連(lian)云港堿(jian)(jian)廠(chang)(chang)是我國(guo)自行設計和組織(zhi)施工的(de)(de)(de)年(nian)產60萬(wan) t的(de)(de)(de)大型(xing)純堿(jian)(jian)廠(chang)(chang)之一?1989年(nian)建(jian)成投(tou)產。連(lian)云港堿(jian)(jian)廠(chang)(chang)經過(guo)(guo)多年(nian)的(de)(de)(de)改(gai)造、擴建(jian)?2007年(nian)生(sheng)產純堿(jian)(jian)117萬(wan) t?產品所需的(de)(de)(de)大宗(zong)原(yuan)、燃料(liao)(石灰石、焦炭、煤(mei))90%以上(shang)是通(tong)(tong)過(guo)(guo)鐵(tie)路運輸的(de)(de)(de)。大宗(zong)原(yuan)、燃料(liao)到(dao)廠(chang)(chang)后?通(tong)(tong)過(guo)(guo)卸(xie)(xie)(xie)(xie)車機(ji)械(鏈斗卸(xie)(xie)(xie)(xie)車機(ji))將(jiang)原(yuan)、燃料(liao)卸(xie)(xie)(xie)(xie)至(zhi)大型(xing)堆(dui)場上(shang)?而后通(tong)(tong)過(guo)(guo)供料(liao)設備將(jiang)原(yuan)、燃料(liao)輸送到(dao)各工序?完成純堿(jian)(jian)生(sheng)產的(de)(de)(de)要求。由于鐵(tie)路運輸緊張(zhang)?鐵(tie)路部門(men)對進入廠(chang)(chang)礦企業(ye)內(nei)(nei)部車輛的(de)(de)(de)卸(xie)(xie)(xie)(xie)車時(shi)間作出(chu)了規定(ding)?超出(chu)規定(ding)的(de)(de)(de)時(shi)間要收取一定(ding)的(de)(de)(de)延時(shi)費用。所以如何在規定(ding)的(de)(de)(de)時(shi)間內(nei)(nei)組織(zhi)完成卸(xie)(xie)(xie)(xie)車任務?對卸(xie)(xie)(xie)(xie)車機(ji)械(鏈斗卸(xie)(xie)(xie)(xie)車機(ji))提(ti)出(chu)了較高(gao)的(de)(de)(de)要求。本文以連(lian)云港堿(jian)(jian)廠(chang)(chang)卸(xie)(xie)(xie)(xie)車機(ji)械安(an)全改(gai)造為例?簡要論述(shu)廠(chang)(chang)礦企業(ye)大宗(zong)原(yuan)、燃料(liao)卸(xie)(xie)(xie)(xie)車機(ji)械安(an)全改(gai)造技術。
1 卸(xie)車機械的現(xian)狀
連(lian)云港堿廠共有 DDK-86型鏈(lian)斗卸車(che)機10臺。10臺鏈(lian)斗卸車(che)機使(shi)用已近(jin)20年?設(she)(she)備(bei)(bei)進入壽命(ming)周期(qi)的(de)衰退期(qi)?設(she)(she)備(bei)(bei)老化(hua)?結構架變形嚴重(zhong)。由于設(she)(she)備(bei)(bei)受到(dao)物料(liao)沖(chong)擊的(de)影(ying)響?造成各部(bu)結構架易(yi)開焊、易(yi)開裂(lie)?部(bu)件磨損加(jia)劇?故障頻繁;桁架結構易(yi)積(ji)料(liao)?且不便于**?加(jia)上(shang)(shang)露天(tian)腐蝕(shi)等原因?使(shi)鋼構件強度降低?結構架穩定(ding)性差?影(ying)響安全(quan)(quan)生產。雖然通過檢修可以(yi)暫時解決存在(zai)(zai)的(de)設(she)(she)備(bei)(bei)故障?但不能從(cong)根(gen)本上(shang)(shang)解決存在(zai)(zai)的(de)設(she)(she)備(bei)(bei)安全(quan)(quan)隱患?再加(jia)上(shang)(shang)生產負荷(he)在(zai)(zai)逐年提高?所以(yi)進行(xing)設(she)(she)備(bei)(bei)安全(quan)(quan)技術改造勢(shi)在(zai)(zai)必行(xing)。
2 設備存在的(de)安全隱患
