斗輪堆取料機使用說明書正文(英文)

1、Project: Botswana Morupule B 4X150MW Power Station DQ500/1000.35 Boom type Bucket Wheel Stacker ReclaimerInstruction for operation and maintenancePAGE Page PAGE 51 of NUMPAGES 51Chapter 1 Summary DQ500/100035 boom bucket-wheel stacker reclaimer (BWSR) is a kind of large, continuous and high efficien

2、t bulk cargo and granular material stacking and reclaiming equipment, developed, designed and manufactured by Changchun Generating Equipment Co., Ltd, China for Botswana Morupule B 4X150MW Power Station project. This “operation instruction” includes necessary data and explanation of the equipment. M

3、ain contents are as follows: performance of the equipment and technical parameter, equipment structure, operating mode and characteristic, operating regulations, safe operating regulation and maintenance as well as service etc. of the equipment. There are interlocking protection between long travel

4、drive, luff, bucket wheel drive and boom conveyor etc transmission part (detailed information refer to the instruction in each Chapter/Section). Operator must read “Operation instruction” carefully and master daily operation and maintenance before starting to work; if operation, maintenance is impro

5、per, not only can reduce the service life of equipment, but also can cause the accident.1.1 Brief introduction of the equipmentThis machine adopts integral hydraulic luffing structure. Bucket Wheel Stacker Reclaimer mainly consists of bucket-wheel mechanism, Super steel structure, boom conveyor, Mai

6、n machine stairs/ladder/walkway and platform , luff unit , slew unit, long travel mechanism, slew deck, portal, Long travel, impact bracket , tripper car, ladder, walkway and platform of tripper car, dust suppression device/sprinkling device, electric room, operators cabin, electrical system and cou

7、nterweight assembly etc; The operator s cab should be suspended installing on the upper part of the pylon at bucket wheel side; the super steel structure which bucket wheel mechanism, boom conveyor, operators cabin etc luffing parts are installed on can luff around luffing pivot; Tripper car is cros

8、s tripper car（it can realize the function of stacking and shuttle reclaiming）；and power cable reeler, control cable reeler, electric room and water source device of sprinkling system etc are installed on the tripper car.1.2 working principleThis equipment is selected to use manual, manual interlocke

9、d and semi-automatic for stacking and reclaiming operation.1.2.1 During stacking operation, the material transferred from auxiliary tripper (yard-conveyor) will be delivered to transfer chute through primary tripper car and head part hopper of the tripper car; - then delivered to boom conveyor, at l

10、ast stacking onto stockpiles. Boom conveyors luffing can realize high & low level stacking; Bucket wheel boom slewing can reach left-right stockyard and stockyard width stacking, Long Travel Drive can realize stacking along the track length.1.2.2 Reclaiming operation is carried out according to laye

11、r reclaiming process as well as bevel reclaiming if necessary. The coal will be excavated and reclaimed by the bucket (bucket wheel mechanism), and delivered to boom conveyor. Then transfer chute via yard conveyor output. Bucket wheel boom luffing can realize high & low level reclaiming; Bucket whee

12、l boom slewing can reach left-right stockyard and stockyard width reclaiming. Forbidden to reclaim the material only depending on long travel.Chapter 2 Performance of the machine and main technical parameter1 Type of equipmentDQ 500 / 1000.35type，it means： 35-slewing radius（the distance from bucket

13、wheelcenter to slewing center of the equipment is 35m）； 1000-stacking capacity 1000 tons/hour；500-reclaiming capacity 500 tons/hour； Qreclaiming ； Dstacking 。2 Natural condition of the coal yard Coalyard type： shuttling type layoutCoal density： 0.851t/m3Height of stockpile： 13m above the rail ,and 1

14、.5 m below the rail3 Main parameter of equipment Rated capacity: Stacking capacity: 1000 t/hReclaiming capacity: 500 t/ha .Long travelTraveling speed： Operating speed: 7 m/min; Commissioning speed: 30 m/minWheel base and wheel gauge： 7 m x 7 mMotor power： 4x11 kWReducer type： FH127GDV160M4BM/HFOutpu

15、t rpm .of reducer： 14.45 r/minBrake type: with the gearboxRail clamp type： TZT-J100Limit switch of anchor device： XCK S141H29b. Slew unitSlewing radius： 35mSlewing speed： 0.020.12r/minSlewing angle： stacking angle: 110 reclaiming angle: 110Motor type： Y2-200L-8Motor power： 15 kWReducer type： PHF062+

