What are the key parts of the trough conveyor:
First, the first round:
There are four requirements for the first round: 1. Correct tooth shape 2. Accurate pitch 3. Good synchronization of both wheels 4. Wear resistance. Among them, items (1)-(3) are required to be guaranteed by processing methods, and item (4) is achieved through material selection and heat treatment. The head wheel is structurally divided into two parts, namely the hub and the ring gear (usually the split head wheel). The first wheel separation not only makes maintenance and replacement more convenient, but more importantly, different materials and heat treatment methods can be selected according to the different performance requirements of the hub and ring gear. The hub is large in volume and the general cast steel can be used to meet the requirements. The gear ring is forged with 42CrMo. Through the use of medium-frequency quenching method to achieve hardened quenching drawings and the actual use of the requirements. The key to the processing of the sprocket is the ring gear, and the basic process route is: overall processing → cutting and slicing → quench forming. After passing the inspection, the ring gear blanks are machined and processed to form a special tooling profile on the large inserting bed after the quenching and tempering process to ensure accurate tooth shape indexing. In order to ensure smooth tooth shape, a grinding process is provided. In order to ensure the synchronization of the two sprockets, special tooling is used to process the coupling holes of the gear hub wheel, and the two ring gears are processed together. After the entire ring gear is processed, the segments are divided into five pieces. Then the tooth surface is quenched with HRC50-55 and the quenched depth is 2.5-3mm.
Second, the chain As the equipment process design for a section of transport, double chain traction, the chain will become the most critical components, the chain has four requirements: 1, high strength, high reliability and high wear resistance. 2. The pitch is accurate; 3. The position of the four holes connected with the chute is accurate; 4. The length of each chain is the same (factory state is 2 meters each). We chose 40Mn2 hot forging steel as the chain plate. The whole precision die forging and the first three parts of the chain, the chain plate, the pin shaft and the sleeve scraping process were added before the assembly. At the same time manganese steel is wear-resistant steel, can meet the requirements of wear. The pin bushes are made of high-grade carburizing steel 15CrMnTi, quenched after carburizing, and have both surface hardness (up to HRC58-63), core strength, and carburizing depth of up to 2?. Pin 50Mn wear-resistant steel, tempered after quenching, flexibility, strength, durability, wear resistance are good. In addition, in order to prevent the locking pin shaft from coming out, during the design process of the chain, in order to prevent the chain from going out during the operation and affecting the use of the entire machine equipment, we further optimized the structure of the pin shaft and pin pin shaft. The design, that is, one end of the pin shaft is made into a shoulder, and the other end is made into a retaining ring at the end surface. Tolerance is maintained by an interference to solve the pin off problem. One end of the pin is made into a shoulder, and the other end is a lock nut. And tightly, to ensure that the locking pin shaft is not out of stock during operation. After the chain with the above technical conditions, the single-chain breaking load can reach 152 tons, which can make the chain more than 10 or so, and the life can reach more than 6 years.
For the accuracy of the chain geometry, it has been proved that the positioning of the groove blank surface of the chain plate can not guarantee the tolerance of parallelism of two holes of the error chain plate of the two chain holes with a pitch of ±0.04 mm and the error of the connecting hole of the two material slots is ±0.10 mm. In the following, we have improved and adopted the large-side face milling of the chain plate as the reference surface for the positioning of the subsequent process, which truly guarantees the accuracy of the geometric dimensions. Specific follow-up processes are:
A, the pitch accuracy of the guarantee is to use a special fixture on the lathe to position the two holes of the machining chain at a time, and the pitch error is controlled within ±0.04 mm;
B. The position of the connection hole of the feed chute is guaranteed by the special tool for drilling, and the positioning clamp is once positioned, all connection holes are drilled, and the pitch error is controlled within ±0.10 mm.
C. Assemble the chain link assembly. Under the premise of controlling the pitch of each chain link, it is preferable to assemble it in order to ensure that the total length of the chain on both sides of the conveyor is within ±3 mm in length, and the length consistency during double-chain traction is ensured.
