As a conveying equipment widely used in power stations, mines, metallurgy, coal and other industries, bucket chain conveyor plays an important role in the field of material transportation with its flexible layout, large conveying capacity, long service life, low maintenance, low operating cost and large conveying slope. Especially when conveying materials with high temperature, large volume, large block size, sharp corners and strong abrasiveness, bucket chain conveyor shows its unique advantages. However, in practical applications, bucket chain conveyor also faces many conveying problems, such as chain deviation, guide rail wear, and loud chain plate noise. This article will explore these problems in depth and propose corresponding solutions to provide a reference for the stable operation of bucket chain conveyor.
1. Bucket chain conveyor chain deviation problem and solution
Bucket chain conveyor chain deviation is one of the common problems, and its main reason is the wear deviation of the rails. After the bucket chain conveyor has been running for a period of time, the two rail surfaces will wear, and the wear deviation will increase with time until serious deviation occurs. The deviation of the chain will not only lead to the increased friction between the roller limit edge on one side of the chain bucket and the rail, causing serious wear on the inner side of the rail and the roller limit edge, but also cause the chain bucket conveyor to deviate to one side, making the overlap surface between the roller on the other side and the rail smaller and smaller, even only 10-20mm, so that the roller is easy to rush out of the rail, causing the chain bucket conveyor to derail and deform the rail.
To address this problem, the following solutions can be taken:
1. Adjust the position of the chain bucket conveyor. Keep the height of the chain bucket conveyor driving shaft unchanged, raise its horizontal section by 800mm as a whole, adjust the angle of the slope section of the chain bucket conveyor, and replace the curved rails to reduce wear deviation and enable the chain to run stably.
2. Modify the rail structure. Change the fixed rail to a rail that can be adjusted left and right or up and down, and reinforce the bracket structure to prevent deformation. In this way, the rail can be adjusted according to the actual situation to ensure that the overlap surface between the chain and the rail is kept at an appropriate distance, thereby avoiding the deviation of the chain.
2. Problems of wear and deformation of chain bucket conveyor rails and solutions
Wear and deformation of chain bucket conveyor rails is also a common problem. Since the return chain bucket of the chain bucket conveyor is close to the ground, any accumulation of slag will be scraped to the tail by the return chain bucket. Although the lower side plate of the conveyor is opened regularly to discharge ash and slag during operation, the conveyor chain bucket will still be deformed. In addition, failure to clean up the accumulated material at the bottom of the conveyor in time, and insufficient lubrication and tightening of the chain bucket rollers and bolts will also cause the rollers to not rotate or fall off, causing the chain bucket to sink partially, scraping the bottom accumulated material or the cross arm channel steel, causing the chain bucket to jump greatly during the operation of the entire chain bucket conveyor. In addition, the large amount of slag discharge during operation is not handled in time, resulting in large-scale deformation and damage of the chain bucket.
To solve this problem, the following solutions can be taken:
1. Weld 90mm long 11# angle steel on the rail and 160mm long 11# angle steel on the column. The backs of the two angle steels are opposite to each other. Use M18×60 bolts to pass through the oblong holes on the two angle steels for fastening, and keep the height of the original support wheel unchanged. In this way, when adjusting the rails left and right, you only need to loosen the bolts to move the rails horizontally on the angle steel of the column. If you need to adjust the height of the rails, you can add or subtract shims between the angle steel on the column and the rails for adjustment, which is time-saving, convenient and fast.
2. Strengthen the cleaning of the accumulated materials at the bottom of the conveyor, regularly lubricate the chain bucket rollers and tighten the bolts to ensure that the rollers can operate normally and avoid local sinking and deformation of the chain bucket.
3. The chain plate of the chain bucket conveyor makes a loud noise and the rollers are often off the track and the solution
The chain plate of the chain bucket conveyor makes a loud noise when running and the rollers often get off the track is also one of the common problems. This is mainly due to the fact that the track and the head and tail are not in the same line, the track is deformed, and the roller is worn. These problems will not only affect the stable operation of the chain bucket conveyor, but also increase the maintenance cost of the equipment and production safety hazards.
For this problem, the following solutions can be taken:
1. Align the track and the head and tail in one line. Reset the baseline and recalibrate the track and the head and tail according to the baseline. Then, according to the actual situation on site, first reposition the head and tail, then draw the baseline according to the positioning of the head and tail to re-align the box, and finally calibrate the track according to the box and the baseline. This ensures that the track and the head and tail are in the same line, reducing the noise during the operation of the chain plate and the risk of the roller coming off the track.
2. Install a pressure rail. Install a set of pressure rails near the arc starting point of the lower layer of the chain bucket machine, and install 2 sets of pressure rails near the horizontal section. After installing the pressure rail, the chain bucket can be restricted from moving up, down, left, and right, thereby effectively preventing the chain bucket from derailing.
3. Replace the severely worn plate chain pressure wheel. For the plate chain pressure wheel that has been severely worn, it is necessary to replace it in time to ensure the stable operation of the chain bucket conveyor.
4. Add an oil drip lubrication device. Install an oil drip lubrication device at the slope of the chain bucket machine to lubricate the card plate and the pin shaft of the chain bucket conveyor to reduce friction and wear and reduce the noise when the chain plate is running.
4. Solutions to other problems of chain bucket conveyors
In addition to the problems mentioned above, chain bucket conveyors also have some other problems, such as low conveying efficiency, high energy consumption, and high noise. For these problems, the following solutions can be taken:
1. Optimize the design parameters of the chain bucket conveyor. According to the characteristics of the material and the conveying requirements, reasonably select the specifications, bucket width, chain speed range and other parameters of the chain bucket conveyor to improve the conveying efficiency and reduce energy consumption.
2. Strengthen the maintenance of equipment. Regularly inspect and maintain the chain bucket conveyor, clean up the accumulated materials, replace the worn parts, adjust the equipment parameters, etc. in time to ensure the normal operation of the equipment and extend its service life.
3. Adopt noise reduction measures. In the design and installation process of the chain bucket conveyor, noise reduction materials and noise reduction technologies are used, such as installing sound insulation covers and using shock absorbers, to reduce the noise pollution of the equipment.
In summary, the chain bucket conveyor has broad application prospects and unique advantages in the field of material transportation. However, in practical applications, the chain bucket conveyor also faces many transportation problems. In response to these problems, corresponding solutions can be taken, such as adjusting the position of the chain bucket conveyor, transforming the rail structure, strengthening the cleaning of accumulated materials at the bottom of the conveyor, aligning the track with the head and tail in one line, adding pressure rails, replacing severely worn plate chain pressure wheels, and adding oil drip lubrication devices. These measures can not only solve the problems of the chain bucket conveyor, but also improve the stability and reliability of the equipment, reduce maintenance costs and production safety hazards, and provide strong support for the production and development of enterprises. And production safety hazards, provide strong support for the production and development of enterprises.