鏈斗卸車機(ji)主要由行(xing)走機(ji)構(gou)、挖掘機(ji)構(gou)、卷揚機(ji)構(gou)、皮帶輸送機(ji)構(gou)、鋼結構(gou)架(jia)(鋼結構(gou)架(jia)采用桁(heng)架(jia)式結構(gou)?由型鋼組焊(han))、操作室(shi)及配電系統(tong)、供電裝置(zhi)、安全設施等部件(jian)組成。
2.1 機(ji)械系統
2.1.1 行走機構
大(da)車行(xing)(xing)走(zou)機構(gou)由電機、減(jian)速(su)機及行(xing)(xing)走(zou)主動(dong)輪(lun)、被動(dong)輪(lun)等(deng)組(zu)成。鏈斗卸車機在(zai)作業時?行(xing)(xing)走(zou)機構(gou)勻速(su)移動(dong)?可以使(shi)料(liao)斗實現(xian)均勻取料(liao)。該機構(gou)存(cun)在(zai)的(de)安(an)全隱患(huan):減(jian)速(su)機底座(zuo)固定板(ban)易被拉斷(duan)?并引(yin)發其他故障。
2.1.2 挖掘機構
挖掘(jue)機構主要由(you)挖掘(jue)鏈條、料斗(dou)、驅動鏈輪(lun)、挖掘(jue)箱體(ti)和(he)(he)引導輪(lun)組(zu)成。挖掘(jue)箱體(ti)上升和(he)(he)下降通過導向(xiang)輪(lun)沿鏈斗(dou)卸車機桁(heng)架(jia)兩(liang)側的(de)軌道上下升降?升降軌道采用角鐵焊接在桁(heng)架(jia)上。
(1)升降軌(gui)道(dao)。在高負荷運行(xing)下?采用角(jiao)鐵做(zuo)升降軌(gui)道(dao)?運行(xing)時箱(xiang)體(ti)不(bu)穩(wen)定?容易(yi)造(zao)成(cheng)箱(xiang)體(ti)脫槽;卸(xie)(xie)料(liao)時?箱(xiang)體(ti)擺動劇(ju)烈?穩(wen)定性不(bu)好?易(yi)造(zao)成(cheng)卸(xie)(xie)料(liao)時過(guo)載?也容易(yi)造(zao)成(cheng)角(jiao)鐵變形以(yi)及損壞頻繁。
(2)料(liao)斗(dou)(dou)斗(dou)(dou)口(kou)。由于料(liao)斗(dou)(dou)直接(jie)與(yu)原、燃料(liao)接(jie)觸?在卸車(che)時料(liao)斗(dou)(dou)受到的磨(mo)損、沖擊(ji)大。而(er)料(liao)斗(dou)(dou)斗(dou)(dou)口(kou)又是磨(mo)損*嚴(yan)重的部位?所以料(liao)斗(dou)(dou)斗(dou)(dou)口(kou)容易被撕裂而(er)損壞。
2.1.3 鋼結構(gou)框架
鏈斗卸車機的(de)鋼結(jie)構框架(jia)采用桁(heng)架(jia)結(jie)構。經(jing)過近(jin)20年的(de)運行?桁(heng)架(jia)變形嚴(yan)重(zhong)?各(ge)部結(jie)構易開焊?加(jia)上腐蝕等原因?鋼構件強度減弱?穩定(ding)性差?影響安全穩定(ding)運行。
2.1.4 皮帶輸送機構
皮(pi)帶(dai)輸送(song)(song)(song)(song)機構由電(dian)動滾筒(tong)、輸送(song)(song)(song)(song)耐沖擊皮(pi)帶(dai)、支承托輥(gun)、尾(wei)輪及(ji)調節(jie)裝(zhuang)置(zhi)、皮(pi)帶(dai)機架等構成。帶(dai)式輸送(song)(song)(song)(song)機承接挖掘機構料(liao)(liao)斗拋卸的物料(liao)(liao)?并(bing)將物料(liao)(liao)水平地(di)運送(song)(song)(song)(song)到堆(dui)場(chang)上進行(xing)堆(dui)垛。存在的安全隱患:受物料(liao)(liao)沖擊的皮(pi)帶(dai)托輥(gun)損壞頻繁。
2.1.5 操(cao)作室(shi)
卸車時?拋卸物料產生的粉塵及噪音大?加上操(cao)作(zuo)室(shi)密(mi)封性能變差(cha)?操(cao)作(zuo)人員的工作(zuo)環境急(ji)需(xu)改善。
2.2 電氣系統
2.2.1 供電(dian)電(dian)源(yuan)
