斗轮堆取料机使用维护说明书.doc

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1、1 斗轮堆取料机使用维护说明书 二零一八年四月二零一八年四月 2 目目 录录 ContentsContents 1 1 设备环境及性能设备环境及性能 Environment and functions of equipment 2 2 主要结构和技术参数主要结构和技术参数 Main structure and technical data 3 3 工作原理与机构概述工作原理与机构概述 Working principle and constitution 4 4 斗轮机使用说明斗轮机使用说明 Operation instruction about the bucket wheel stacker

2、 and reclaimer 5 5 操作及维护说明操作及维护说明 operation and maintenance specification 6 6 易损件明细表：易损件明细表： List of wearable parts: 3 本文仅对机械部分安全操作、检查维护等方面作以说明。(该机电气控制系统另见 臂式斗轮堆取料机电气说明书) The instruction only describes the safety operation, inspection and maintenance of the mechanical part.(instruction of electrical

3、 control system is in the electrical instruction) 1.1. 设备环境及性能设备环境及性能 EquipmentEquipment environmentenvironment andand functionsfunctions 1.1 环境 climatic condition 周围气温 ambient temperature：max 40.8C 相对湿度 relative humidity： 84% 工作环境：极端积满灰尘和腐蚀性 Working condition: extremely dirty and causticity 工作风速 wo

4、rking wind speed： 70Km/h 非工作风速 non-working wind speed：120Km/h 1.2 设备性能 Equipment functions 堆料能力 stacking capacity：1200 t/h 取料能力 reclaiming capacity： 300t/h 回转半径 slewing radium： 35 m 回转角度 slewing angle： 110 物料： 煤 material: coal 粒 度 granularity： 050mm 密 度 density： 0.650.78t/m3 堆 积 角 repose angle： 3550

5、 含水率 humidity： 29.240% 堆高： 轨上：12m 轨下：1.5m height of pile: up rail 12m down rail 1.5m 轨距 rail distance： 7 m 轨道型号 rail type：50kg/m 走行距离：约 146 m travel distance: appr. 146m 4 尾车型式：半趴式单尾车，折返取料 type of tripper: fix type 供电方式：电缆卷筒 power supply: cable drum 供电电压 supply voltage： 6000v 50Hz 供电位置： 料场中部 power s

6、upply position: center of material yard 地面带式输送机：（理论带面距轨顶）：1000mm ground belt conveyor: (from top plane of horizontal idlers of upper idlers to top of the rail) 带宽 width：1400 mm 带速 speed：2.5 m/s 2.2. 主要结构和技术参数主要结构和技术参数 mainmain structurestructure andand technicaltechnical datadata （1）主要结构 main struct

7、ure 臂式斗轮堆取料机主要由斗轮机构、上部金属结构、悬臂带式输送机、俯仰机构、 转台、回转机构、门座、行走机构、中心落料斗系统、半趴式折返尾车、放缆系 统、 电气室、司机室、润滑系统、洒水系统、检测系统、配重、电控系统、电缆卷筒 等 部分组成。 （见图 d696p） cantilever bucket wheel stacker and reclaimers are composed of bucket wheel unit, boom, cantilever belt conveyor, hydraulic luffing unit, slewing driving unit, gate

8、seat frame, traveling mechanism, middle material feeding tripper, semi-grovel back-folding tail car, cable system, electronic room, operating room, lubrication system, spraying system, examination system, weighting system, electronic control, cable reel, and etc.(see attached drawing d696) （2）斗轮机构 (

9、单向运行) bucket wheel mechanism (single direction running) 斗轮转速 rotary speed of bucket wheel： 7.5 r/min 斗 子 数： 8 个 number of bucket: 8pcs 5 驱动装置：37Kw （电动机+偶合器+减速机） driving unit type: motor+coupling+gear reducer （3）悬臂胶带机(双向运行 重锤拉紧) cantilever belt conveyor (double directions running, gravity take-up) 驱动

10、装置：75Kw （电动机+偶合器+制动器+减速机） driving unit: 75kw (motor+coupling+break+reducer) 带 宽 width：B=1400 mm 带 速 speed： V=2.8 m/s （4）俯仰机构 luffing mechanism 型 式：整体平衡液压俯仰 type: incorporate balance hydraulic luffing type 俯仰角度：满足堆高要求约 12.91+9.33 luffing angle: meet the requirements of material height. Appr. - 12.91+

