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Inclining Wagon Tipper

key word:Heat exchange element


Product description

Model: CFH-2A  

 

1. Usage

It is used to dump coal, ore and other bulk materials.

 

 

2. Specifications and performance

 

2.1. Tipping form:

        Incline type

2.2. Maximum weight of dump vehicle:

       100T

2.3. Maximum tipping angle:

        Normal operation: 160 Degree

        Limit state: 165 Degree

2.4. Turning speed of the dumper:

        High speed: 1.126r/min

        Low speed: 0.281 R / min

2.5. One cycle time of Tipper tipping:

        ≈56s

2.6. Size of dumper platform:

        Length: 14520mm

        Width: 3290mm

2.7. Rules for tipping vehicles:

       1435mm

2.8. Dump wagon size:

       Length: 10000mm-14500mm

       Width 3000mm-3200mm

       Height: 2400mm-3600mm

2.9. Driving motor power: 2 × 110kw

2.10. Clamping mechanism form: mechanical locking of gravity clamping wagon

2.11. General dimension:

       Length: 18414mm

      Width: 8300mm

      Height: 8900mm

2.12. Total weight:

        140.69t

 

3. Structural composition

3.1. Transmission device; 3.2. end plate; 3.3. clamping mechanism ; 3.4. bracket ; 3.5. platform ; 3.6. main bearing device

3.1 Transmission device

There are two sets of transmission devices, symmetrically distributed on the left and right, each composed of motor, reducer, brake, pinion, bearing seat, coupling and master controller (cam controller).

In order to reduce the impact during the tipping process so as not to damage the tipped vehicle and the parts of the tipper, the tipper must be driven at two speeds, running at low speed during the starting, leaning and returning to zero of the tipper, and turning into high-speed operation for the rest of the time will shorten the tipping cycle. The tripper adopts yzrdf355l1-10 / 40 metallurgy and hoisting three asynchronous wound rotor two speed motors as the driving motor to realize two speed transmission. The ratio of high speed to low speed is 1:4, which meets the requirements of stable starting of tripper. Moreover, simple control and maintenance can greatly reduce operating costs. The reducer is zsy400-31.5 three-stage cylindrical gear reducer with hard tooth surface, the center distance of low-speed stage is 400mm, and the speed ratio is 31.5. The pinions supported on the bearing pedestal are meshed with the pin teeth on the end plate circumference to drive the turning of the dumper, and the surface of the pin teeth is hardened and hardened to extend the service life. The motor and the input shaft of the reducer are connected by a pin coupling with a brake wheel, and the output shaft of the reducer and the pinion shaft are connected by a gear coupling. The function of the master controller is to send the command to control the motor start, stop, switch between high and low speed when the end panel is turned to a certain angle, so it is only necessary to install a transmission device close to the control distribution cabinet to shorten the wiring distance. It is connected with the output shaft of the reducer, so the set of transmission device equipped with the master controller, the output shaft of the reducer is double output shaft.

3.2 End plate

There is one end plate on the left and one on the right, with symmetrical shape. Each end plate is fastened and combined into one by the front and rear halves with bolts. A pin tooth is arranged around the outer edge of the end plate to engage with the driving pinion, which is driven by the pinion to rotate back and forth to complete the tipping operation of the tipper. A counterweight block is placed in the cavity of the rear half of the end plate. The front half of the end plate is fastened and combined with the carrier beam with high-strength bolts. The front end of the front half of the end plate is connected with the platform with a round pin to bear the weight of the platform and the vehicle during the tipping process.

3.3 Clamp mechanism

The function of the car clamping mechanism is to clamp the overturned vehicle. It is fixed with the car dumper in the process of overturning. When the overturning angle exceeds 90 degrees, it will not fall off. The clamping mechanism is composed of equalizing beam, clamping arm, clamping beam, pawl device, ratchet block and ground stop. The middle part of the equalizing beam is connected with the clamping arm by a round pin, and both ends of the equalizing beam are pressed against the tipped vehicle. There is a spring device at one end of the outer side, which has two functions: 1. The height of the side plate of the vehicle is uneven, so that four equalizing beams and eight pressing points can bear the force evenly. 2. After the material in the vehicle is unloaded, the bolster spring of the bogie of the vehicle will play a compensation role when it returns to the position, so as to avoid the side plate of the vehicle being subjected to excessive pressure. The clamping arm is a lever whose axis is a broken line. The middle point is connected with the support on the supporting beam by a round pin, and the upper end is connected with the equalizing beam by a round pin, so that the clamping force can be evenly pressed on the vehicle. The lower end of the clamp arm is a rectangular flange, which is fixedly connected with the clamp beam with high-strength bolts. The whole clamping mechanism has 4 clamping arms and equalizing beams to connect them into one. There is a set of pawl device at both ends of the clamping beam, which can lock the position of the clamping mechanism in the process of turning over. The ratchet block is fixed on the end plate with bolts, and is matched with the pawl device to lock the clamping mechanism. The ground stop is fixed on the ground foundation with foundation bolts. It is used to block the cam in the pawl device so that the pawl leaves the pawl block, and the originally locked clamping mechanism is released.

