Apron Feeder Chain In The Use Of The Process And What Are The Precautions
Apron feeder is a kind of conveying equipment with heavy load, large processing capacity and strong impact resistance, mainly composed of drive, chain, sprocket, upper tug, return tug, frame, tension device, etc., which can be widely used in coal, mining, metallurgy, chemical industry, electric power and other industries. As an important traction component, apron feeder chain plays a vital role in its stable operation. The following is for everyone to sort out the problems and precautions in the use of apron feeder chain:
(a) chain wear too fast
In the operation of apron feeder, the chain wear too fast is a common problem, it will significantly shorten the service life of the chain, increase equipment maintenance costs and downtime. There are many reasons for the chain to wear too fast.
Excessive load is one of the important factors that lead to fast chain wear. When the weight of the material delivered by apron feeder exceeds the rated carrying capacity of the chain, the tension on the chain will increase significantly, and the pressure between the chain links will also increase, which will exacerbate the wear of the chain plate, pin, roller and other components. In some mining scenarios, if the material is over-loaded in order to increase the output, the chain is overloaded for a long time, and the wear rate is 2-3 times faster than normal. In order to solve this problem, it is necessary to carry out material transportation in strict accordance with the rated capacity of the equipment to avoid overload operation. The weight of the material can be monitored in real time by installing devices such as load sensors, and the delivery volume can be adjusted in time once overload is found.
Poor lubrication is also a key reason why chains wear too quickly. When the chain is running, there is relative movement between the chain links, between the chain and the sprocket, if the lack of good lubrication, these contact surfaces will directly friction, generating a lot of heat and wear debris, accelerating the wear of the chain. According to statistics, the wear rate of the chain with insufficient lubrication is 5-8 times that of the normal lubrication chain. To solve the lubrication problem, it is necessary to select the appropriate lubricant and lubricate according to the specified lubrication cycle. As mentioned earlier, under high temperature and heavy load conditions, the choice of composite lithium grease, and under ordinary conditions, the choice of mineral oil-based lubricating oil. At the same time, during the lubrication process, it is necessary to ensure that the lubricant is evenly applied to all key parts of the chain, such as pins, sleeves, rollers, etc.
In addition, the poor engagement between the chain and the sprocket will also lead to increased wear. If the tooth shape of the sprocket is worn, the chain pitch is extended, or the installation accuracy of both is insufficient, the chain and the sprocket will have impact and uneven force when meshing, and then accelerate the wear of the chain. For example, when the tooth surface of the sprocket appears wear, spalling and other defects, the chain will appear in the process of engagement, the phenomenon of jumping and stuck, resulting in excessive local force of the chain and increased wear. In response to this situation, the wear of the sprocket and chain should be checked regularly, and the sprocket or chain with serious wear should be replaced in time. At the same time, when installing, it is necessary to strictly control the installation accuracy of the sprocket and the chain to ensure that the two are well engaged.
(2) chain deviation
Chain deviation is another problem that can not be ignored in the operation of apron feeder, which will not only affect the normal delivery of materials, but also may lead to abnormal wear of the chain, sprocket and other parts, and even lead to equipment failure, resulting in production interruption.
The deviation of the chain will cause the material to deviate during the conveying process, resulting in the material accumulation on one side, affecting the uniformity and stability of the conveying. At the same time, the deviated chain will have friction with the side plate, guide rail and other components of the equipment, accelerating the wear of the chain and these components. In severe cases, the chain may be disconnected, making the device unable to operate normally. In the apron feeder of a building materials factory, due to the deviation of the chain, the chain plate and the side plate frequent friction, only one month, the chain plate and the side plate due to serious wear and need to be replaced, not only increasing the maintenance cost, but also leading to a week of production line downtime, resulting in huge economic losses.
The reasons for chain deviation are more complex. Installation error is a common factor, such as the inaccurate installation position of the sprocket, the axis is not parallel or is not perpendicular to the center line of the apron feeder, which will cause the chain to be subjected to uneven side forces during operation, resulting in deviation. The uneven tension on both sides is also an important reason for chain deviation. In the process of long-term operation of the chain, due to wear, stretching and other reasons, there may be inconsistent length on both sides, which leads to uneven tension on both sides. The uneven distribution of the material will also produce side forces on the chain, causing deviation.
