Maintenance of Shearer in Tashan Mine
Publish: 2021-04-21 07:36:59
1. Shearer is a large-scale complex system which integrates mechanical, electrical and hydraulic. The working environment is bad. If there is a fault, it will lead to the interruption of the whole coal mining work and cause huge economic losses. With the development of coal instry, the function of shearer is more and more, its structure and composition are more and more complex, so the cause of failure is also complex. The following on the shearer maintenance should pay attention to do a description<
daily maintenance management system of shearer:
daily inspection:
1. Check whether the cable and water pipe are squeezed or damaged
2 whether the bolts of main components are fully tightened, and the butt bolts and iron wedges between major components should be kept tight at all times
3 the operation of each handle is flexible and reliable
4 whether the oil level of each part is appropriate, whether the oil is emulsified by water, and whether the grease nozzles are filled with oil
5 whether the nozzle is blocked or damaged, and whether the water filter is blocked
6 whether the pick is blunt or missing
7 when the machine is working, attention should be paid to the abnormal sound of each part, the temperature rise of each part, and the distribution of oil pressure, water pressure and water volume
8 check the engagement of gear rail wheel and pin rail, and the wear of guide shoe and smooth shoe
weekly inspection: 1. Check and clean the coarse and fine filter elements installed in the hydraulic transmission department, and the fine filter element must be replaced in time
9 check the brake installed in the traction box, measure the friction plate wear, and replace it in groups when it exceeds the specified value
10 check whether the working grease meets the requirements
11 check whether the pressure gauge works normally
12 measure the oil temperature and cooling water inlet and outlet temperature of each part of the shearer when it is working
13 check and deal with daily problems that cannot be handled, and record the running status of the whole machine
14 check the daily maintenance of the shearer by the driver.
daily maintenance management system of shearer:
daily inspection:
1. Check whether the cable and water pipe are squeezed or damaged
2 whether the bolts of main components are fully tightened, and the butt bolts and iron wedges between major components should be kept tight at all times
3 the operation of each handle is flexible and reliable
4 whether the oil level of each part is appropriate, whether the oil is emulsified by water, and whether the grease nozzles are filled with oil
5 whether the nozzle is blocked or damaged, and whether the water filter is blocked
6 whether the pick is blunt or missing
7 when the machine is working, attention should be paid to the abnormal sound of each part, the temperature rise of each part, and the distribution of oil pressure, water pressure and water volume
8 check the engagement of gear rail wheel and pin rail, and the wear of guide shoe and smooth shoe
weekly inspection: 1. Check and clean the coarse and fine filter elements installed in the hydraulic transmission department, and the fine filter element must be replaced in time
9 check the brake installed in the traction box, measure the friction plate wear, and replace it in groups when it exceeds the specified value
10 check whether the working grease meets the requirements
11 check whether the pressure gauge works normally
12 measure the oil temperature and cooling water inlet and outlet temperature of each part of the shearer when it is working
13 check and deal with daily problems that cannot be handled, and record the running status of the whole machine
14 check the daily maintenance of the shearer by the driver.
2. 1、 Analysis and elimination of the failure of the Shearer to start
B. the control transformer is damaged or the output power air switch is damaged
C. the rectifier bridge on the relay board of the shearer control box is damaged, and the 24 VDC power supply for the main controller is not available
D. the operation display station or key board is damaged; Reset & quot; The button cannot be reset
e. the central processing unit (CPU) of the main controller crashes or fails to work
F. open circuit of motor temperature protection circuit
g. the main controller does not work
Troubleshooting:
A. find out the fault according to the conventional detection method and repair or replace the components< B. repair or replace the transformer
C. check the bridge rectifier on the relay board, and replace the rectifier bridge if it is damaged
D. after confirmation, replace the key board or operate the display station
E. pull off the disconnector to send power again
F. check the temperature control circuit with a multimeter according to the relevant parts on the display screen< Check the power supply of the main controller< (2) analysis and elimination of the failure of shearer lifting and lowering; (3) one of the operation display stations has poor communication or the operation key board is damaged
B. main controller failure
C. solenoid valve or load relief valve cannot work normally< The oil level of oil tank is too low or the filter is blocked
e. the pressure setting value of the heightening safety valve is low or damaged
F. the height adjustment hydraulic pump is damaged
g. the hydraulic system enters too much air or injects unqualified oil
exclusion method:
A. connect the relevant circuit or replace the keyboard
B. replace the main controller or auxiliary board
C. observe the display light on the solenoid valve. When the power supply is on, the light will be on. If not, check the power supply circuit. Otherwise, check the suction force and valve core of the solenoid valve, and repair or replace the valve
D. It is required to add qualified hydraulic oil or clean the oil filter
E. readjust or replace
E. replace the hydraulic oil pump
