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Typical failure analysis and processing of belt conveyor
Lihua ZHAO?,Yin LIN
School of Mechanical Engineering, Northeast Dianli University, Jilin City, Jilin Province Changchun Road 169,132012,China
Abstract:
The paper analyzes two typical failure forms of roller and conveyor at the belt conveyor, and describes the maintenance methods of prevention and elimination failures to ensure the normal operation of belt conveyor.
1. Introduction:
Belt conveyor is a commonly used equipment of continuous transport, it has a high efficiency and large conveying capacity, simpler construction, small amount of maintenance. Can be achieved at different distances, different materials transportation. It iss widely used in mining, coal handling system in thermal power plant and other projects. Belt conveyor will often occur some typical problems in the course, this paper Based on research common typical failure of belt conveyor during use, analysis the cause of failure, proposed some effective methods to solve the problem.
2. Typical faults of conveyor belt:
2.1. Conveyor belt deviation
In the belt conveyor, as the conveyor belt is traction components, transmit power and motion, also is carrying components, support material load. Working more complex, so at work often happen belt deviation. Deviation is the conveyor belt during operation, the center line of belt deviation the center line of conveyor. As the conveyor belt deviation may cause between the belt edge and rack wear, cause belt edge premature damage, Ranging impact the life of conveyors, affect the throughput of materials, Weight is caused by withdrawal material, even happen stop occurrence, direct impact on production. As the conveyor belt is more important, the most expensive parts. Its price about 25%~50% to the conveyor. So analysis the reasons of belt deviation, reduce and eliminate belt deviation, It is an important part of ensure belt to work, extend equipment life. Cause the belt occurs deviation because of the following factors.
2.1.1. In the device itself
a. Rack rigid is poor, large deformation under load, causing the belt deviation.
b. The larger error of roller outer cylindrical, caused deviation when the conveyor belt running.
c. The supporting roller rotation is not flexible, causes the conveyor belt both sides stress to be uneven, causes the conveyor belt deviation.
d. The parallelism error cylindrical axis and roller axis is too big, causes the conveyor belt deviation.
e. Conveyor belt itself is questionable quality, thin and thick uneven, caused a shock lead running conveyor belt deviation.
f. Conveyor belt manufacturing quality have defects, the length of belt both sides edge is inconsistent, cause running conveyor belt deviation.
g. Not parallel with belt connector, connection error is too big, cause belt deviation.
2.1.2. Installation adjustment
a. Drive, change roller axis and conveyor centerline vertical error is too big, make conveyor and horizontal line have a bigr inclination, cause belt deviation.
b. Roller axis and conveyor centerline vertical error is big, will cause belt deviation also.
c. The connection strength between rack and ground is not enough, the rack unstable, causing belt deviation.
d. The feeding plate of discharge trough and improperly located, both sides of the conveyor belt uneven force cause belt deviation.
2.1.3. With maintenance
a. The cleaning performance of sweeper is poor, make the roller cylindrical diameter local increases.
b. Feeding mouth location is wrong, so that the material partial load on the conveyor belt, cause belt deviation.
c. Poor maintenance and improper adjustment, resulting in the conveyor belt deviation.
d. For the steel cord belt, as the manufacture of steel cord is uneven force, so that a deviation occurs in the operation, or a strong difference of belt, large elongation under load, causing the vibration, the belt will deviation.
e. Also, the vibration of running conveyor belt system can cause the deviation.
f. In addition, when conveying some viscous material, make the roller, etc. bonding materials, make the cylindrical diameter of roller part increases, causing belt deviation.
2.2. Measures to prevent the belt deviation
2.2.1. Due to equipment in the manufacture of conveyor belt causes the deviation, primarily through improved design, manufacture precision to prevent and reduce the occurrence of conveyor belt deviation.