16、KF107AD6Transmission ratio of reducer： i= 774.4Brake type： YWZ9-200/E23c .Bucket-wheel mechanismReclaiming capacity： 500 t/hOuter diameter of bucket-wheel： 5rpm of bucket-wheel 6.5 r/minBucket capacity ： 0.Bucket quantity： 9nos.Driving device parameter：Motor type ： Y225M-4Motor power： 45kWReducer ty

17、pe： P2HF052+MC2RLS03Transmission ratio of reducer： i=226.86Limited torque fluid coupling type: YOXA450d. Luff unitLuffing angle： Luff up 12.04，Luff down 11.87Luffing speed： 35 mType of hydraulic cylinder： 250MP5Hydraulic cylinder form: double acting cylinderRated working pressure： 16MpaBoom conveyor

18、Length of boom conveyor： 36.Conveying capacity： 1500t/hBelt width x belt speed： 1200mm x 3.15m/sIdler diameter： 133mmTrough angle of the ilder: 35Take up type: Heavy bob take upDriving device parameter：Motor type： Y280S-4Motor power： 75 kWReducer type： MC3RLHF05+1FANTransmission ratio of reducer： i=

19、20.22Limited torque fluid coupling type： YOXZ -450Brake type： YWZ-300/45Longitudinal spliting protection switch type： HFZL-KDual direction pulling wire switch type： KLT2-Misalliance detecting switch type： FPK-12-30Speed sensor type: SJK-B-boom conveyor material flow detecting switch type： LJ-f. . Du

20、st suppression system/ Sprinkling systemWater tank volume: 10mPump type 40DL6.2-11.8X7Flow of the pump: 6.2m3/Delivery lift: 82.6mType of motor equipped with pump: Y132S1-4Motor power: 5.5kWRotational speed of motor: 1450r/minLiquid level relay: UQK-02Electromagnetic valve： ZCLF-20Water pressure ent

21、ering into water tank： 0.10.2MPaPower cable reeler Cable specification： F-3PNCT3x35+1x16mm2Cable cross dimensions: 91.6mm Cable reeler type: T1C-J2D-4x2(right)Control cable reeler Cable specification： F-3PNCT-30 x2.5+2Gmm2Cable cross dimensions: 82.8mm x23.7mmCable reeler type: T1C-J3K37x1(left)Tran

22、sfer chuteElectrical thrustor MT300500-60Jamming detector LD-Xj. Tripper car guide chute device locking prevention device ZFB-6 blockage detector LD-XLimited switch Anti-collision device of boom rack： FKLT2-IOther limited switches XCK S141H29Note：Other limit switches mean boom rack luffing limited p

23、osition, slewing angle, slewing luff and terminal limited position of Long travel .Detection deviceDetection device for traveling distance： XCC 1406PR01K type rotary encoderDetection device for slewing angle: XCC 2506PS81KB type rotary encoderDetection device for luffing angle: XCC 2506PS81KB type r

24、otary encoderDetection device for stockpile level： 20-39 type inclining switch.Chapter 3 Equipment structure Section 1: General Structure The equipment (see details in general arrangement drawing DQ9912.0ST) consists of bucket-wheel mechanism, super steel structure, boom conveyor, main ladder platfo

25、rm, luffing hydraulic device, portal, support pivot, slew deck, transfer chute, slewing mechanism, limited switch device, detection device, long travel, central lubrication system, power cable reeler device, control cable reeler device, tripper car, impact bracket, ladder platform of tripper car, du

26、st suppression /sprinkling system, electric room, electrical system, operators cabin, nameplate, counterweight assembly, foundational layout, load and so on.Super structure of main machine is an integral structure which consists of boom rack, pylon, counterweight boom and front and back bracing , al

27、l parts will be connected by pin roll which fixed by block. Head part is bucket-wheel mechanism; back part is counterweight assembly which can adjust the balance of super structure. Super structure is fixed on slew deck by support pivot, the upper part of the support pivot (bearing body) will be wel

28、ded with the lower plane of the pylon; the lower part of the support pivot (supporting block) will be welded with the upper plane of the Slew deck. The completed structure can waggle around the support pivot point, Hydraulic cylinder which lie between slew deck and pylon acts can achieve integral lu

