1、越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 1 / 86 第一篇 前言 Chapter 1： Foreword DQ1200/2500.40 悬臂式斗轮堆取料机是由长春发电设备总厂为越南沿海一期火力发电厂项目开发、设计、制造的一种大型、连续、高效的散状、粒状物料堆取作业的设备。本设备
2、具有取料，堆料、分流功能。 DQ1200/2500.40 Boom type bucket wheel stacker reclaimer (BWSR) is a kind of large, continuous and efficient bulk cargo stacking if operation is not proper, not only can reduce the service life of the equipment, but also can cause the accident. 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维
3、护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 2 / 86 第二篇设备的性能及主要技术参数 Chapter 2： Performance of the machine and main technical parameter 1 设备型号 D Q 1200 / 2500 .40 回转半径 40 米（斗轮中心到臂架回转中心的距离） ； 堆料出力 2500 吨 /小时；
4、取料出力 1200 吨 /小时； 取料； 堆料； 1. Type of equipment D Q 1200 / 2500 .40 40slewing radius； stacking capacity 2500 t/h； reclaiming capacity 1200t/h； reclaiming； stacking； 2 煤场自然状况 Natural Condition of the coal yard 煤场形式： 通过式布置 Coalyard mode: pass through type layout 环境温度： +16.7 +37.2 Environmental temperatu
5、re: +16.7 +37.2 煤的密度： 0.9t/m3 Coal density： 0.9t/m3储煤场堆高： 轨上 13.5m 轨下 1.5m Height of stockpile： 13.5m above the rail , 1.5 m below the rail 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and main
6、tenance instruction 3 / 86 3 设备主要参数 Main parameter of equipment 总体参数： General parameter: 额定堆料出力 2500t/h； Rated stacking capacity 2500t/h 额定取料出力 1200t/h； Rated reclaiming capacity 1200 t/h a 行走机构 Long travel 行走速度： Traveling speed: 工作速度 7.5m/min Operating speed 7.5m/min 调车速度 30m/min Commissioning spee
7、d 30m/min 轴距与轨距： Wheel base and wheel gauge： 8m x7m 8m x7m 电动机功率： Motor power： 8x11kW 8x11kW 减速器型号： Gearbox type： FDADS168B-M160MB4F-L150/80NH FDADS168B-M160MB4F-L150/80NH 减速器传动比： Transmission ratio of reducer: i=99.31 i=99.31 夹轨器型号： Rail clamps type: TA0250 TA0250 锚定装置限位开关： Limit switch of anchor d
8、evice WLCA12 型 WLCA12 type b 回转机构 Slew unit: 回转半径： Slewing radius: 40m 40m 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 4 / 86 回转速度： Slewing speed: 0.032 0.116r/min
9、0.032 0.116r/min 回转角度： Slewing angle: 110 110 电动机型号： Motor type: YP180L-8 YP180L-8 电动机功率： Motor power: 2X11kW 2X11kW 减速器型号： Reducer type: P3KA14 P3KA14 减速器传动比： Transmission ratio of reducer: i=682.06 i=682.06 制动器型号： Brake type： TE200/EB300/50 TE200/EB300/50 回转过力矩限位开关： Over torque limit switch for Sl
10、ewing mechanism TL-N10MY1 TL-N10MY1 c 斗轮机构 Bucket wheel mechanism 取料出力： Reclaiming capacity: 1200t/h 1200t/h 斗轮外径： Outer diameter of bucket wheel: 6300mm 6300mm 斗轮转速： Rotational speed of bucket-wheel 6.86r/min 6.86r/min 料斗容积： Bucket volume/capacity 0.45m3 0.45m3料斗数量： 9个 越南沿海一期火力发电厂项目 DQ1200/2500.40
11、悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 5 / 86 Bucket qty. 9 pieces 驱动装置参数： Driving gear parameter: 电动机型号： Motor type Y280M-4 .Y280M-4 电动机功率： Motor power: 90kW 90kW 减速器型号： Gearbox type: P2K
12、A17 P2KA17 液力偶合器型号 : Fluid coupling type YOXA500 YOXA500 d 俯仰装置及系统 Luffing unit and system 变幅角度： Luffing angle 上仰 11.95 下俯 9.68 Luffing up 11.95 Luffing down9.68 变幅速度： Luffing speed: 5m/min（斗轮中心处） 5m/min ( at center of bucket wheel) 系统额定压力： System rated pressure: 16MPa 16MPa 油泵电动机型号： Oil pump motor
13、type : Y 系列 Y series 电动机功率： Motor power: 22kW 22kW 液压缸缸径： Hydraulic cylinder diameter 320/220 320/220 e 悬臂胶带机 Boom conveyor 额定输送能力： 2500t/h 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and main