For the chain deviation problem, the following adjustment and correction methods can be taken. Check the installation accuracy of the sprocket regularly, use measuring instruments such as theodolite, level, etc., to detect the parallelism and perpendicularity of the sprocket axis, and adjust it in time if there is any deviation. The installation error can be solved by adjusting the position of the sprocket, the thickness of the gasket or reinstalling the sprocket. Install tension adjustment devices, such as tension wheel, tension cylinder, etc., regularly check the tension of the chain to ensure uniform tension on both sides. When it is found that the tension on both sides of the chain is inconsistent, the adjustment device is used to tighten the side with less tension, so that the tension on both sides can reach balance. Guide devices can also be installed on the chain running path, such as chain guides, guide rails, etc., to limit the direction of movement of the chain and prevent deviation. The guide device should be installed in the part of the chain that is easy to run off, such as the entrance and exit of the sprocket, and ensure that the gap between the guide device and the chain is suitable, which can play a guiding role and will not produce too much resistance to the chain.
(3) chain breakage
Chain break is one of the most serious faults of apron feeder, once it occurs, it will cause the equipment to stop instantaneously, which has a great impact on production. Therefore, it is essential to understand the causes of chain breakage and take effective preventive measures and emergency treatment methods.
Fatigue is one of the common causes of chain breakage. In the long-term operation process, the chain is repeatedly subjected to tensile, bending, impact and other loads, and the chain plate, pin and other components will produce fatigue cracks. Over time, these cracks will gradually expand, eventually causing the chain to break. According to research, the chain may appear fatigue cracks after 100,000-200,000 cycles of load. Overload is also an important cause of chain breakage. When apron feeder encounters sudden material blockage, stuck and other situations, the chain will bear a huge tension, exceeding its tensile strength, resulting in fracture. The quality problems of the chain itself, such as material defects, improper heat treatment, etc., will also reduce the strength and toughness of the chain and increase the risk of fracture.
In order to prevent chain breakage, the operating conditions of apron feeder should be strictly controlled to avoid overload operation. Install overload protection devices, such as safety valves, torque limiter, etc., when the load borne by the chain exceeds the set value, the protection device will automatically act to stop the equipment and avoid the chain to break due to overload. Non-destructive testing of the chain is carried out regularly, such as ultrasonic detection, magnetic particle detection and other methods, to detect whether there are cracks and other defects in the chain. Once a cracked link is found, it should be replaced in time to prevent crack expansion leading to chain breakage. When choosing a chain, it is necessary to choose products of reliable quality to ensure that the materials and manufacturing processes of the chain meet the relevant standards and requirements. At the same time, pay attention to the storage and use environment of the chain to avoid the chain being affected by factors such as moisture and corrosion and reduce its strength.
If the chain is unfortunately broken, emergency measures should be taken immediately. First, stop apron feeder quickly to ensure the safety of people and equipment. Then, the broken chain is inspected to analyze the reasons for the break, so that corresponding improvement measures can be taken to prevent similar problems from happening again. When replacing the chain, choose the same product as the original chain specification and model, and install it according to the correct installation method. After the installation is completed, the chain should be debugged and tested to ensure its normal operation. In the process of chain replacement, it is necessary to do a good job of on-site safety protection, set up warning signs to prevent personnel from straying into dangerous areas.
The use and maintenance of apron feeder tank chain is a systematic and meticulous work, starting from the correct installation, through regular cleaning, reasonable lubrication, close monitoring and other daily maintenance measures, timely response to the chain wear too fast, deviation, fracture and other common problems, timely replacement of spare parts and upgrade, each link is closely linked. Together to ensure the stable operation of the chain.
Continuous maintenance plays a key role in ensuring the stable operation of industrial production. The stable operation of the chain can ensure that apron feeder can efficiently transport materials and avoid production interruption caused by equipment failure, so as to ensure the continuity of the production line, improve production efficiency and create greater economic benefits for the enterprise.
Looking to the future, as technology continues to advance, apron feeder tank chain technology will also continue to develop. In terms of materials, there will be new materials with higher strength, more wear resistance and corrosion resistance, further improving the performance and service life of the chain. In terms of structural design, it will also be more optimized to adapt to more complex and harsh working conditions. Intelligent monitoring and maintenance technology will also gradually be applied to the management of the chain, through sensors, internet of things and other technologies, to achieve real-time monitoring and data analysis of the operating status of the chain, predict hidden faults in advance, achieve accurate maintenance, further improve the reliability and production efficiency of the equipment, and provide strong support for the intelligent and efficient development of industrial production.