29、ff of super structure. Slew support bearing is mounted between upper and lower pedestal ring, upper pedestal ring supports the slew deck, and lower pedestal ring is fixed on the portal. Slew driving device is fixed on the slew deck, and through output axis pinion of slewing reducer, the spur pinion

30、is meshed with big gear ring which is fixed under the bearing of lower pedestal ring, which shall transmit upper structure to rotate around slew center. Pivot of traveling mechanism is welded with support leg of portal. Since such structure adopts integral machine luff structural type, it has less c

31、onnecting joints, less services, and high security.Section 2: Detailed structure of unit and operating features1 Bucket-wheel mechanism1.1 StructureBucket-wheel mechanism mainly consists of bucket wheel drive device, ring chute, bucket wheel body, bucket wheel shaft, bucket, sliding chute and guide

32、chute device etc. Bucket wheel drive device consists of motor, gearbox/reducer, block and drive gear etc.; through motor-gearbox transmitted to bucket wheel shaft. So bucket wheel body can be driven by bucket wheel drive device, and can be carried out reclaiming operation. Total nine buckets with bu

33、cket teeth are fixed on bucket wheel body (bucket teeth should be detachable) by pin rolls and pins, Bucket wheel mechanism consists of them. Bucket wheel body is cell less type, in order to discharge the material within appointed area, ring chute shall be installed inside bucket wheel body circle,

34、and wearing resistance liners will be installed on the surface of ring chute. Material reclaimed by bucket wheel will be conveyed to boom conveyor through sliding chute.1.2 Disassembly and assembly When disassembling head part of bucket wheel and drive device, in order to avoid loss of stability of

35、upper structure, boom rack shall be locked and then to start disassembly operation. 1.2.1 Disassemblya. Motor Prior to disassembling external connections of the motor, then loosen the base bolts, after taking away the bolts, the coupling on the motor can be disassembled from inner hole of the fluid

36、coupling along bottom plane. b. Gearbox/reducer After disassembling fixed bolts of the base, then disassemble the fluid coupling, and the Gearbox/reducer can be disassembled.c. bucket Before assembly or disassembly the bucket, Prior to fix the bucket wheel body in order to avoid rotation of bucket w

37、heel due to losing balance; then loosen bolts, disassemble pin roll, and take off bucket, Bucket teeth are fixed at teeth block with wedge, disassemble the wedge and easily replace bucket teeth.d. ring chute and chute The inner radial clearance between ring chute and bucket wheel body are adjustable

38、 . Normal clearance value is 510mm. The clearance between guiding chute plate and conveyor are adjustable, Being adjusted, only disassemble the wedge on the guiding chute plate. Normally, there is 5mm clearance between guiding chute plate and conveyor.1.2.2 AAssembly is carried out in reverse sequen

39、ce of disassembly. During assembly, pay more attention no dust and foreign matters are allowed to enter into junctions, and such junctions shall be smeared with greaseAfter finished installation, unloading commissioning should be carried out, if limit switches can work normally, loading commissionin

40、g in full speed will be carried out.Note: I. During installing reducer on the bucket wheel shaft, following process must be carried out:a. Do not tighten the locking bolts before expanded sleeve is installed on the shaft diameter.b. Before the hollow shaft of the reducer will be installed on the mid

41、dle shaft or bucket wheel shaft, the outer diameter of the shaft and inner hole of hollow shaft must be cleaned carefully with alcohol or acetone, so as to ensure there is not any lubrication or grease on the connecting surface. Before expanded sleeve is installed on the shaft diameter. The surface

42、must be cleaned and be coated with thin lubricationc. After expanded sleeve is exactly installed on the hollow shaft of the reducer, tighten 34 equidistant bolts by hand at once. When tightening, it must be sure that two flanges keep parallelism with each other, and then tighten all bolts by hand.d.