3.4  Carriage beam

The trolley beam is a square box beam, its left and right ends are consolidated with the end plate by high-strength bolts, and there are four middle fulcrums of the trolley arm at the top. In the process of overturning, the overturned car leans on the supporting beam, and its weight is borne by the supporting beam. When the turning angle is more than 90 degrees, the weight of the vehicle is pressed to the balance beam and transferred to the clamping arm, and finally transferred to the support of the supporting beam from the middle fulcrum of the clamping arm. Therefore, the supporting beam is an important component with complex force.

3.5 platforms

The platform is composed of two I-shaped main beams as the main load-bearing members, with 1435mm rail gauge on the top. In order to park the overturned vehicle, the outer rail is provided with a wheel stop plate, which can prevent the wheel from falling off the track when turning to 90 degrees. The whole platform is placed on two platforms. There is a convex cone on each platform seat and two concave cones under the platform. By using these two pairs of concave and convex cones, the platform can be accurately positioned in both vertical and horizontal directions. There is a roller behind the concave cone of each platform, which can roll on the inclined surface of the platform seat. Its function is to make the process of leaning on the vehicle smoothly without impact. Because the platform is located by two pairs of cones, there is no contact with the surrounding foundation, and there is no external force in the horizontal direction, so the weighing accuracy can be ensured when the weighing device is installed. There is a hook at both ends of the platform. When the tipper is turned over more than 90 degrees, the hook body's self weight makes it hook the round cylindrical hook seat on the platform. At this time, the weight of the platform borne by the end plate will not be pressed on the overturned vehicle, which is conducive to protecting the vehicle from damage.

3.6 Assembly of main bearings

The main bearing assembly is a component that bears the weight of the whole Tipper and the tipped vehicle and determines the rotation center of the tipper. It is composed of main shaft, locking device, double row spherical roller bearing, bearing seat, pressing plate, retaining ring and other parts. The main bearing of the tipper will bear more than 100 tons of weight during the tipping process, so the strength of bearing parts such as the main shaft, bearing, bearing seat, locking device and so on is particularly important. One end of the main shaft is inserted in the end plate. For the convenience of assembly, the locking device is used to make the main shaft and the end plate position radially, and the friction force between the locking device and the main shaft and the end plate is used to make the main shaft and the end plate consolidated into a whole without relative displacement. In this way, the keyway on the spindle is not machined to avoid weakening its strength. The other end of the spindle is equipped with spherical roller bearing to ensure that the spindle rotates easily. There is a pressing plate at both ends of the main shaft so that it can be reliably fixed in the end plate and spherical roller bearing without axial displacement. There are thrust rings on both sides of the spherical roller bearing in the bearing pedestal to fix the axial device of the whole dumper, so that the rotating part of the dumper will not collide with the surrounding foundation.

 

4. Tipping process

When the heavy-duty gondola with bulk materials is accurately positioned in the middle of the platform, the motor in the transmission device starts to run at a low speed to drive the end plate to rotate clockwise, and the front end of the end plate lifts the platform upward through the platform pin. Because the platform pin is not on the center line of the platform but is 160mm away from the outside, the platform will incline to the inside with the overturned vehicle. At this time, the concave cone under the platform which is in contact with the platform base leaves the convex cone of the platform base, and the roller under the platform will roll along the inclined surface of the platform base. With the increase of the angle of the end plate, the platform pin rises gradually, and the inclination angle of the platform and the tipped vehicle increases gradually. Until the side of the vehicle all lean on the supporting beam, the whole leaning process is completed. When the end plate continues to rotate, the roller of the platform will also leave the plane on the platform seat, and the motor will switch to high-speed operation.

When the end plate rotates clockwise, the support at the top of the trolley beam drives the clamping arm to move backward and downward through the round pin, the lower part of the clamping arm drives the clamping beam and the pawl device to slide downward along the slope of the ground stop, and the upper end of the clamping arm drives the equalizing beam to move downward through the round pin. At this time, the platform drives the overturned vehicle upward gradually, so the upper end of the vehicle is gradually close to the equalizing beam until it is in full contact with the equalizing beam. In this process, compared with the end plate, the clamping arm swings backward with the round pin on the top support of the supporting beam as the axis, and the pawl device moves along the arc line fixed by the pawl block teeth. When the equalizing beam contacts the upper end of the vehicle completely, the clamping arm cannot continue to swing backward. The end plate driving platform and the overturned vehicle drive the whole clamping mechanism to rotate together through the equalizing beam, and the cam in the pawl device Just leave the ground stop, because the self weight of the cam drives the pawl to insert into the ratchet block to lock the car clamping mechanism, so when the turning angle exceeds 90 degrees, the overturned vehicle will not fall off.

When the dumper is turned to the maximum angle of inclination, after the materials in the car are unloaded, the motor drives the end plate to rotate anticlockwise, the end plate drives the platform, and the overturned vehicle and the clamping mechanism turn back together until the pawl cam of the locomotive mechanism contacts with the ground stop and is blocked, the cam moves the pawl to release the pawl from the pawl block, and the clamping mechanism is opened. As the end plate continues to rotate and the cam slides up along the slope of the ground stop, the clamping arm swings forward with the round pin of the supporting seat at the top of the trolley beam as the axis, and the upper end of the clamping arm drives the equalizing beam to lift through the round pin, and disengages from the overturned vehicle.

