters the chain. Replace the boom belt conveyor drive base. The transformation scheme is shown in the figure below:          

4.盘式给料器 4. Disc feeder

问题：1）根据停产前现场使用反馈，物料撒漏外泄严重。
Problems: 1) According to the feedback from the on-site use before the shutdown, the material leakage is serious.

2）驱动电机能力不足，无法带载启动。 2) The drive motor capacity is insufficient and cannot be started with load.

如下图所示： As shown in the figure below:

解决方案：1）盘式给料器旋转给料过程中，在离心力的作用下，物料将向着外墙板挤压。在外墙板的外侧布置密封用橡胶板形成组织物料外溢的第一级密封，少量溢出的物料随回转盘回转到出料口的位置时，会被卸料板推入下料溜槽而进入臂架皮带机。这样尽量减少进入下一级溢料槽的物料。原设计支撑轮为圆柱滚轮，旋转过程中和回转盘底面有额外的摩擦，消耗额外的能量，加速辊面的磨损，也造成了回转运动的不平稳。支撑轮改为带有锥面的滚轮，锥滚轮的中心指向给料器的回转中心。
Solution: 1) During the rotary feeding process of the pan feeder, under the action of centrifugal force, the material will be squeezed towards the exterior wall panel. The rubber plate for sealing is arranged on the outside of the exterior wall panel to form the first level of sealing of the organization of material overflow, and when a small amount of spilled material is turned to the position of the discharge port with the rotary plate, it will be pushed into the blanking chute by the stripper and enter the boom belt conveyor. This minimizes the amount of material that goes into the next overflow chute. The original design support wheel is a cylindrical roller, and there is additional friction with the bottom surface of the rotary disc during the rotation process, which consumes additional energy, accelerates the wear of the roller surface, and also causes the unevenness of the rotary motion. The support wheel was changed to a roller with a taper surface, and the center of the taper roller pointed to the center of rotation of the feeder.

2）改造说明如下图所示，更换驱动装置，包括电机、减速机等，拆除原有 8 个支撑轮，安装新的 8 个支撑轮，拆除原有 6 个水平导轮，安装新的 6 个水平导轮，并进行调心校准，耐磨衬板调整厚度，改造方案如下图所示：
2) The transformation description is shown in the following figure, replace the driving device, including the motor, reducer, etc., remove the original 8 support wheels, install the new 8 support wheels, remove the original 6 horizontal guide wheels, install the new 6 horizontal guide wheels, and carry out self-alignment calibration, adjust the thickness of the wear-resistant lining, and the transformation scheme is shown in the following figure:

给料器设一级密封如下图所示： The feeder is set with a primary seal as shown in the figure below:

支撑轮型式如下图所示： The type of support wheel is shown in the figure below:    

5.链斗提升机构 5. Chain bucket lifting mechanism

问题：1）原图纸链条链斗的设计，链斗间距较小仅为 1200mm，另外链斗斗深 895mm，链斗在抛料时出现后一链斗物料打在前一链斗斗背现象；物料会出现一定的回流，这也是造成提升减速机轴承损坏的部分原因。2）驱动底座变形。如下图所示：
Problem: 1) The design of the chain bucket in the original drawing, the chain bucket spacing is only 1200mm, and the depth of the chain bucket is 895mm. There will be a certain amount of backflow of materials, which is also part of the reason for the damage of the bearing of the lifting reducer. 2) The driving base is deformed. As shown in the figure below:

解决方案：在驱动链轮组上同轴安装5个辅助链斗，使之等间距。在链轮进入链轮回转时辅助链斗同步回转，且两个链斗之间始终有一个辅助链斗。其功能是进行导料，所有卸载物料均通过辅助链斗后再抛至盘式给料器中，从根本上解决后一链斗物料打在前一链斗斗背的现象以及物料回流问题。针对减速机轴承损坏，初步判断是两根链条磨损量不一致，  链条的延伸长度不一致，同时外加悬链式取料引起的偏载，致使提升轮轴两侧承载不均， 引起轴承损坏，为了从根本上解决这个问题，需对取料装置进行大的改造。更换驱动底座。
Solution: Install 5 auxiliary buckets coaxially on the drive sprocket pack so that they are
equally spaced. When the sprocket enters the sprocket rotation, the auxiliary bucket rotates synchronously, and there is always an auxiliary bucket between the two buckets. Its function is to guide the material, and all the unloaded materials are thrown into the disc feeder after passing through the auxiliary chain bucket, which fundamentally solves the phenomenon that the material of the latter chain bucket hits the back of the previous chain bucket and the problem of material return. In view of the damage of the reducer bearing, the preliminary judgment is that the wear of the two chains is inconsistent, the extension length of the chain is inconsistent, and the eccentric load caused by the catenary type reclaiming is added at the same time, resulting in the uneven bearing on both sides of the lifting axle, causing bearing damage, in order to fundamentally solve this problem, the reclaiming device needs to be greatly transformed. Replace the driving base.

