First, the scale conveyor conveyor repair process scale conveyor is a commonly used equipment in the foundry industry, it is mainly used for casting, coke, ore and other material transfer transmission equipment, our plant this device is currently a more typical type of BL continuous Slat conveyor, which is mainly composed of drive device, drive sprocket and chain, frame, belt plate, tension sprocket and so on;
Second, the maintenance process
1, repairs are as follows:
Replace part of the slats and related parts, replace the tension sprocket assembly, re-prepare the tension sprocket bracket, base and replace it, replace all the tracks, frame; replace reducer, coupling;
2. According to the arrangement of equipment repair work, this repair work requires maintenance of 5 fitters, among whom 2 are able to skillfully use electric and gas welding tools, have excellent operating technology and hold special operation certificates, 1 electrician and 1 Tianchang.
3. For the demolition work of the equipment, cut off the power supply according to the following sequence, hang the police card, disassemble the motor, reducer, loosen the tension, remove the slats, transmission, tensioning device, track, frame, etc. Place the disassembled parts centrally in the designated site; in the disassembly process of the equipment, the work must be performed strictly in accordance with the safety operating procedures.
4, the installation of equipment and technical requirements are as follows:
1) Installation of the drive device: First, the drive device should be fixed according to the drawing requirements; (When the machine base is adjusted, use the points of electric welding on the embedded part, and the base can not easily move.)
2) Technical requirements:
The tolerance of the verticality of the center line of the drive sprocket to the center line of the conveyor (in the length per meter) ≤ 1mm;
The lateral center between the two sprockets is limited to the concentricity tolerance of the conveyor centerline ≤±1 mm. Drive sprocket shaft installation inclination tolerance ≤ 1mm;
The axial misalignment of meshing gear should be less than 4mm, and the tooth meshing contact surface must reach more than 60%;
The parallel tolerance of the drive shaft and sprockets should be <0.2/1000.
Bearings in the operation of the slat conveyor need to bear 20 to 50 tons of load, 15 ~ 20KN of traction, with high precision, need to be scraped before installation, in accordance with the requirements of the process in 25 × 25mm 16 ~ 20 scraping points; when the scraped bushes are rotated with a force of 100~150 N, the shaft should rotate evenly and smoothly in the bearing without noise. Lubrication must be added to the bearing during assembly to prevent the bearing surface from scratching.
3) Adjust the sprocket tensioning device and assembly requirements Determine the position of the tensioning device according to the drawing requirements. Take the driving sprocket shaft as a reference, take the center point between the two sprocket in the axial direction of the two sprockets and the center of the two sprocket gear teeth to the direction of the tensioning device respectively (wire) and fix it. The tightness of the steel wire is appropriate to determine Tensioning device, relative position of rack and track. Adjust the horizontal position of the tensioner frame, tighten the relative position of the device and the drive device and the track, and fix the tension device;
skills requirement:
The tolerance of the verticality of the sprocket shaft to the longitudinal centerline of the conveyor is ≤1mm; the tolerance of the coincidence between the transverse centerline of the two sprocket and the centerline of the conveyor is ≤±1mm.
The tolerance of the inclination of the tensioning axle (in terms of length per meter) ≤ 1 mm. The two pieces should be able to slide freely between the adjustment frames without jamming and pinching.
The centerline of the tensioning sprocket's adjustment slider must be on the centerline of the slat conveying section, and its coaxiality error is < 2MM. After the sprocket is adjusted in position, it must be fixed with a jacking thread or a positioning block.
Tension sprocket adjustment slider construction centerline must be on the centerline of the slat transport, seven concentricity error <2mm. After the sprocket has been adjusted in position, it must be fixed with a jacking thread or a positioning block.
4) Assembly of the slat conveyor section requires that the center of the roller axis of the screed be vertically 1/1000 of the centerline of the conveyor set.
The tilt of the roller shaft allows 1/1000 tea. The fit of the roller inner sleeve and the roller cannot slide or rotate. The end of the inner sleeve must be at least 0.5~1mm higher than the outside, and the roller must be assembled by press-fitting.
A clearance of 0.5~1mm must be ensured between the two chain plates to ensure that the rollers will not be pinched when they are on the track or climbing.
5) Installation requirements for rails and brackets The tolerances of the centre line of the track to the slat conveyor are <1 mm and the wheel-rail tolerance is 2 mm. The straightness tolerance per meter length of track is < 5mm. The relative elevation tolerance of the two tracks in the same cross-section is ≤ 2 mm. The tolerance of the longitudinal inclination of the track in the horizontal section is 1/1000 to 1/1500 of the length, but the tolerance in the full length is ≤10mm.. The joint of the running track should be smooth and smooth, and its left and right offset tolerance should be ≤1mm; Up and down offset tolerance ≤ 0.3mm. In addition to the use of bolts, the fixation in the rail climbing area must be clamped and fixed with a pressure plate at a distance of 300 to 800 mm and welded to the bracket.
6) Rack: The centerline of the centerline of the rack and the longitudinal axis of the conveyor should be completely coincident with a tolerance of <2mm for its concentricity. On the horizontal section of the conveyor, the tolerance of the installation plane height of the upper support bearing track on the rack column is 1/1000 to 1.5/1000 according to the distance between the upper and the lower ends of the conveyor. Parallel reading of two adjacent racks does not exceed 2mm. On each meter length, the error of the rack's lateral inclination does not exceed 1 mm. The value of the squareness of the installed floor of the home team is less than 2mm; the connection between the rack and the track is welded, and the seam must be fully welded. The weld length is not less than 90% of the weld face length. Welds should be uniform, smooth, and smooth. The drive unit frame and the tensioner frame must have sufficient welding strength with the embedded steel plate on the ground.