Third, the trough material trough requirements are three points: 1, the shape of the geometric shape and size is accurate, 2, and the U-shaped shaft seat connected with the roller shaft is firm and the position is accurate; 3, the deformation process in the process of processing and transportation.
The trough adopts the overall lofting and blanking, and several angle shapes of the trough are molded on the 300T hydraulic press at a time so that the shape of the trough is approximately the same. We adopt the final machining process of groove bottom plate and baffle plate to ensure the consistency of each chute shape, and the group and drilling are completed on the combined mold at one time, fully meeting the requirements of the drawings. In addition, due to the U-shaped shaft seat is easy to twist deformation, we will change the U-shaped to "â–¡" shape, milling (joint) with the joint surface, the one-time assembly and welding on a special mold. In order to ensure that the requirements of the drawings are met, the relative positional accuracy of the shaft seat holes is not satisfied, resulting in machine deviation, or even derailment. Finally, the shaft seat must be bored. At the same time, in order to control the deformation of the chute, during the manufacturing process, there are added process support ribs and the container packaging method is adopted during transportation.
Fourth, the main technical requirement of the tension spring spring is that the elastic coefficient characteristics of the two ring springs must be exactly the same, and the tension forces of the left and right sides must be the same. To ensure this, the springs used in our factory have been supplied by the Shanghai China Spring Factory with reliable quality assurance.
V. Rollers Currently, the oil cups are generally not filled with oil. In the process of transportation, installation and operation, a large number of oil cups fall off, causing dust to enter the rollers, resulting in bearing damage and failure. The surface hardness of the roller does not meet the requirements and the wear is serious. The nuts of the bolts connecting the roller shaft and the shaft seat are spot welding, which is inconvenient to maintain.
In response to the above problems, we have adopted the following measures in conjunction with the users' opinions:
1. Change the oil cup to a bayonet butter mouth;
2. The final machining process of the roller wheel body is medium frequency quenching;
3. The nut of the bolt connecting the roller shaft and the shaft seat is changed from the ordinary nut to the locking nut.
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First, the first round:
There are four requirements for the first round: 1. Correct tooth shape 2. Accurate pitch 3. Good synchronization of both wheels 4. Wear resistance. Among them, items (1)-(3) are required to be guaranteed by processing methods, and item (4) is achieved through material selection and heat treatment. The head wheel is structurally divided into two parts, namely the hub and the ring gear (usually the split head wheel). The first wheel separation not only makes maintenance and replacement more convenient, but more importantly, different materials and heat treatment methods can be selected according to the different performance requirements of the hub and ring gear. The hub is large in volume and the general cast steel can be used to meet the requirements. The gear ring is forged with 42CrMo. Through the use of medium-frequency quenching method to achieve hardened quenching drawings and the actual use of the requirements. The key to the processing of the sprocket is the ring gear, and the basic process route is: overall processing → cutting and slicing → quench forming. After passing the inspection, the ring gear blanks are machined and processed to form a special tooling profile on the large inserting bed after the quenching and tempering process to ensure accurate tooth shape indexing. In order to ensure smooth tooth shape, a grinding process is provided. In order to ensure the synchronization of the two sprockets, special tooling is used to process the coupling holes of the gear hub wheel, and the two ring gears are processed together. After the entire ring gear is processed, the segments are divided into five pieces. Then the tooth surface is quenched with HRC50-55 and the quenched depth is 2.5-3mm.