14、tenance instruction 6 / 86 Rated conveying capacity 2500t/h 带宽 x 带速： Belt width x belt speed 1600mm x3.15m/s 1600mm x3.15m/s 托辊直径： idler diameter: 159mm 159mm 托辊槽角： Groove angle of idler： 35 35 拉紧方式： Take-up type 液压张紧 Hydraulic take-up 驱动装置参数： Driving device parameter 电动机型号： Motor type: Y315M1-4 Y31
15、5M1-4 电动机功率： Motor power: 132kW 132kW 减速器型号： Reducer type: B3DH09+1FAN B3DH09+1FAN 减速器传动比： Transmission ratio of reducer: i=25 i=25 限矩型液力偶合器型号： Torque release fluid coupling type YOX Z-500 YOX Z-500 制动器型号： Brake type: TE400/EB800/60 TE400/EB800/60 双向拉绳开关型号： Two-directional pulling wire switch type K
16、LT2- KLT2- 跑偏检测开关型号： Misalignment detecting switch type FPK-12-30 FPK-12-30 胶带机料流检测开关型号 : LJ- 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 7 / 86 Boom conveyor-mater
17、ial flow detecting switch type LJ- 速度监控仪 : Speed sensor type: SJK-B- SJK-B- 纵向撕裂检测开关 Longitudinal split protection switch type HFZL-K HFZL-K 系统额定压力： System rated pressure 16MPa 16MPa 液压缸缸径： Hydraulic cylinder diameter 100/56 100/56 f 头部分流固定单尾车（胶带为系统胶带） Head branching fix single tripper car (The belt
18、 is system belt) 额定输送能力： Rated conveying capacity: 2500t/h 2500t/h 带宽 x 带速： Belt width x belt speed: 1600mm3.15m/s 1600mm3.15m/s 托辊直径： Idler diameter: 159mm 159mm 托辊槽角： Groove angle of idler： 35 35 g 动力电缆卷筒装置 Power cable reel drum device 电缆规格： Cable specification： 3x35+4x25/4E+1x(12E9/125) 3x35+4x25
19、/4E+1x(12E9/125) 电缆断面尺寸： Cable cross-section dimensions： 91.7x28.3 91.7x28.3 h 控制电缆卷筒装置 Control cable reel drum device 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 8
20、 / 86 电缆规格： Cable specification： 24x2.5mm2 24x2.5mm2电缆断面尺寸： Cable cross-section dimensions： 69.2x15.8 69.2x15.8 i 水缆卷筒装置 Water cable reel drum device 水缆规格： Water cable specification 1.5 英寸 1.5 inch 水缆直径尺寸： Cable diameter dimensions： 51 51 j 除尘系统 Dust suppression system 水箱容积： Water tank cubage 10 m3
21、10 m3水泵型号： Type of water pump: 40DL6.2-11.8X7 多级离心泵 40DL6.2-11.8X7 multistage centrifugal pump 水泵流量： Pump flow 6.2 m3/h 6.2 m3/h 扬程： Delivery lift 82.6m 82.6m 水泵配带电动机型号： Motor type equipped with pump Y132S1-4 Y132S1-4 电动机功率： Motor power: 5.5 kW 5.5 kW 电动机转速： Rpm of motor: 1450 r/min 1450 r/min 浮球液位控
22、制器： Float level controller UQK-02 UQK-02 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 9 / 86 升降式止回阀（ Dg40） Lift check valve （ Dg40） H41T-16 H41T-16 截止阀（ Dg40） Cut-of
23、f valve（ Dg40） J41H-16 J41H-16 电磁阀： Magnetic valve ZCLF-40 ZCLF-40 入水箱水压： Water pressure entering into water tank0.1 0.2(MPa) 0.1 0.2(MPa) k 中部料斗 Center chute 系统额定压力： System rated pressure 16MPa 16MPa 油泵电动机型号： Oil pump motor type Y 系列 Y series 电动机功率： Motor power 3kW 3kW 液压缸缸径： Hydraulic cylinder dia
24、meter 63/45 63/45 堵塞检测器： Coal blocking signal switch LDX LDX l 限位装置 Limit switch device 臂架防撞装置： Anti-collision device of boom rack： QS303E 与 QS30VR3R 配合 QS303E match with QS30VR3R 其它限位开关： Other limit switches： WLCA12 型 WLCA12 type 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL PO
25、WER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 10 / 86 注：其它限位开关指变幅极限限位、回转角度及回转变幅、大车行走终端限位、分流限位等。 Note： Other limit switches mean bucket wheel boom rack luffing end limited position, slewing angle, slew luffing and terminal limited posit
26、ion of Long travel and tripper car branching switch etc. m 检测装置 Detection device 行走距离检测装置： Detection device for traveling distance TRD-GK50-BZ TRD-GK50-BZ 回转角度检测装置 : Detection device for slewing angle: E6C3-AG5C（ 1024P/R） E6C3-AG5C（ 1024P/R） 变幅角度检测装置： Detection device for luffing angle: E6C3-AG5C（绝对
