带式输送机安装工艺指导书.doc

带式输送机安装工艺指导书工艺名称Process name工艺要求Process request公差Tolerance 质量问题Quality Question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）According to the installation size of the belt conveyor,Verify installation base is in line with the requirements,Whether measuring installation based on the same horizontal plane(Refers to the horizontal) 水平面公差1/1000Level of tolerance 1/1000 地基水平Foundation Level可用垫片调整到水平为止Available shim adjustment at the level带式输送机安装中心线The center line of the belt conveyor installation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According to the requirements of assembly diagram of installation dimension,Its size is copied to the foundation,After draw the line,Confirmed by the test engineering quality inspection again 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3mmPulley and roller line to the center line of the conveyor frame vertical degree 2/1000,Two adjacent rollers diagonal 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Center head tail rack row first,Pop up the center line of belt conveyor with a soft line again,According to the center line on both sides of the picture frame and the leg line 头尾架Head and tail frame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）In the inspection qualified after the installation of the center line,The head and tail rack installation tools used for thousand pendant, spirit level, ruler, mainly measuring head and tail frame, pulley is in the same horizontal plane(request 1/1000),Then measure the verticality of cylinder axis of the center line of the conveyor(request 2/1000) 水平公差1/1000垂直公差2/1000The level of tolerance1/1000The vertical tolerance2/1000地基不平，头尾架变形The foundation uneven,Head to tail frame deformation地基不平可用垫片进行调整；机架变形可调整机架(1) the foundation uneven gasket available to adjust(2)the frame deformation adjustable frame 支腿landing leg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10mm100-300m,直线度30mm以内The first Detecting whether the leg transformation,Methods are the two pillar of diagonal measurement,If observed two columns on the same plane,After confirmed with no quality problem,According to the anchor line installation,After installation to ensure that the leg on either side of the column the straightness in arbitrary length of 25 m,tolerance of 5 mm,Conveyor length 100 m or less,straightness 10mm100-300m,Straightness of 30 mm 对角线4，在任意25m直线度5mm100m直线度10mm,100-300m直线度30mm以内Diagonal 4,In any 25 m straightness 5 mm or less 100 m straightness is 10 mm, 100-300 - m straightness within 30 mm 地基不平，支腿变形The foundation uneven,Head to tail frame deformation 用垫片调整地脚；修正支腿或变换 (1) with the gasket to adjust the anchor(2) correction of leg or change 中间架Middle Frame 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According to the figure fine blanking point location is determined,First installation and its corresponding to the middle of the frame,Then according to the numeral middle frame for installation,Install while measuring hole diagonal 4 mm or less,After the installation must be done by the quality inspection personnel qualified rear can carries on the next working procedure 两侧中间架水平度2/1000，安装托辊横梁孔的对角线公差4mmOn both sides of the middle 2/1000 levelness,Install idler beam hole diagonal tolerance of 4 mm or less 两中间架不在同一水平面上，对角线超差Two the middle frame is not in the same horizontal plane, diagonal error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Should be carefully adjusted, measurementNote:This is key technology in terms of conveyor running deviation or not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The request of installation about head and return pulley is flexible rotation水平度1/1000Levelness1/1000垂直度2/1000Vertical 2/1000滚筒转动不灵活；Pulleys rotation is not flexible垂直度超差Vertical beyond tolerance滚筒两侧瓦合用垫片进行调整到转动灵活为止；Adjust both sides of pulleys tile combination washer to flexible rotation检查划线是否有误，Check the dash whether have mistake用调整螺栓进行调整be adjusted by adjusting the screw托辊横梁及托辊convey frame and roller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）Carefully review the general assembly drawing,Notice the installation location of impact rollers, forward beams and excessive beam,spherical roller beams(spherical rollers both side cant install firstly) 输送带Conveyor belt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Conveyor must be strictly checked before installation to confirm turning whether flexible and reliable.Installation conveyors after confirmed.Transporting conveyor belts use With sharp tools or direct contact with wire rope is forbidden.Lifting can use penetration with a heart tube (pipe diameter80mm).Connector of conveyor belt use then paste sulfide by professional workers. 带边撕裂Band edge tear吊装工具不对，更换工具Lifting tools is wrong,change tools跑偏开关、拉绳开关Deviation switch,Rope switch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After installing conveyor belts ,and Before commissioning，deviation switch and rope switch must be installed successful.or commissioning is forbidden 驱动装置Drive means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Install buff drive and drive pulley，the log of two couplings must alignment.(This piece is pin coupling）Installation concentricity0.7mm，Add Lubricating oil as equipment request after installation.同心度0.7mmConcentricity0.7mm转动时颤动或两相邻的轴承发热Rotation fibrillation or two adjacent bearings heating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-adjust the position of drive means .Driving under the gasket in the frame while Down different heart,Mobile drive unit to slave Before and after different heart.The aim is to achieve the desired effectPloughunloader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，胶板探出刮板10-15mm，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Install plough unloader at feed opening,after installing, adjust it. rubber board is longer than scraper,about 10-15mm. Scraper and conveyor belt should be adjusted with no gap,before commissioning,lift the pough to reduce driving resistance. 试运行Commissioning运行前准备工作：preparation before operating 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；Check the driving device lubrication point,the injected oil grade and quantity to meet the requirements. 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、Check injected operation medium(oiled water) of fluid coupling quality,quantity,whether match the transmission power(should be added to the total volume of operation medium quality 75%-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、Check the brake shoe and brake wheel gap,whether meets the requirements of 1.5-3mm.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、Check the the steering of the gearbox input shaft,steering of inverted valve,meets the requirements. cold startup.五、检查跑偏开关、拉绳开关是否安装完毕；五Check the deviation switch and cord switch are installed.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Rotate the mechanical part of the transmisison is flexible,with or without stuck phenomenom.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、Check the basis and every bolts are fastening,weld is welding seamless,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、Check the electrical signal,electrical control protection,electrical insulation, whether meet the demands of electrical manual,move the motor,check the motor rotation direction. 启动电机后减速机不转动； After starting the motor,reducer doesnt rotate.整机无法启动； the conveyor cant be operated.启动后联轴器振动，轴承位发热升温超过40C（含环境温度）coupling vibration starts,bearing position heating temperature rising over 40 degrees.(including ambient temperature) 液力偶合器是否加够了介质数量，Fluid coupling add enough quantity of operation medium 有逆止器的带式输送机是否转向不对，check the belt conveyor with inverted valve is turning right. 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。 If the coupling vibration or bearing position is high temperature,re-adjust the concentricity of the coupling or bearing is lack of oil.空载运行中的观察内容及设备调整The observed and equipment adjust during no load operation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：During test run,you should scrutinize the service behavior of every part,find the problem and adjust it.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；Observe whether one part rub the other part,or off tracking,if off tracking appear,must dispose in time to protect the conveyor belt from broken.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；If the off tracking degree more than 5% of belt width should adjust,after adjust finishing,install the aligning roller.三、检查设备各运转部件，有无异常声音及异常振动；Check each part of the equipment,whether have abnormal noise or abnormal vibration.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；Check the temperature rise of reducer,fluid coupling,lube and bearing whether oil leak.五、制动器、各种限位开关保护装置的动作是否灵敏可靠；Check brake and all limit switch,whether it is sensitive.六、拉紧装置运行是否良好，有无卡死现象；Tension device running well,whether locking