43、 Tighten all bolts evenly with torque wrench in turn, each bolt will be tightened about 90 degree per time until they reach the torque specified in the reducers operation instruction .When tighten the last circle, the torque will be increased 5%.II. Connection between bucket wheel body and bucket wh

44、eel shaft, following process must be carried out:a. Before bucket wheel body will be installed, the outer diameter of bucket wheel shaft and inner hole of reducer hollow shaft must be cleaned carefully with alcohol or acetone, so as to ensure there is not any lubrication or foreign matters on the co

45、nnecting surface. Before expanded sleeve is installed. The surface must be cleaned.b. Tighten all bolts with torque wrench clockwise or counter-clockwise evenly, each bolt will be tightened about 90 degree per time until the tightening torque of each bolt reaches 355N.m.After finished installation,

46、unloading commissioning should be carried out, if everything is normal, loading commissioning will be carried out. 2 Long travel dirve2.1 Structurea. Traveling mechanism mainly consists of 630 drive wheel bogie assembly, equalizer, rail clamps, anchoring device, rail cleaner, end buffer, pin roll, b

47、lock, pivot and so on. 630 drive wheel bogie assembly mainly consists of drive trolley frame, motor, reducer vertical hollow shaft reducer, wheel assembly, middle shaft, gear box etc. Traveling mechanism is installed at low part of support leg of portal. All wheels are the same specification, which

48、is double-rim type. Gear transmission adopts the closed structure and oil bath lubrication. Reducer adopts vertical bevel-helical hollow shaft and the surface is hardened tooth, it should be connected to middle gear shaft with shrink disc. During bucket wheel stacker reclaimer is in non-operating st

49、ate, the anchoring peg must be inserted the anchoring block, so as to avoid the storm. The rail clamp will be interlocked with speed sensor. When wind speed exceeds 20m/s, warning system sends off warning signal in operators cab, When wind speed exceeds 25m/s, rail clamp clamps automatically. The eq

50、uipment cant start until the rail clamp is released. When rail clamp is released, it can ensure to have sufficient releasing degree, dont worry about draining oil, the releasing degree will be reduced or be clamped. It has well security. Traveling mechanism adopts VVVF to realize variable speed trav

51、eling. Normally, working speed is 7 m/min, and the commissioning speed is 302.2 Disassembly and assemblyBefore disassembly, you must know the structure of each components and the method of assembly & disassembly sufficiently. During assembly, dont damage the parts and components. Assembly is carried

52、 out in reverse sequence of disassembly, no dust and foreign matters are allowed to enter into junctions, and such junctions shall be smeared with grease.Before hollow axle of reducer is put on middle axle, both outer surface and inner surface of axles shall be cleaned thoroughly with alcohol or ace

53、tone, no lubricant on any connection surface. Shrink disc shall be cleaned before being put on outer surface of hollow axle and coated with a thin film of lubricant. After shrink disc is accurately installed around hollow axle of reducer, manually tighten bolt by 3-4 intervals. Two flange discs shal

54、l be parallel when bolt is being tightened, and then tighten other bolts manually. Tighten all bolts clockwise or counter clockwise with torque wrench, each bolt shall be tighten about 90 each time, until tightening torque of each bolt reaches to requirement specified in operation instruction of Red

55、ucer.3 Slew unit 3.1 StructureSlewing mechanism mainly consists of slewing drive device, slewing bearing, pedestal ring, flange, gear, gear cover, and fasteners. Slewing drive consists of motor, reducer, brake, torque limited coupling, engine base and cover etc. Slewing mechanism is installed betwee

56、n portal and slew deck. Lower part of lower pedestal ring is fixed on the portal, while upper part of lower pedestal ring is connected with external ring of slewing bearing. Upper part of upper pedestal support the slew deck, while lower part of upper pedestal ring is connected with internal ring of

57、 slewing bearing; Slewing drive is installed at rear part of slew deck. Drive gear on output axle of reducer is meshed with outer gear of slewing bearing. Motor generates transmission force to make slew deck slewing around portal, and further finish main machine slewing.3.2 Disassembly and assemblyD

58、isassembly for maintenance, before operation, you must know the structure of each components and the method of assembly & disassembly sufficiently. During assembly, dont damage the parts and components. Assembly is carried out in reverse sequence of disassembly, no dust and foreign matters are allow

59、ed to enter into junctions, and such junctions shall be smeared with grease 3.2.1 Disassembly and assembly for drive deviceFirst, disassemble fasteners and gear cover on the flange, it is up to electrical professional to disconnect external wire on motor and to mark interphase signs; then disassembl

60、e connection wire of position switch of torque limited coupling; disassemble driving pinion, pull out driving device upward, put the device on ground to make disassembly. a. MotorLoosen and take off fastener of motor base and retainer ring of torque limit coupling with wrench, pull out motor along a