2.2.2. For installation adjust improper and daily use causes deviation, mainly the following aspects should be considered:
Conveyor belt in drive roller or on rear rollers deviation, usually by adjusting the position of the roller bearing ways to eliminate, usually by adjusting the position of the roller bearing ways to eliminate.
a. The longitudinal centerline of the roller rotation axis and conveyor is not perpendicular, resulting in the conveyor belt one side loose and the other tight, belt move from the tight side to the loose side, Occurs deviation phenomenon. Should be adjusted bearing position of the tighten deviation side. Make horizontal pull of belt equal, eliminate deviation. When tail roller is spiral tensioning, the reasons of tail deviation may be due to the top tight power of tensioning device both sides screw rod are not equal, resulting in caused by imbalance.
b. Cylinder axis is not horizontal, at both ends bearing of the height difference is cause another reason of head or tail deviation. At this point, at both ends roller bearing should add and subtract shims way to leveling roller axis ,to eliminate conveyor belt deviation.
c. Roller surface adhesion material, equivalent to increasing the roller local rdiameter, will cause the conveyor belt deviation, should strengthen empty segment cleaning of conveyor belt to reduce the adhesive material or dust accumulation on the conveyor belt. In addition, the conveyor belt between the nose and tail parts deviation, called central or local deviation. Such deviation reasons is more complex, it is with the conveyor belt along device exposure to a relationship. Need a detailed analysis for specific issues. Using the following methods can resolve these issues.
A. Load or no-load branch roller axis with the conveyor belt running centerline is not perpendicular, causing tape at the roller deviation. Deviation ends should adjustment to the conveyor belt running direction. At this time often need to adjust the adjacent groups of rollers in order to achieve the purpose of eliminating deviation, adjusting deviation angle should not be too big.
B. Conveyor belt joint with the tape centerline (trumpet) is not perpendicular, to cause the deviation, Should improved installation connection accuracy to eliminate deviation.
C. If material loaded on the conveyor belt is straight; make the material block and weight distribution along bandwidth direction distribution serious inequality, cause deviation, through adjustment blanking tube and skirt plate location method to be eliminated.
D. Recently, it was suggested that the method of application film for transfer partial conveyor belt, because of high manufacturing costs and some technical problems not well solved, makes this method very difficult to promote the use.
3. The typical failure of roller:
3.1. Operation is not flexible
Each belt conveyor have lot number rollers, installation shown in Picture 1, their work status directly affects the conveyor is working. According to the actual work of conveyor, roller in the conveyor system can be classified four kinds according their efect, trough roller, parallel roller, buffer roller and self-aligning roller; according to the loads case can be divided two kinds, no-load roller and bearing roller. Trough roller use bearing branches of materials, play a supporting role and increased throughput role.
Parallel roller is a long-shaped roller, for no-load branch of conveyor, to play a supporting role of no-load branch tape; buffer roller is trough roller too. Flexible support trough roller be installed on conveyor load branch, Installed in the material office. Reduce the impact of material for conveyor belt, protect the tape and support bearing. Generally based on the elastic support were divided into rubber ring and spring plate; the role of self-aligning roller is a certain degree of automatic adjustment of conveyor belt deviation, To avoid excessive wear of belt and materials scattered. In the load and no-load branch are equipped with a number of self-aligning roller. The self-aligning principle shown in Fig. 2..
Manufacture installation quality of roller directly affect the life and running resistance of conveyor belt. roller repair and replacement costs are also an important part of conveyor belt operating expenses. The roller operation quality for conveyor of the running resistance, power consumption, roller and belt life, maintenance workload and cost of transportation has a significant impact. Therefore, analysis method to extend the service life of rollers, also an important contents to ensure stable operation of belt conveyor, practical significance in engineering. Trough roller of belt conveyor systems used on material bearing branch, play supporting role and increased throughput role. Parallel roller is a long-shaped roller, for no-load branch of conveyor, to play a supporting role of no-load branch tape; buffer roller is trough roller too. Flexible support trough roller be installed on conveyor load branch, Installed in the material office. Reduce the impact of material for conveyor belt, protect the tape and support bearing. The role of self-aligning roller is a certain degree of automatic adjustment of conveyor belt deviation, To avoid excessive wear of belt and materials scattered. In the load and no-load branch are equipped with a number of self-aligning roller. If roller appear rotating not flexible or not turning phenomenon. The drag coefficient of roller operation by rolling into a slide, value was ten times to increase. The results will result in increased running resistance of belt conveyors, electric power consumption increases. As the roller rotation is not flexible, the friction between roller and conveyor belt by rolling friction into sliding friction, make the friction increase between the two, shorten the equipment life . Therefore, we must often replace a large number of idlers, conveyor belt, resulting in increased equipment maintenance, operating costs increased.