11、9.33 仰俯速度：（斗轮中心处）约 5m/min luffing speeed: (center of the bucket wheel) appr. 5m/min 油缸型式： 双作用缸 oil cylinder type: double functions cylinder （5）回转机构 slewing mechanism 回转机构型式：三排滚柱式回转支承，外齿传动 type of slewing mechanism: three lines roller slewing support, outer teeth driving 回转角度 slewing angle：110 回转半径：（

12、从回转中心到斗轮中心）35m slewing radium: (from slewing center to bucket wheel center) 驱动方式：电动机+安全联轴器+制动器+减速机+开式齿轮传动 driving pattern: motor+coupling+brake+gear reducer+open gear 驱动功率 driving power：15 Kw 行走机构 carriage traveling mechanism 行走速度： 工作6 m/min，调车30m/min 6 traveling speed: working 6m/min, shunting 30m/

13、min 驱动方式： FLENDER“三合一”减速机(8 驱动 变频调速电机) driving method: FLENDER triad gear reducer (8 driving, variable frequency speed adjustable motor) 驱动功率 driving power： 8X5.5kw （6）尾车 tripper 尾车型式：半趴式折返尾车 type of tripper: fixed single tripper 尾车俯仰方式：双油缸同步工作 Luffing pattern of tripper: double cylinder working 尾车最

14、大倾角 ma. Inclined angle： 14 带宽 width：1400mm （7）中心落料斗系统 center material dropping hopper unit 带电动推杆的挡料板装置。 Swing chute with electrical push bar. （8）供电方式 power supply method 电缆卷筒，上机电压为：6000V 50HZ cable drum. Voltage to machine is 6000V and 50HZ. 控制方式 control method （9）机上半自动控制和手动控制 control aside machine,

15、 program control and manual control （10）装机总功率 total power： 约 240 kW 最大负荷功率 max. loading power：180kW 3.3. 工作原理与机构概述工作原理与机构概述 WorkingWorking principleprinciple andand mechanismmechanism summarizesummarize 臂式斗轮堆取料机是在长形料场中，利用走行，俯仰，回转三大运动，旋转斗 轮装置，将料场中的物料取出，卸到悬臂带式输送机上，再经过地面胶带机运出， 完成取料作业（此时尾车悬臂处于主机下方） ；堆料时

16、，地面胶带机的物料由来料 尾车卸到悬臂带式输送机上，悬臂带式输送机逆向运行。同样利用走行，俯仰，回 转三大运动，将物料按要求堆积到料场中（此时尾车悬臂处于主机上方） 。 Through traveling, luffing and slewing of this kind of equipment, we 7 rotate the bucket wheel unit to reclaim the material from yard, and discharge the material to the belt conveyor. Through ground belt conveyor it

17、 realizes reclaiming function. The belt conveyor can run along double directions. While stacking, the material on the ground belt conveyor is discharged from feeding tripper to cantilever belt conveyor. According to the above three functions-traveling, luffing and slewing, the material is stacked to

18、 the yard. The material can be transported back to ground belt conveyor to front according to the requirements by tee hopper. Or the material partly be transported back to the ground belt conveyor, partly transported to the yard. It has directly through and material divided functions. 3.1 斗轮机构 bucke

19、t wheel mechanism 斗轮机构安装在悬臂梁的前端，随悬臂梁一起俯仰和回转,以挖取不同高度和角度 的物料。斗轮机构主要由斗轮装配、圆弧挡板、导料槽、斗轮轴装配、斗轮驱动装置 等组成。 The bucket wheel mechanism is installed in front of the cantilever beam. It can luff and slew together with the cantilever beam to dig different height and angle material from the pile. The bucket wheel

20、 mechanism is mainly composed of bucket assemble, material hopper system, arc guard plate, discharging chute, bucket wheel shaft, bucket wheel driving unit, and etc. 斗轮型式为无格式。利用圆弧挡料板调整装置，可调整圆弧挡料板与斗轮体之间 的间隙约 5mm，以保证即不漏料，又不卡阻。导料槽溜料板与水平面夹角为 56，并 设有耐磨衬板，厚度为 12mm，可更换。 Bucket wheel type has no pattern. By