Second, the chain As the equipment process design for a section of transport, double chain traction, the chain will become the most critical components, the chain has four requirements: 1, high strength, high reliability and high wear resistance. 2. The pitch is accurate; 3. The position of the four holes connected with the chute is accurate; 4. The length of each chain is the same (factory state is 2 meters each). We chose 40Mn2 hot forging steel as the chain plate. The whole precision die forging and the first three parts of the chain, the chain plate, the pin shaft and the sleeve scraping process were added before the assembly. At the same time manganese steel is wear-resistant steel, can meet the requirements of wear. The pin bushes are made of high-grade carburizing steel 15CrMnTi, quenched after carburizing, and have both surface hardness (up to HRC58-63), core strength, and carburizing depth of up to 2?. Pin 50Mn wear-resistant steel, tempered after quenching, flexibility, strength, durability, wear resistance are good. In addition, in order to prevent the locking pin shaft from coming out, during the design process of the chain, in order to prevent the chain from going out during the operation and affecting the use of the entire machine equipment, we further optimized the structure of the pin shaft and pin pin shaft. The design, that is, one end of the pin shaft is made into a shoulder, and the other end is made into a retaining ring at the end surface. Tolerance is maintained by an interference to solve the pin off problem. One end of the pin is made into a shoulder, and the other end is a lock nut. And tightly, to ensure that the locking pin shaft is not out of stock during operation. After the chain with the above technical conditions, the single-chain breaking load can reach 152 tons, which can make the chain more than 10 or so, and the life can reach more than 6 years.
For the accuracy of the chain geometry, it has been proved that the positioning of the groove blank surface of the chain plate can not guarantee the tolerance of parallelism of two holes of the error chain plate of the two chain holes with a pitch of ±0.04 mm and the error of the connecting hole of the two material slots is ±0.10 mm. In the following, we have improved and adopted the large-side face milling of the chain plate as the reference surface for the positioning of the subsequent process, which truly guarantees the accuracy of the geometric dimensions. Specific follow-up processes are:
A, the pitch accuracy of the guarantee is to use a special fixture on the lathe to position the two holes of the machining chain at a time, and the pitch error is controlled within ±0.04 mm;
B. The position of the connection hole of the feed chute is guaranteed by the special tool for drilling, and the positioning clamp is once positioned, all connection holes are drilled, and the pitch error is controlled within ±0.10 mm.
C. Assemble the chain link assembly. Under the premise of controlling the pitch of each chain link, it is preferable to assemble it in order to ensure that the total length of the chain on both sides of the conveyor is within ±3 mm in length, and the length consistency during double-chain traction is ensured.
Third, the trough material trough requirements are three points: 1, the shape of the geometric shape and size is accurate, 2, and the U-shaped shaft seat connected with the roller shaft is firm and the position is accurate; 3, the deformation process in the process of processing and transportation.
The trough adopts the overall lofting and blanking, and several angle shapes of the trough are molded on the 300T hydraulic press at a time so that the shape of the trough is approximately the same. We adopt the final machining process of groove bottom plate and baffle plate to ensure the consistency of each chute shape, and the group and drilling are completed on the combined mold at one time, fully meeting the requirements of the drawings. In addition, due to the U-shaped shaft seat is easy to twist deformation, we will change the U-shaped to "â–¡" shape, milling (joint) with the joint surface, the one-time assembly and welding on a special mold. In order to ensure that the requirements of the drawings are met, the relative positional accuracy of the shaft seat holes is not satisfied, resulting in machine deviation, or even derailment. Finally, the shaft seat must be bored. At the same time, in order to control the deformation of the chute, during the manufacturing process, there are added process support ribs and the container packaging method is adopted during transportation.
Fourth, the main technical requirement of the tension spring spring is that the elastic coefficient characteristics of the two ring springs must be exactly the same, and the tension forces of the left and right sides must be the same. To ensure this, the springs used in our factory have been supplied by the Shanghai China Spring Factory with reliable quality assurance.
V. Rollers Currently, the oil cups are generally not filled with oil. In the process of transportation, installation and operation, a large number of oil cups fall off, causing dust to enter the rollers, resulting in bearing damage and failure. The surface hardness of the roller does not meet the requirements and the wear is serious. The nuts of the bolts connecting the roller shaft and the shaft seat are spot welding, which is inconvenient to maintain.
In response to the above problems, we have adopted the following measures in conjunction with the users' opinions:
1. Change the oil cup to a bayonet butter mouth;
2. The final machining process of the roller wheel body is medium frequency quenching;
3. The nut of the bolt connecting the roller shaft and the shaft seat is changed from the ordinary nut to the locking nut.
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