27、型） E6C3-AG5C(Absolute type) 料位检测装置： Detection device for material level VEGAPULS54 VEGAPULS54 n 司机室及支架 Operators cabin and support 系统额定压力： System rated pressure 16MPa 16MPa 油泵电动机型号： Oil pump motor type Y 系列 Y series 电动机功率： Motor power 3kW 3kW 液压缸缸径： Hydraulic cylinder diameter 80/45 80/45 越南沿海一期火力发电
28、厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 11 / 86 第三篇设备的构造 Chapter 3 Equipment Structure 第一节 整体构造 Section 1 General Structure 设备的组成详见总图 (F4281-MANU010-0010-M01。由斗轮机构、上部金属结构
29、、悬臂胶带机、主机梯子平台、俯仰机构、行走机构、门座、中部料斗、缓冲托架、回转机构、集中润滑装置、限位装置、检测装置、尾车、尾车梯子平台、电气室、电气系统、司机室及支架、厂牌、配重组、洒水装置、动力电缆卷筒装置、控制电缆卷筒装置、水缆卷筒、转盘、支承铰座、基础布置及载荷等组成。 The equipment (see details in general arrangement drawing F4281-MANU010-0010-M01) consists of bucket wheel mechanism, super steel structure, boom conveyor, main
30、 machine ladder/walkway stairs and platform, luffing unit, Long travel, portal, center chute, impact bracket, slew unit, central lubrication system, limit switch device, detection device, tripper car, ladder platform of tripper car, electrical house, electrical system, operators cabin and bracket, n
31、ameplate, counterweight assembly, dust suppression system, power cable reel device, control cable reel device, water cable reel device, slew deck, supporting pivot block, foundational layout and load etc. 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/
32、250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 12 / 86 CHANGCHUN GENERATING EQUIPMENT CO.,LTD,CHINA主机的上部结构由前臂架、门柱、配重架及前、后拉杆等组成整体结构，其各构件之间用销轴连接，销轴由卡板固定。其前端悬挂斗轮机构，后端装有用以调节上部结构的平衡的配重组。上部结构通过支承铰座固定于转盘上，支承铰座的上端与门柱尾部铰接；支承铰座的下端与转盘上平面焊接。整个上部结构可以绕支承铰座铰点摆动，由位于转盘与门柱之间的液压缸的
33、作用实现上部结构的整体俯仰。回转支承轴承被镶嵌在回转上、下座圈中，上座圈支承转盘，下座圈固定在门座上。回转驱动装置固定在转盘上通过回转减速器输出轴小齿轮与固定在下座圈上的轴承下半体大齿圈啮合，带动上部结构绕回转中心转动。行走机构铰支座与门座调整环，工地装配焊接。门座采用四点支撑方式。中部转运料斗设在主机的回转中心线上，上口与尾车头部落煤斗（尾车处于堆料工况时）及悬臂胶带机驱动滚筒处导料槽衔接；下口与缓冲托架衔接。设备动力供电电源采用扁电缆，通过电缆卷筒卷绕上机。主机变幅液压装置固定在转盘上。尾车上装有动力、控制电缆卷筒、水缆卷筒、电气室及洒水装置的水源装置。 Super structure o
34、f main machine is an integral structure which consists of bucket wheel boom, pylon, counterweight boom and front and back bracing , all parts will be connected by pin roll which fixed by snag plate. Head part is bucket wheel mechanism; rear part is counterweight assembly that can adjust the balance
35、of super structure. Super structure is fixed on slew deck by supporting pivot block, the upper part of the supporting pivot block and the end part of the 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Oper
36、ation and maintenance instruction 13 / 86 pylon will be hinged joint; and lower pivot support should be welded with the upper plane of slew deck. The complete structure can waggle around the support pivot point, Hydraulic cylinders action between slew deck and pylon can achieve integral luffing of s
37、uper 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. The pinion of slewing reducer output axis should mesh with the big gear ri
38、ng fixed under the bearing on the lower pedestal ring, through meshing mode can drive the super structure to rotate around slew center. Pivot block of traveling mechanism should be assembled and welded with adjusting ring of portal at site. Portal adopts four-points supporting. Transfer chute is ins