21、 adjusting the arc guard plate, the clearance between arc guard plate and bucket wheel (appr. 5mm) could be adjusted to guarantee no material leakage and no block. The angle between material discharging chute and horizontal plan is 56. The thickness of the wearable liner is 12mm and it is very easil

22、y to change. 3.2 上部金属结构 upper metal structure 上部金属结构是转台以上的俯仰部分，支撑斗轮机构、悬臂胶带机和配重部分。 8 主要由前臂架、门柱结构、配重架、拉杆等组成。前臂架和配重架由两片工字型断面 的主梁和水平桁架组成，工字型主梁为板焊结构。水平桁架由槽钢和角钢组合焊成。 门柱结构中主要部分为箱型梁，保证足够的刚度和强度。变俯铰点处采用球面轴承支 承，并与俯仰机构铰轴共用一套手动润滑系统。 The upper metal structure is the luffing part above the slewing support. It bear

23、s the bucket wheel mechanism, cantilever belt conveyor and counter weight parts. It is mainly composed of front arm frame, gate column structure, counter weight frame and push lever. The front arm frame and counter weight frame are composed of two main beams with I cross section and horizontal truss

24、. I-type main beam is plate welding structure. The horizontal truss is welded by channel steel and angle steel. The box beam is the main part in the gate column structure to ensure the enough rigidity and intensity. The ball bearing supports the luffing hinge and use one set electrical lubrication s

25、ystem with slewing bearing. 3.3 悬臂胶带机 cantilever belt conveyor 悬臂胶带机双向运转。取料时,物料经斗轮挖取,通过导料槽转载到悬臂皮带机上, 悬臂皮带机将物料运送到中心漏斗,使物料转运给尾车配套地面带式输送机上；堆料时， 地面胶带机的物料由来料尾车卸到悬臂带式输送机上，悬臂带式输送机反向运行，将 物料按要求堆积到料场中。 The cantilever belt conveyor can run along double directions. While reclaiming, the bucket wheels dig the ma

26、terial and put it to the cantilever belt conveyor through discharging chute. The conveyor transports the material to the center hopper then to the ground belt conveyor. While stacking, the material on the ground conveyor is discharged to the cantilever conveyor through material feeding tripper. The

27、cantilever conveyor runs along the reverse direction to transport the material to the yard according to the requirements. 悬臂胶带机主要由驱动装置、托辊组、改向滚筒组、垂直张紧装置等组成。为保 证电机起动性能，实现电机带载过载保护，采用了限矩型液力偶合器，减速机输出轴 套挂于传动滚筒的轴上，驱动装置底座通过一摆杆支撑在回转平台上。 9 The cantilever belt conveyor is mainly composed of driving unit, idler

28、s, reverse pulley and vertical take-up units. In order to ensure the startup performance of the motor, realize the overload protection of the motor, the torque limit liquid coupling is used. The output shaft of the reducer is hung on the shaft of the driving pulley. The driving unit house connects w

29、ith the slewing platform through the swing link. 主要漏斗均装有衬板，以延长漏斗的使用寿命。悬臂胶带机上托辊槽角 35，并 配有自动调心托辊组，在斗轮导料槽及中心漏斗下部设置了缓冲托辊组。悬臂皮带机 设有跑偏开关，紧急拉绳开关，中部设有打滑检测和料流检测装置开关及纵向撕裂检 测器。传动滚筒表面为菱形花纹胶面。 The liners are installed in the main hoppers to prolong the service life. The trough angle of the carrying idler is 35,

30、with automatic alignment idlers fixed on cantilever belt conveyor and baffling idlers set fixed on the lower part of bucket wheel chute and center hopper. Distracting switch and emergency switch are fixed on cantilever belt conveyor; sliding detector, block detector, and anti-torn detector are fixed

31、 in the middle part. The surface of transmission pulley is diamond rubber. 3.4 俯仰机构 luffing mechanism 俯仰机构是调整斗轮及上部金属结构工作位置的机构。俯仰机构采用液压油缸 式。液压系统采用双油缸的结构型式。 油缸上部与上部金属结构中的门柱铰接， 下部与转台铰接。液压站布置在转台平台上。 The luffing mechanism is for adjusting the working positions of bucket wheel and upper metal structure. T