改技术方案如下图所示： The technical scheme is shown in the figure below:

6.伸缩取料装置 6. Telescopic reclaimer

在横切取料过程中发生多次脱链现象，原因是前部链轮和根部链轮的包角均不大，挖掘取料过程链斗有横切的分速度，挖掘侧和非挖掘侧的链轮张力相差较大，两根链条的磨损及拉伸变形不一致，致使上部链斗提升机构出现减速机的多次损坏，同时链斗也出现变形、开裂等问题。如下图所示：
In the process of cross-cutting and reclaiming, many times of off-chain phenomenon occurs, the reason is that the wrapping angle of the front sprocket and the root sprocket is not large, the chain bucket has the sub-speed of cross-cutting in the excavation and reclaiming process, the sprocket tension difference between the excavation side and the non-excavation side is large, and the wear and tensile deformation of the two chains are inconsistent, resulting in the multiple damage of the reducer of the upper chain bucket lifting mechanism, and the chain bucket also appears deformation, cracking and other problems at the same time. As shown in the figure below:

6.1链斗挖掘 6.1 Chain bucket mining

问题：链斗挖掘部分为悬链式布置型式，在取料过程中，因横切阻力作用，使得取料悬链处于一定的弧状运行，所有横切力全部作用在头尾链轮处，在挖掘深度大，横切速度快的作业状态下，极易出现脱链或跳齿现象，同时加剧了链条与链轮之间的磨损，另外悬链式的取料方式造成链条在物料中运行，粉尘进入链条的间隙，使得链节之间不能自由回转加速了链条的磨损。如下图所示：
Problem: the chain bucket excavation part is a catenary layout type, in the process of reclaiming, due to the cross-cutting resistance, the reclaiming catenary is in a certain arc operation, all the cross-cutting force acts on the head and tail sprockets, in the operation state of large excavation depth and fast cross-cutting speed, it is very easy to appear off the chain or skipping teeth, and the wear between the chain and the sprocket is aggravated simultaneously, and the catenary type reclaiming mode causes the chain to run in the material, and the dust enters the gap of the chain, so that the chain links can not rotate freely and accelerate the wear of the chain. As shown in the figure below:

解决方案：整体更换链斗挖掘部分，设计为双层导轨取料装置，确保所有链斗均沿导轨直线移动，取料横切力通过导轮传递至钢结构，确保不发生跳齿、脱链等安全事故。这样，因链   斗的保持直线移动，取料部的链条始终处于直线状态，脱离物料平面，大幅减小链条与物料接触的机会，提高链条的使用寿命。改造专项技术方案如下图所示：
Solution: Replace the excavation part of the chain bucket as a whole, and design it as a double-layer guide rail reclaiming device to ensure that all chain buckets move in a straight line along the guide rail, and the cross-cutting force of the reclaiming is transmitted to the steel structure through the guide wheel, so as to ensure that there are no safety accidents such as tooth jumping and chain disconnection. In this way, because the bucket keeps moving in a straight line, the chain of the reclaiming part is always in a straight state, detached from the material plane, greatly reduces the opportunity of chain and material contact, and improves the service life of the chain. The special technical scheme for transformation is shown in the following figure:    

问题：水滑环锈蚀严重，无法正常供水 Problem: The water slip ring is badly corroded and cannot supply water properly

解决方案：采购新的水滑环。 Solution: Procurement of new hydroslip rings.

11. 视频监控 11. Video surveillance

问题：现有视频监控系统采用模拟摄像头，画面清晰度差、点位布置不足，无法为司机提供有效辅助支持，不能够满足设备操作需要。
Problem: The existing video surveillance syst
em adopts analog camera, the picture clarity is poor, the point layout is insufficient, can not provide effective auxiliary support for the driver, can not meet the needs of equipment operation.

解决方案：整体更换视频监控系统 Solution: Replace the video surveillance system as a whole

本次改造拟整体更换视频监控系统，能够有效覆盖取料头、大车、提升筒体、给料皮带等关键位置视频画面，清晰观察到设备生产作业过程中关键点位的状态画面，视频点位覆盖不少于 10 个，便于司机针对性调整取料策略，提升设备运行可靠性、稳定性及生产作业效率。
The transformation plans to replace the video surveillance system as a whole, which can effectively cover the video screen of key positions such as the reclaiming head, cart, lifting cylinder, feeding belt, etc., and clearly observe the status of key points in the process of equipment production and operation, and the video points cover no less than 10, which is convenient for the driver to adjust the reclaiming strategy and improve the reliability, stability and production efficiency of the equipment.