Many factors for affect the flexibility of running rollers and life span, summarized in the following areas:
a. Manufacturing quality of roller
Roller manufacturing problems mainly in the bearing stiffness is not enough, it is difficult to ensure
precision of roller assembly, thereby constraining the flexibility of running roller.
b. Sealed lubrication and the use of maintenance
Main factors of affect roller rotation not flexible include sealing and bearing lubrication problem. As the work environment of belt is more severe. Generally speaking, the dust are great on used site. The seal form of bearing have a great influence on the running flexibility for rollers. If sealed not well, Dirt is easy into bearing to cause the roller rotation is not flexible, In addition, bearing grease if using the general calcium base grease is easy to change color to dry, can not play a very good lubricant role.
3.2. Solutions
a. In the roller manufacturing processes guarantee the accuracy requirements, For example, pressing bearing bore to achieve three precision, tube at both ends of dimensional tolerances, concentricity and ovality must meet national standards. The products have strict quality inspection to ensure that all
products qualified.
b. Sealed lubrication, in addition to manufacturing quality assurance, go with good lubricating materials, such as use of lithium-based grease, can improve the lubrication of bearings which extend the life of the roller is necessary.
c. Bearing used to ball bearings support, plastic sealing ring labyrinth seal structure, this can ensure roller worked reasonable force, While ensuring dust effect good, resistance small, easy assembly and disassembly, easy to maintain, reduce conveyor operating costs.
4. Conclusion:
Wide range applications of belt conveyors, and the work environment is generally more difficult, to keep equipment running in good working condition, extend equipment life, improve the quality of operation, reduce operating costs has been the goal of engineering and technical personnel. Analyze and resolve the impact normal operation of the main problems, to ensure the good functioning of device, it is an important work of equipment maintenance. This paper analyzes the proposed method. Helpful improve site maintenance staff levels to solve practical problems, for practical project has important significance.
References:
[1] yixiang Lang. Transportation machinery equipment in thermal power plant.[M]Northeast dianli university book; 1998.08.
[2] lihua Zhao. Operation and Maintenance of Coal Handl ing Sys tem in Thermal Power Plant , [J].Colliery Machine;2011,NO. 02.