When the end plate continues to rotate anticlockwise to the roller on the platform bottom and the slope on the platform base, the motor shall be switched to low speed operation to reduce the impact of return. After the roller on the platform bottom contacts the slope on the platform base, it will push the platform to swing outward with the platform pin axis, and drive the unloaded vehicle away from the trolley beam until the concave cone under the platform is flat When the convex cones on the pedestal coincide, the platform will return to the original position, which is called zero position. A turnover cycle is completed. After the unloaded vehicle is pushed out by the shunter and pushed into the second heavy vehicle for positioning on the platform, the second cycle can be started.

 

5. Precautions for use

5.1. If there is no vehicle on the platform, the dumper shall not be started, otherwise it will be possible to burn when the motor is overloaded when returning to zero. When the dumper needs to be overhauled, an empty car shall be placed on the platform.

5.2. The vehicle shall not be overturned if its size exceeds the specified range.

5.3. The vehicle shall be placed in the center of the platform without partial load.

5.4. In order to ensure that the pawl device of the clamping mechanism can operate reliably, the foreign matters on the pawl device and the ratchet block shall be checked and removed frequently, so as to prevent the pawl from engaging into the ratchet and causing the vehicle falling accident.

5.5. In order to reduce the impact when leaning against the vehicle and returning to zero and ensure that the vehicle will not be damaged, the motor can be switched from low speed to high speed only after the vehicle fully relies on the trolley beam when adjusting the switching contact of the master controller; when turning back, the motor shall be switched to low speed in front of the platform roller without contacting the platform seat slope.

5.6. In order to make the platform fully supported on the platform base in a free state when the platform is at the zero position, the platform pin hole on the end plate is crescent shaped. When adjusting the return contact of the master controller, it is necessary to coordinate with the adjustment of the brake to make the platform pin in the middle of the crescent hole when the end plate stops at the zero position.

5.7. The limit position switch on the brake and end plate is a safety device to ensure the safe operation of the dumper without offside collision accident. It must be checked and adjusted frequently to make it in good condition. When checking the limit position switch on the end plate, it must be confirmed that the action is reliable by the collision block on the end plate. , it can not be confirmed by other means, otherwise, in case of offside, the switch will not act and collision accident will occur.

 

6. Lubrication

Parts belong to Lubrication position Lubrication Point Lubrication method Lubrication grease Lubrication cycle
Transmission Device Coupling 2 Manual oil filling 3# General Lithium grease Check and change oil every 6 months
Bearing seat for Pinion 4 Manual oil filling 3# General Lithium grease Monthly check and replenishment
Oil change every 6 months
Gearbox 2 Manual oil filling Mechanical oil N46 Monthly check
Oil change every 6 months
Pinion tooth surface 2 Manual oil filling 3# General Lithium grease Cleaning and oil filling for each shift
Wagon clamping device pawl device 4 oil cup cover spinning 3# General Lithium grease Oil filling for each shift
Pawl block 2 Manual oil filling 3# General Lithium grease Oil filling for each shift
stop gear 2 Manual oil filling 3# General Lithium grease Oil filling for each shift
Main bearing device Main bearing seat 2 oil cup cover spinning 3# General Lithium grease Monthly check and replenishment
Oil change every 6 months

 

 7. Fault and Resolution

 

No. Fault location fault phenomenon fault cause Troubleshooting
1 Transmission Device The transmission device vibrates too much or has noise when it is overturned The foundation bolts of the transmission system are loose and broken. Check and adjust the transmission system, and deal with the foundation bolt defects.
The transmission gear and pin gear are lack of grease or seriously worn. Supervise and urge the post to timely lubricate the transmission gear and pin gear or replace the transmission gear and pin gear.
The connecting bolts of the rotating parts are loose. Check all parts and fasten bolts.
Unstable rotation during tipping. The coupling connecting bolts of the transmission reducer are loose or the rolling key is used. Tighten the connecting bolts or repair and replace the damaged parts.
Drive the internal gear of the reducer. Replace the damaged gear or reducer.
2 Clamping Device The equalizing beam does not move. The hinge pin of clamping beam or equalizing beam is stuck. The pin shaft of each hinge point shall be disassembled for flexible treatment and grease lubrication.
The wagon is not pressed tightly when pressing. The car is not pressed tightly when pressing. Disassemble the pin shaft of each hinge point of the locking device for flexible treatment and grease lubrication, check the foundation bolt of the unlocking stop arm, and make corresponding treatment.
3 Platform platfrom shifting The limit stops at both ends of the platform are worn out. Repair and replace the wear out stop.
Platform does not reset. Too much ash on the reset pallet affects the reset of the pallet. Urge the post to remove the ash on the pallet in time.
4 End plate Excessive vibration or noise during unloading. Pin teeth wear out of limit Replace worn pin teeth