根据现有司机室的情况，拟设置两台 27 寸视频显示器，方便司机操作。
Based on the existing driver’s cab, it is proposed to set up two 27-inch video monitors for the convenience of the driver.

主要点位包括： Key locations include:

1、取料头前部配置自动跟踪视频监控装置，自动调整视频监控角度，更好的捕捉跟踪
1. The front of the reclaiming head is equipped with an automatic tracking video monitoring device, which automatically adjusts the video monitoring angle for better capture and tracking

取料头部安全状态； Safety status of the reclaiming head;

2、取料头上方平台配置高清一体化视频监控装置，专门监控链斗情况，便于司机调整
2. The platform above the reclaiming head is equipped with a high-definition integrated video monitoring device to monitor the situation of the chain bucket and facilitate the driver’s adjustment

取料控制策略，提升链斗内物料填充率。 The material reclaiming control strategy improves the material filling rate in the chain bucket.

3、在回转平台前部设置自动跟踪视频监控装置，可接收俯仰角度，自动调整视频监控
3. Set up an automatic tracking video surveillance device in the front of the rotary platform, which can receive the pitch angle and automatically adjust the video surveillance

角度，满足取料头进仓及作业过程中筒体与舱口间防碰撞安全监控需要；
Angle, to meet the needs of anti-collision safety monitoring between the cylinder and the hatch during the operation of the reclaiming head;

4、大车、给料皮带等位置设置辅助监测摄像头，便于司机监测设备运行状态。
4. Auxiliary monitoring cameras are set up at the positions of the cart and feeding belt to facilitate the driver to monitor the operation status of the equipment.

12
润滑系统 12 Lubrication system

从外观看润滑管路锈蚀严重，因设备已使用8年多。加之设备长时间不运行，油路会堵塞。
From the outside, the lubrication pipeline is seriously corroded, because the equipment has been used for more than 8 years. In addition, if the equipment does not run for a long time, the oil circuit will be blocked.

解决方案：更换全新的润滑系统，重新布置管路，安装新系统。
Solution: Replace the lubrication system, rearrange the piping, and install the new system.

13 洒水除尘系统 13 Sprinkler dust removal system

问题：因整机粉尘外溢严重，尤其在各个物料转载点外侧，形成了大量的煤粉堆积层，故
Problem: Due to the serious dust overflow of the whole machine, especially on the outside of each material transfer point, a large amount of pulverized coal accumulation layer has been formed

需对相关洒水除尘系统进行改造。 The relevant sprinkler and dust removal system needs to be modified.

解决方案：对除尘系统进行改造升级，重新布置除尘管路。
Solution: Transform and upgrade the dust collection system and rearrange the dust removal pipeline.

14. 取料头液压系统 14. Hydraulic system of reclaiming head

问题：由于液压泵设置于顶部结构，负载变化时张紧油缸无杆腔压力无法快速响应补偿，存在链条瞬间松弛风险。现场实际使用经常出现链条张紧不足，需人工手动张紧的情况。
Problem: Because the hydraulic pump is set on the top structure, the pressure of the rodless cavity of the tensioned cylinder cannot be quickly compensated when the load changes, and there is a risk of instantaneous relaxation of the chain. In actual use on site, the chain tension is often insufficient, and manual tensioning is required.

解决方案：整体更换取料头液压系统 Solution: Replace the reclaiming head hydraulic system as a whole

为解决上述问题，重新设计液压原理，重新制作，重新布置管路，安装各个阀组，快速补偿张紧油缸压力，始终保持链条张紧并且张紧力处于合理范围，防止链条脱链。15. 配重
In order to solve the above problems, the hydraulic principle is redesigned, the pipeline is remade, the pipeline is rearranged, each valve group is installed, the pressure of the tensioning cylinder is quickly compensated, and the chain tension is always kept tight and the tension force is within a reasonable range to prevent the chain from falling off the chain. 15. Counterweights

根据初步计算原设备的配重是有问题的，导致液压缸在俯仰范围的全行程负压运行，回转以上部分的重心偏离回转中心太多，会减低回转大轴承的寿命。
According to the preliminary calculation, the counterweight of the original equipment is problematic, resulting in the full stroke negative pressure operation of the hydraulic cylinder in the pitching range, and the center of gravity of the above part of the rotation deviates too much from the center of rotation, which will reduce the life of the large rotating bearing.    

解决方案：详细计算，重新核算配重。 Solution: Calculate in detail and recalculate the counterweight.

16 电控系统 16 Electronic control system