供電(dian)(dian)采(cai)用(yong)三相(xiang)四(si)線制。鏈(lian)斗卸(xie)車(che)機*初投用(yong)時(shi)?供電(dian)(dian)電(dian)(dian)源(yuan)是分別獨(du)立的?由配電(dian)(dian)室(shi)經獨(du)立電(dian)(dian)氣(qi)回路分別送到相(xiang)對(dui)應(ying)的設備(bei)動(dong)(dong)力箱上(shang)(shang)?通過動(dong)(dong)力箱、移(yi)動(dong)(dong)式(shi)電(dian)(dian)纜(lan)(lan)到達(da)設備(bei)上(shang)(shang)的總(zong)動(dong)(dong)力箱。每(mei)一臺設備(bei)移(yi)動(dong)(dong)式(shi)電(dian)(dian)纜(lan)(lan)采(cai)用(yong)配重式(shi)電(dian)(dian)纜(lan)(lan)卷(juan)(juan)筒結(jie)構?受電(dian)(dian)器采(cai)用(yong)滑環銅碳刷式(shi)結(jie)構。設備(bei)在室(shi)外頻繁移(yi)動(dong)(dong)作(zuo)業(ye)(ye)(ye)?加上(shang)(shang)現(xian)場工(gong)況條件差?卷(juan)(juan)筒上(shang)(shang)的電(dian)(dian)纜(lan)(lan)經常(chang)磨損破皮?移(yi)動(dong)(dong)式(shi)電(dian)(dian)纜(lan)(lan)配重經常(chang)轉動(dong)(dong)不靈活?卷(juan)(juan)筒內受電(dian)(dian)器也經常(chang)進水發生短路?嚴重影響(xiang)設備(bei)的穩定運(yun)(yun)行?同(tong)時(shi)危及(ji)人身安全。另一方面由于(yu)每(mei)根電(dian)(dian)纜(lan)(lan)長度(du)有限?鏈(lian)斗卸(xie)車(che)機在作(zuo)業(ye)(ye)(ye)時(shi)?存在一定的無法作(zuo)業(ye)(ye)(ye)區域?不利(li)于(yu)卸(xie)車(che)作(zuo)業(ye)(ye)(ye)的穩定運(yun)(yun)行。
2.2.2 大車行走電機回路
行(xing)走電機啟動(dong)用 JX 系列(lie)環行(xing)電阻(zu)進(jin)(jin)行(xing)控(kong)制(zhi)?通(tong)過接觸(chu)器(qi)進(jin)(jin)行(xing)啟動(dong)電阻(zu)的(de)切除?存在故障(zhang)率高等缺陷。
2.2.3 卷(juan)揚電機
卷揚電機(ji)使用繞線電機(ji) YZR 系列?卸車時(shi)?粉塵大?封(feng)閉性能差(cha)?轉(zhuan)子滑環炭刷磨損發(fa)現(xian)不及時(shi)會造成電機(ji)損壞。
3 安全改造技(ji)術
3.1 機械系統
3.1.1 行走機構
減(jian)速(su)(su)機(ji)底(di)(di)座固(gu)定板(ban)(ban)(ban)(ban)(ban)易被拉斷(duan)?主要(yao)原因是行(xing)走機(ji)構減(jian)速(su)(su)機(ji)底(di)(di)座的固(gu)定鋼板(ban)(ban)(ban)(ban)(ban)韌性差所致。改造(zao)前(qian)?固(gu)定鋼板(ban)(ban)(ban)(ban)(ban)厚度(du)為16mm?直接焊(han)接在(zai)結構架上?下邊無支撐(cheng)架和(he)加(jia)強(qiang)筋(jin)?在(zai)高(gao)負荷條(tiao)件下不能滿足行(xing)走機(ji)構的運行(xing)要(yao)求。改造(zao)后減(jian)速(su)(su)機(ji)固(gu)定底(di)(di)座板(ban)(ban)(ban)(ban)(ban)采用(yong)厚度(du)為20mm?材質為16Mn 的鋼板(ban)(ban)(ban)(ban)(ban)?底(di)(di)座板(ban)(ban)(ban)(ban)(ban)下部安裝支撐(cheng)架?支撐(cheng)架上焊(han)接加(jia)強(qiang)筋(jin)板(ban)(ban)(ban)(ban)(ban)。改造(zao)后的減(jian)速(su)(su)機(ji)底(di)(di)座板(ban)(ban)(ban)(ban)(ban)強(qiang)度(du)明顯提高(gao)?投(tou)用(yong)后沒有出現被拉斷(duan)現象(xiang)。
3.1.2 挖掘機構