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Second, the maintenance process
1, repairs are as follows:
Replace part of the slats and related parts, replace the tension sprocket assembly, re-prepare the tension sprocket bracket, base and replace it, replace all the tracks, frame; replace reducer, coupling;
2. According to the arrangement of equipment repair work, this repair work requires maintenance of 5 fitters, among whom 2 are able to skillfully use electric and gas welding tools, have excellent operating technology and hold special operation certificates, 1 electrician and 1 Tianchang.
3. For the demolition work of the equipment, cut off the power supply according to the following sequence, hang the police card, disassemble the motor, reducer, loosen the tension, remove the slats, transmission, tensioning device, track, frame, etc. Place the disassembled parts centrally in the designated site; in the disassembly process of the equipment, the work must be performed strictly in accordance with the safety operating procedures.
4, the installation of equipment and technical requirements are as follows:
1) Installation of the drive device: First, the drive device should be fixed according to the drawing requirements; (When the machine base is adjusted, use the points of electric welding on the embedded part, and the base can not easily move.)
2) Technical requirements:
The tolerance of the verticality of the center line of the drive sprocket to the center line of the conveyor (in the length per meter) ≤ 1mm;
The lateral center between the two sprockets is limited to the concentricity tolerance of the conveyor centerline ≤±1 mm. Drive sprocket shaft installation inclination tolerance ≤ 1mm;
The axial misalignment of meshing gear should be less than 4mm, and the tooth meshing contact surface must reach more than 60%;
The parallel tolerance of the drive shaft and sprockets should be <0.2/1000.
Bearings in the operation of the slat conveyor need to bear 20 to 50 tons of load, 15 ~ 20KN of traction, with high precision, need to be scraped before installation, in accordance with the requirements of the process in 25 × 25mm 16 ~ 20 scraping points; when the scraped bushes are rotated with a force of 100~150 N, the shaft should rotate evenly and smoothly in the bearing without noise. Lubrication must be added to the bearing during assembly to prevent the bearing surface from scratching.
3) Adjust the sprocket tensioning device and assembly requirements Determine the position of the tensioning device according to the drawing requirements. Take the driving sprocket shaft as a reference, take the center point between the two sprocket in the axial direction of the two sprockets and the center of the two sprocket gear teeth to the direction of the tensioning device respectively (wire) and fix it. The tightness of the steel wire is appropriate to determine Tensioning device, relative position of rack and track. Adjust the horizontal position of the tensioner frame, tighten the relative position of the device and the drive device and the track, and fix the tension device;
skills requirement:
The tolerance of the verticality of the sprocket shaft to the longitudinal centerline of the conveyor is ≤1mm; the tolerance of the coincidence between the transverse centerline of the two sprocket and the centerline of the conveyor is ≤±1mm.
The tolerance of the inclination of the tensioning axle (in terms of length per meter) ≤ 1 mm. The two pieces should be able to slide freely between the adjustment frames without jamming and pinching.
The centerline of the tensioning sprocket's adjustment slider must be on the centerline of the slat conveying section, and its coaxiality error is < 2MM. After the sprocket is adjusted in position, it must be fixed with a jacking thread or a positioning block.
Tension sprocket adjustment slider construction centerline must be on the centerline of the slat transport, seven concentricity error <2mm. After the sprocket has been adjusted in position, it must be fixed with a jacking thread or a positioning block.
4) Assembly of the slat conveyor section requires that the center of the roller axis of the screed be vertically 1/1000 of the centerline of the conveyor set.
The tilt of the roller shaft allows 1/1000 tea. The fit of the roller inner sleeve and the roller cannot slide or rotate. The end of the inner sleeve must be at least 0.5~1mm higher than the outside, and the roller must be assembled by press-fitting.
A clearance of 0.5~1mm must be ensured between the two chain plates to ensure that the rollers will not be pinched when they are on the track or climbing.
5) Installation requirements for rails and brackets The tolerances of the centre line of the track to the slat conveyor are <1 mm and the wheel-rail tolerance is 2 mm. The straightness tolerance per meter length of track is < 5mm. The relative elevation tolerance of the two tracks in the same cross-section is ≤ 2 mm. The tolerance of the longitudinal inclination of the track in the horizontal section is 1/1000 to 1/1500 of the length, but the tolerance in the full length is ≤10mm.. The joint of the running track should be smooth and smooth, and its left and right offset tolerance should be ≤1mm; Up and down offset tolerance ≤ 0.3mm. In addition to the use of bolts, the fixation in the rail climbing area must be clamped and fixed with a pressure plate at a distance of 300 to 800 mm and welded to the bracket.
6) Rack: The centerline of the centerline of the rack and the longitudinal axis of the conveyor should be completely coincident with a tolerance of <2mm for its concentricity. On the horizontal section of the conveyor, the tolerance of the installation plane height of the upper support bearing track on the rack column is 1/1000 to 1.5/1000 according to the distance between the upper and the lower ends of the conveyor. Parallel reading of two adjacent racks does not exceed 2mm. On each meter length, the error of the rack's lateral inclination does not exceed 1 mm. The value of the squareness of the installed floor of the home team is less than 2mm; the connection between the rack and the track is welded, and the seam must be fully welded. The weld length is not less than 90% of the weld face length. Welds should be uniform, smooth, and smooth. The drive unit frame and the tensioner frame must have sufficient welding strength with the embedded steel plate on the ground.
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