[3]lihua Zhao. Typical failure analysis and processing of belt conveyor[J].Hoisting and Conveying Machinery;2003,NO 10.
[4] lihua Zhao. The adjustment method of conveyor belt deviation [J]. Colliery Machine. 2001. No.05.
帶式輸送機的典型故障分析與處理
趙麗華*林茵
中國吉林省，吉林市長春路169132012號，東北電力大學，機械工程學院
摘要：
本文分析了兩種帶式輸送機失效的典型形式：托輥和輸送帶。并介紹了預防和消除故障的維護方法，以確保帶式輸送機的正常運作。
1、介紹：
帶式輸送機是一種常用的連續(xù)輸送設備，它具有效率高、輸送量大、結構簡單、維修量小等特點?？梢詫崿F(xiàn)不同距離、不同材料的運輸。它們廣泛應用于礦山、火電廠輸煤系統(tǒng)等項目。帶式輸送機在運作中經常出現(xiàn)一些典型問題，本文在帶式輸送機使用過程中常見的典型故障的研究基礎上，分析失敗的原因，并提出了一些有效的解決問題的方法。
2、帶式輸送機的典型故障：
2.1.輸送帶的跑偏：
在帶式輸送機中，輸送帶作為牽引組件，它不僅傳遞動力和運動，也承載組件，支持負載。工作比較復雜，所以在工作中經常發(fā)生皮帶跑偏。跑偏是皮帶輸送機在運行過程中，輸送帶中心線的跑偏。由于輸送帶跑偏會使帶之間的邊緣和齒條磨損，從而導致帶邊緣的過早損壞，其影響包括影響輸送帶的壽命，影響材料的通量，撤出材料的重量，甚至發(fā)生停止運作的現(xiàn)象，直接影響到生產。作為輸送機最重要、最昂貴的零件，它的價格約占輸送機的25%～50%，因此皮帶跑偏的原因分析，減少和消除皮帶跑偏是確保帶工作，延長設備使用壽命的一個重要部分。造成皮帶跑偏的因素有：
2.1.1.裝置本身：
a：機架剛性差，大負荷下變性，造成皮帶跑偏。
b：滾子外圓柱誤差較大，是輸送帶運行時發(fā)生偏差。
c：托輥轉動不靈活，是輸送帶兩側應力不均勻，導致輸送帶跑偏。
d：輥軸與圓柱軸的平行度誤差太大，導致輸送帶跑偏。
e：輸送帶本身的質量問題，薄厚不均勻，造成的沖擊導致運行輸送帶跑偏。
f：皮帶輸送機制造質量有缺陷，帶兩側邊的長度不一致，導致輸送帶運行時跑偏。
g：不平行的帶連接器，使連接誤差太大，造成皮帶跑偏。
2.1.2.安裝調整：
a：驅動，換輥軸和輸送中心線的垂直誤差太大，使輸送帶和水平線有一個傾斜，造成皮帶跑偏。
b：輥軸與輸送帶中心線的垂直誤差大，也會造成皮帶跑偏。
c：機架與地面之間的連接強度不夠，架身不穩(wěn)，造成皮帶跑偏。
d：送料盤的放料槽位置不當，兩側的輸送帶受力不均勻造成皮帶跑偏。
2.1.3維修：
a：清洗性能的清洗能力差，使?jié)L子的圓柱直徑變大。
b：進料口位置錯誤，使材料的部分載荷作用在輸送帶上，導致皮帶跑偏。
c：維修和調整不當，造成輸送帶跑偏。
d：對于鋼芯輸送帶，如過制造時鋼芯受力不均勻，則在運作中會發(fā)生跑偏，或者存在一個大的差異帶，在斷裂伸長率大載荷的作用下，產生振動，輸送帶會發(fā)生偏差。
e：輸送帶運行系統(tǒng)的震動也可引起跑偏。
f：此外，當輸送一些粘性物質如粘合材料時會使托輥圓柱滾子的外徑部分增大，造成皮帶跑偏。
2.2防止皮帶跑偏的措施：
2.2.1由設備在制造輸送帶時造成的偏差，主要通過改進設計方案，制造精度，以減少和防止輸送帶跑偏。
2.2.2安裝調整不當和日常使用造成的偏差，主要應從以下幾方面考慮：
輸送帶在驅動輥或后方輥的偏差，通常通過調整滾子軸承的位置進行消除。
a：輥軸的縱向旋轉中心線和輸送帶不垂直，從而使輸送帶的一側松，一側緊，帶從緊邊運動到松邊，發(fā)生偏差現(xiàn)象。應調整軸承緊偏差一側的位置，使皮帶水平拉力相等，消除偏差。當尾部輥螺旋張緊，尾偏差的原因可能是頂緊力張緊裝置的兩側螺桿不相等，從而造成不平衡。
b：氣缸軸線不水平，在兩個軸承兩端的高度差是造成頭部或尾部偏差的另一個原因。此時，兩端的滾子軸承應采用加減墊片的方法來平衡托輥，消除皮帶輸送機的跑偏。
c：托輥表面的粘附材料，相當于增加了托輥的本來直徑，這將導致輸送帶跑偏，應加強輸送帶空段的清洗，以減少粘附材料或輸送帶上的灰塵堆積。此外，輸送帶之間的鼻子和尾巴部分的偏差，稱為中央或局部偏差。這種偏差的原因是復雜的，它是與輸送帶呈接觸關系。需要對特殊問題進行詳細的分析。使用以下方法可以解決這些問題：
A：負載或空載的分輥軸與輸送帶的運行中心線不垂直，造成膠帶在滾筒上的偏差。偏差的兩端應調整輸送帶的運行方向。在這個時候，為了消除偏差，往往需要調整托輥的相鄰組，且調整角度的偏差不宜過大。
B：輸送帶接頭的中心線不垂直時，所造成的偏差，應改進安裝的連接精度來消除誤差。
C：如果材料在輸送帶上的載荷作用是豎直的，將使沿帶寬方向分布的材料塊的重量嚴重不均勻，產生偏差，通過調整下料管和主板的定位方法來消除。
D：最近，有人建議，采用應用膜的方法轉變部分的輸送帶，因為制造成本高和沒有很好的解決一些技術問題，使這種方法很難得到推廣使用。
3．典型的托輥失效形式：
3.1.操作不靈活：
每個皮帶輸送機都有很多托輥，安裝圖如1所示，其工作狀態(tài)直接影響輸送機的工作情況。根據(jù)輸送機的實際工作情況，托輥在輸送機系統(tǒng)中根據(jù)他們的影響可以分為四類：槽形托輥、平形托輥、緩沖托輥和調心滾子；根據(jù)負載情況可分為兩類：空載托輥和支撐托輥。槽形托輥使軸承材料分行，起到支撐作用和提高吞吐量的作用。
平形托輥是一個長方形，是輸送機空載時的分支，起支撐空載皮帶的作用。緩沖托輥和槽形托輥作用相同，槽形托輥靈活的安裝在負載段，并安裝在材料室。能減少材料對皮帶輸送機的影響，并保護帶和支撐軸承。根據(jù)彈性支撐一般可以分為橡膠密封圈和彈簧鋼板，調心滾子的在皮帶跑偏時有自動調整的作用，為了避免皮帶的過度磨損和材料的分散，在空載和負載段都配備了一些調心滾子。自動調心原理如圖2.