39、talled on slewing centerline of the main machine, the upper open is connected with the head part of coal falling hopper(during the tripper car is in stacking operation) and the guide chute installed at the drive pulley of boom conveyor, the lower open is connected with the impact bracket The power s
40、upply of the equipment adopts flat cable which will be winded on the machine by cable reel. Main machine luffing hydraulic device should be fixed on the slew deck. Power cable reel, control cable reel, water cable reel, electrical house and the water source device of dust suppression system etc are
41、all installed on the tripper car. 第二节 分部套详细结构及运作特点 Section 2: Detailed structure of unit and operating features 1 斗轮机构 Bucket wheel mechanism 1.1 构造 Structure 本装置主要由斗轮驱动装置、圆弧挡板、轮体、 斗轮轴、斗子及溜料导料装越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom
42、Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 14 / 86 置等组成。减速器为正交出轴行星传动，与电机、液力偶合器构成一体，通过胀套固定在斗轮轴上，减速器上装有杠杆式过力矩保护装置，当挖掘力超过设计值的 1.5 倍时，自动切断电机电路，实施过载保护。 Bucket wheel mechanism mainly consists of bucket wheel drive device, ring chute, bucket wheel body; bucket wheel shaft; buc
43、ket and sliding chute etc. The speed reducer is normal output shaft planet drive, integrated with motor and fluid coupling, fixed on the bucket wheel shaft by expansion sleeve. A lever-type over torque protection device is installed on the speed reducer. The protection device will cut-off the power
44、supply when the digging capacity is over 1.5 times of design value. 9 个镶有斗齿的斗子用螺栓和销子固定在轮体上 (斗齿为可拆卸 ) 构成斗轮。斗轮体为无格式结构， 为使物料在给定区域卸料， 在斗轮的内侧设置圆弧挡板， 圆弧挡板表层为耐磨衬板。由斗轮挖取上来的物料，通过溜料槽导向悬臂胶带机。为防止物料掉入回程胶带，设有胶带头部回程护罩。 Nine buckets with bucket teeth are fixed on bucket wheel body by bolts and pins and form bucket
45、wheel. Bucket wheel body shall be cell-less structure. In order to discharge the material in the designated area, mount the ring chute in side the bucket wheel, there is wearing plate on baffle plate surface. Coal reclaimed by bucket wheel will be transmitted to belt conveyor through sliding and gui
46、ding chute. For prevention the material falling to the return belt, return cover hood is installed at the belt conveyor head. 1.2 拆卸和组装 Disassembly and assembly 为使拆卸头部斗轮及斗轮传动装置时，不致引起设备上部机构失稳，必须将前臂架锁定，然后才能进行拆卸作业。 When disassembling head part of bucket wheel and drive device, in order to avoid loss of
47、 stability of upper structure, boom rack shall be locked, and then to start disassembly operation. 越南沿海一期火力发电厂项目 DQ1200/2500.40 悬臂式斗轮堆取料机使用、维护说明书 DUYEN HAI 1 THERMAL POWER PLANT PROJECT- DQ1200/250040 Boom Bucket Wheel Stacker cum Reclaimer Operation and maintenance instruction 15 / 86 1.2.1 拆卸 Disa
48、ssembly a 斗子 Bucket 拆装斗子之前，为避免不平衡引起斗轮转动，首先将斗轮轮体固定，然后松开斗子尾部螺栓，卸下斗耳上的销轴，即可取下斗子。斗齿是用锲子固定在齿座上的，拉出锲子，即可拆下斗齿。 Prior to disassembling and assembling the bucket, in order to avoid rotation of bucket wheel due to losing balance, firstly fix the bucket wheel body, loosen bolts at the tail part of the bucket,
49、disassemble pin roll on the bucket lug, and then take off bucket. Bucket teeth are fixed at teeth block with wedge, disassemble the wedge and easily replace bucket teeth. b 导料槽 Guide chute 导料板与胶带机的间距是可调的，调整时，拆下导料板上的锲子即可。应保证导料板下胶条既能被压住又能与悬臂胶带机的胶带接触良好。否则导料板应予以更换。 Space between guide chute plate and belt conveyor is adjustable, during the course of adjustment, disassembling wedge of guide chute plate. It must be ensured the slab rubber under t