(1)挖(wa)掘(jue)(jue)軌道(dao)。挖(wa)掘(jue)(jue)軌道(dao)由∠70角鐵(tie)改造為 P24鋼軌?垂直安裝(zhuang)?由軌道(dao)壓(ya)板來(lai)固定;同時導向輪也改造為與 P24鋼軌結(jie)構相配合的結(jie)構。改造后卸料(liao)作業時?挖(wa)掘(jue)(jue)箱體穩(wen)定性增強?生產(chan)能力(li)提(ti)高?故障率(lv)降低。
(2)挖掘料(liao)(liao)斗。挖掘料(liao)(liao)斗斗口由原來(lai)的16Mn 材質改造(zao)為60Si2Mn 耐磨材質。改造(zao)后?提高了料(liao)(liao)斗的耐磨性能與(yu)使用壽命。
3.1.3 鋼結構(gou)框架
改造(zao)前鏈斗卸車機鋼(gang)結(jie)(jie)構框架采用桁架結(jie)(jie)構?改造(zao)后將桁架結(jie)(jie)構改為箱體結(jie)(jie)構。箱體結(jie)(jie)構不僅使機架的強度和穩定性能(neng)得(de)到了提高(gao)?而且(qie)滿(man)足了高(gao)負荷條件下卸車時(shi)的安全(quan)要求。
3.1.4 皮帶輸送機(ji)構
改(gai)造(zao)(zao)前托(tuo)(tuo)輥(gun)支架(jia)損壞頻繁(fan)?托(tuo)(tuo)輥(gun)支架(jia)材(cai)質為(wei)(wei) A3;改(gai)造(zao)(zao)后將托(tuo)(tuo)輥(gun)支架(jia)材(cai)質改(gai)為(wei)(wei)16Mn。改(gai)造(zao)(zao)投用后?不僅延長了托(tuo)(tuo)輥(gun)及托(tuo)(tuo)輥(gun)支架(jia)的使(shi)用壽命?而且(qie)極大地降低了皮帶機構的故障率(lv)?延長了設(she)備(bei)的使(shi)用壽命。
3.1.5 操作室
操(cao)作(zuo)室(shi)的(de)改造采(cai)(cai)用鋼(gang)結(jie)構骨架?內外鋪彩色(se)鋼(gang)板?石棉礦板隔熱保溫?門窗采(cai)(cai)用彩色(se)鋼(gang)板沖(chong)壓成型結(jie)構?操(cao)作(zuo)椅(yi)可適應任何位置(zhi)(zhi)操(cao)作(zuo)?操(cao)作(zuo)室(shi)內配(pei)置(zhi)(zhi)空調設備。改造后?內部密封(feng)性能得到(dao)了提高(gao)?室(shi)內寬(kuan)敞明(ming)亮?操(cao)作(zuo)視野開闊?操(cao)作(zuo)人員的(de)工(gong)作(zuo)環境得到(dao)了明(ming)顯的(de)改善。
3.2 電氣系統
3.2.1 供電(dian)電(dian)源
將原來(lai)的(de)(de)獨(du)立配重(zhong)式(shi)電(dian)(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)供電(dian)(dian)(dian)(dian)(dian)(dian)改為封閉(bi)安全(quan)滑觸線(xian)供電(dian)(dian)(dian)(dian)(dian)(dian)。具(ju)體(ti)方(fang)式(shi)為:將每(mei)臺(tai)鏈斗卸車機配重(zhong)式(shi)電(dian)(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)拆(chai)除?全(quan)線(xian)安裝1條(tiao)供電(dian)(dian)(dian)(dian)(dian)(dian)封閉(bi)安全(quan)滑觸線(xian)?配電(dian)(dian)(dian)(dian)(dian)(dian)室內到現(xian)場的(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)源電(dian)(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)利舊?在(zai)配電(dian)(dian)(dian)(dian)(dian)(dian)室內將電(dian)(dian)(dian)(dian)(dian)(dian)源電(dian)(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)并聯(lian)接于同一開關下送到現(xian)場動(dong)力箱后(hou)?分別作為封閉(bi)安全(quan)滑觸線(xian)的(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)源接入點(dian)。