滾子軸承 物料 V型帶的運動方向
圖1：安裝示意圖 圖2：調心原理
托輥的制造和安裝質量直接影響到輸送帶的壽命和運行阻力，托輥的維修和更換成本也是皮帶輸送機運行費用的重要組成部分。托輥的運行質量對輸送機的運行阻力、功耗、托輥和皮帶的使用壽命、維修工作量和運輸成本等具有重大的影響。因此，分析延長托輥使用壽命的方法，也是一個確保皮帶輸送機穩(wěn)定工作的重要內容，在工程中有實際意義。皮帶輸送機中的槽形托輥使軸承材料分行，起到支撐作用和提高吞吐量的作用。平形托輥是一個長方形，是輸送機空載時的分支，起支撐空載皮帶的作用。緩沖托輥和槽形托輥作用相同，槽形托輥靈活的安裝在負載段，并安裝在材料室。能減少材料對皮帶輸送機的影響，并保護帶和支撐軸承，調心滾子的在皮帶跑偏時有自動調整的作用，為了避免皮帶的過度磨損和材料的分散，在空載和負載段都配備了一些調心滾子。如果托輥出現(xiàn)轉動不靈活或不轉的現(xiàn)象時，托輥將從滾動變?yōu)榛瑒?，其阻力系?shù)的值將增加十倍，其結果是導致皮帶輸送機運行阻力的增加，從而電力消費也增加。由于托輥轉動不靈活，托輥與皮帶間的滾動摩擦變?yōu)榛瑒幽Σ?，使兩者間摩擦力增大，縮短了設備的使用壽命。因此，我們必須經常更換大量的托輥、輸送帶，從而增加了設備的維修，經營成本增加。
影響托輥運行的靈活性和壽命的諸多因素如下：
a：托輥的制造質量
托輥的制造問題主要是在軸承的剛度不夠，很難保證托輥的安裝精度，從而限制了托輥運行的靈活性。
b：密封潤滑和使用維護
影響托輥轉動不靈活的主要因素包括密封盒軸承的潤滑問題，其工作環(huán)境是更嚴重的。一般來說，灰塵是最大的危害。密封形式的軸承對托輥運行的靈活性有重大影響，如果密封的不好，灰塵就容易進入軸承，使?jié)L子轉動不靈活。此外，軸承的潤滑劑如果使用普通的鈣基潤滑脂則很容易變色變干，不能起到很好的潤滑作用。
3.2.解決方案：
a：在托輥的制造過程中保證精度要求。例如：沖壓軸承孔時要達到三個精密，管兩端的尺寸公差、同性度和橢圓度必須符合國家標準。產品要有嚴格的質量檢測，確保產品合格。
b：密封潤滑。除了應保證制造的質量外，還要采用良好的潤滑材料，例如：鋰基潤滑脂，這樣對提高軸承的潤滑情況以及延長托輥的壽命是必要的。
c：軸承用滾珠軸承支撐，采用復雜結構的塑料密封圈可以確保托輥工作時受力合理，同時可以保證除塵效果好、阻力小、易于拆裝、便于維護，降低輸送機的運行成本。
4.總結：
帶式輸送機的應用廣泛，工作環(huán)境一般比較困難。保持良好的工作狀態(tài)，延長設備的使用壽命，提高運行的質量，降低經營成本，一直都是工程技術人員的目標。設備保養(yǎng)的重要工作是，分析和解決影響正常運作的主要問題，確保設備的良好運轉。本文分析了提出的方法，有助于提高現(xiàn)場維護人員解決實際問題的能力，對實際工程有重大意義。
參考文獻：
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