32、he luffing mechanism is hydraulic oil cylinder type. The structure of the hydraulic system is double oil cylinders type. The upper of cylinder hinged with the gate column of upper metal structure, the lower part hinged with slewing platform. The hydraulic station fixed on the slewing platform. 3.5 转

33、台 Slewing platform 和门座 gate seat body 转台和门座均为箱型梁结构。门座为四点支撑形式，为便于运输，转台和门座厂 内整体加工后分为左右两部分。现场组焊并进行探伤检查。 10 Slewing platform and gate seat are both of box type beam structure. The gate seat is of four-point-supporting type. In order to transport easily, the slewing platform is divided into left and righ

34、t two parts after whole machined in workshop. It will be welded at site and ultrasonic defection test will be done at site. 3.6 回转机构 slewing mechanism 回转机构由回转支承和回转驱动装置两大部分组成。回转支承采用三排滚柱式回 转支承。回转驱动装置采用电动机+安全联轴器+制动器+减速机+开式齿轮传动，加长 轴上的小齿轮与固定在门座体上的回转支承外齿圈啮合，从而完成堆取料过程中的回 转运动。变频调速电机可按 1/cos 规律变频调速，以保证恒定的生产能

35、力。因结构 限制，本机回转角度限定为 110。 The rotary mechanism is composed of slewing support and slewing driving unit. The slewing support is three lines roller support. Big load bearing capacity, impact structure, small rotary resistance and long service life are the main advantages for the support. The slewing dri

36、ve unit composed of motor, safety coupling, brake, gear reducer, and open gear box. The pinion on lengthen shaft mesh with the ring gear of slewing bearing fixed on the portal frame to perform the slewing motions during stacking and reclaiming process of the equipment. Frequency conversion motor can

37、 adjust the speed by the rule of 1/cos to ensure the constant capacity. Restricted by the structure, the slewing limit angle is 110. 3.7 尾车 tripper 尾车为半趴式折返尾车，主梁在中间部位以铰连接，主梁前半部位的起伏由两个 油缸完成。堆料作业时，尾车主梁前半部位升起，取料作业时，尾车主梁前半部位俯 下。整个尾车用挂钩装置与主机相连,工作时挂钩将主机与尾车锁紧，尾车变换时挂钩 松开。主梁前半部位的起伏与挂钩装置共用一套液压系统，油箱布置于尾车底梁平台 上

38、。 The tripper is fixed single tripper. The main beam hinged at the middle part, and the floatation of its former part is realized by the two cylinders. When stacking, the former part of the main beam of tripper 11 hoists; when reclaiming, the former part of the main beam of tripper falls. The whole

39、tripper is connected with the body part by hoop unit. The hoop locks the body part and tripper when working, and the hoop unlocks when tripper changing. 尾车平台设液压站电控箱一个，内设有按钮站，用于操作尾车主梁前半部位的升 降动作和尾车挂勾装置的挂勾和脱勾动作。 One electrical control box for hydraulic station is fixed on tripper platform, in which swi

40、tches station is fixed for the operating of hoisting and falling of the former part of trippers main beam, and locking and unlocking of hoop unit of tripper. 尾车主梁前半部位的起伏工作顺序为： The floatation sequence of the former part of trippers main beam: 堆料时：两挂钩装置脱钩大车前进（工作速度）两尾车变幅油缸上升 大车后退（工作速度）两挂钩装置挂钩 Stacking:

41、 unlock the two hoops-big car walks forward (working speed)- amplitude cylinder of two tripper hoisting-big car walks backward( working speed)- lock the two hoops 取料时：两挂钩装置脱钩大车前进（工作速度）两尾车变幅油缸下降 大车后退（工作速度）两挂钩装置挂钩。 Reclaiming: unlock the two hoops-big car walks forward (working speed)- -amplitude cylinder of two tripper falling-big car walks backward( working speed)- lock the two hoops 尾车平台上安装有动力电缆卷筒装置与控制电缆卷筒装置、及高、低压电气室和 洒水系统。 P