封閉(bi)安全(quan)滑觸線(xian)主(zhu)要由(you)導(dao)管(guan)(guan)、受電(dian)(dian)(dian)(dian)(dian)(dian)器(qi)、中間進線(xian)盒及其(qi)他附(fu)件(jian)組(zu)成(cheng)。導(dao)管(guan)(guan)形狀(zhuang)為方(fang)型(xing)?是(shi)1根半(ban)封閉(bi)的(de)(de)異(yi)型(xing)管(guan)(guan)狀(zhuang)部件(jian)?是(shi)滑觸線(xian)主(zhu)體(ti)部分?導(dao)管(guan)(guan)內各導(dao)軌間相(xiang)互(hu)絕緣?并與外殼絕緣?從而(er)保證安全(quan)性。受電(dian)(dian)(dian)(dian)(dian)(dian)器(qi)是(shi)在(zai)導(dao)管(guan)(guan)內運(yun)行(xing)的(de)(de)1組(zu)電(dian)(dian)(dian)(dian)(dian)(dian)刷(shua)殼架?由(you)安置在(zai)用電(dian)(dian)(dian)(dian)(dian)(dian)設(she)備上的(de)(de)撥叉或牽引繩帶動(dong)?使(shi)之與用電(dian)(dian)(dian)(dian)(dian)(dian)設(she)備同步運(yun)行(xing)?并通過導(dao)軌、電(dian)(dian)(dian)(dian)(dian)(dian)刷(shua)的(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)能輸(shu)送到設(she)備。改造后(hou)?受電(dian)(dian)(dian)(dian)(dian)(dian)器(qi)的(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)刷(shua)由(you)高導(dao)電(dian)(dian)(dian)(dian)(dian)(dian)性能的(de)(de)耐磨金(jin)屬石(shi)墨材(cai)料(liao)制成(cheng)?受電(dian)(dian)(dian)(dian)(dian)(dian)器(qi)移動(dong)靈活?定(ding)向(xiang)性好?有效控制接觸電(dian)(dian)(dian)(dian)(dian)(dian)弧和串弧現(xian)象?露天(tian)輸(shu)電(dian)(dian)(dian)(dian)(dian)(dian)對檢修人(ren)員及操作人(ren)員無任何(he)傷(shang)害?解決了(le)連續作業存在(zai)的(de)(de)問題。
改造(zao)后?卸車機械能(neng)充分利用堆場面積進行(xing)作業?可以在堆場任意位置進行(xing)卸料?同時安全(quan)滑(hua)觸(chu)線(xian)(xian)能(neng)防雨、防雪、防冰凍、防塵、防腐蝕(shi)老化以及異(yi)物觸(chu)及?供(gong)電(dian)的安全(quan)性(xing)與穩定性(xing)也(ye)得到(dao)了很(hen)大的提高。實踐(jian)證明?改造(zao)后的封閉安全(quan)滑(hua)觸(chu)線(xian)(xian)供(gong)電(dian)方(fang)式能(neng)保證設備安全(quan)穩定運行(xing)。
3.2.2 大車行走(zou)電機回路
改(gai)造(zao)后(hou)?拆除(chu)原電阻器?在轉子回(hui)路(lu)中串(chuan)聯1臺 BP 系(xi)列頻敏(min)變阻器?BP 系(xi)列變阻器結構簡單?維護方便?適用于較差工況(kuang)的作業條件。運(yun)行(xing)(xing)證明(ming)?改(gai)造(zao)后(hou)的大車行(xing)(xing)走電機(ji)回(hui)路(lu)使用效果較好?取代了原用的 JX 系(xi)列環型電阻。
3.2.3 卷揚(yang)電機
根據(ju)卸車作(zuo)業(ye)時卷揚機(ji)構的(de)工作(zuo)特點?將原繞線 YZR系(xi)列電(dian)機(ji)改造為 YZ 系(xi)列電(dian)機(ji)?直接啟動(dong)?電(dian)機(ji)基本處于免維(wei)護狀態只要(yao)對電(dian)機(ji)進(jin)行(xing)計劃檢(jian)修就可以滿足實際運行(xing)需要(yao)。