F. exhaust the hydraulic system or change the oil< (3) analysis and elimination of automatic sinking fault of shearer drum after lifting; (a) hydraulic lock is not tight or valve core is stuck
B. the pipeline is damaged or the joint is loose
C. liquid flowing through the front and rear cavities of the heightening cylinder
exclusion methods:
A. repair or replacement
B. tighten or replace the pipeline
C. replace the oil cylinder< 4. Analysis and elimination of shearer non traction fault A. operation display station is not reset or main controller is faulty
B. the delay relay falls off or the air switch falls off< B / > < B / > C. The 36vac power supply for the coil of vacuum contactor is not connected
D. the output power of traction transformer is too high or too low
E. data failure of frequency conversion controller shall be handled according to the failure prompted by programmer
F. there is no 20Vdc or 115VAC power supply for the inverter controller
g. the inverter is faulty and K1 is not closed
elimination method:
A. power on and reset again, and replace the main controller if it does not reset after several tests< B. press the relay or close the air switch
C. check the control power supply to make it within the allowable range< Adjust the voltage or replace the damaged parts
E. frequency converter parameter error, correct data
F. replace fuse Fu5 and fuse fu6 of auxiliary power box
g. check the inverter circuit according to the fault content of the programmer< First, disconnect the load motor wiring and check with a digital multimeter. The outline of transistor IGBT is shown in Fig. 9-13 and IGBT schematic diagram 9-14. The parameters between collector (c) and emitter (E) are measured by diode of multimeter. In static detection, when the positive electrode is connected to emitter E and the negative electrode is connected to collector
electrode C, the good transistor display value should be between 0.28-0.8v DC; If the positive electrode is connected to collector C and the negative electrode is connected to emitter e, a good transistor should show a reading of 1 (overflow), that is, C and E are cut off or a rising number. Dynamic detection: when the negative pole is connected to B and the positive pole is connected to e, the reading of C and e should be 0.38-0.65v. When IGBT mole is working, base B is not allowed to open circuit, otherwise IGBT mole will be damaged< 6. Analysis of common faults of frequency converter. 1. Current fault 200% current; B. Phase to phase short circuit and grounding of motor wiring; C. The load is too large; D. The power mole is damaged
2. Voltage fault low link volt low DC line voltage A. check rectifier mole; B. Fu4, R1, R2.
low line voltage: if the line voltage is lower than 85% of the normal voltage, it can cause the fault. Fu2 burnout
high voltage fault of hi line volt line may be caused by: A. too fast deceleration; B. The input voltage is 10% higher than the normal voltage; C. Incorrect parameter input ring programming
3. High temperature fault
the causes of high temperature rise of drive overtmp inverter may be: A. poor heat dissipation; B load is too high; C. The connection between inverter and motor is virtual; D. The temperature switch is not qualified
motop overtmp shows that the causes of motor overheating are as follows: a. the glue of thermal plug is open or the temperature protection circuit is open; B. The load is too large; C. The motor load parameters are not set correctly. The results of dB over TEM show that the causes of high brake temperature rise may be as follows: A. too high power supply voltage; B. Too frequent speed change; C. Too much load
4. Charging fault
the following aspects can be checked: A. check whether the fuse is on or off; B. Check the rectifier bridge:; C. Measure the charging resistance. If it is burned, replace the main control board. Contact open contact off / charging FLT charging fault
5. Communication fault comm0-5
analysis: A. whether the plug of the connecting line between the main control board and the console is tightly inserted; B. Whether the communication wiring is too close to the power line; C. If remote operation is used, whether the shielding layer is grounded; D. If none of the above conditions exist, replace the controller or motherboard
6. The charging light is not on
analysis: A. check whether the input line is well connected; B. When the inverter is in the shutdown state, whether the DC voltage reading is 20V; C. Whether the inverter controller is in good condition
7. Fault of motor not running
analysis: A. whether the wiring on the motor is in good condition; B. Whether the wiring between motor and frequency converter is open circuit; C. Check whether the connector of control cable is inserted tightly
8. Main board fault data fault, replace the frequency conversion main controller.
B. the control transformer is damaged or the output power air switch is damaged
C. the rectifier bridge on the relay board of the shearer control box is damaged, and the 24 VDC power supply for the main controller is not available
D. the operation display station or key board is damaged; Reset & quot; The button cannot be reset
e. the central processing unit (CPU) of the main controller crashes or fails to work
F. open circuit of motor temperature protection circuit
g. the main controller does not work
Troubleshooting:
A. find out the fault according to the conventional detection method and repair or replace the components< B. repair or replace the transformer
C. check the bridge rectifier on the relay board, and replace the rectifier bridge if it is damaged
D. after confirmation, replace the key board or operate the display station
E. pull off the disconnector to send power again
F. check the temperature control circuit with a multimeter according to the relevant parts on the display screen< Check the power supply of the main controller< (2) analysis and elimination of the failure of shearer lifting and lowering; (3) one of the operation display stations has poor communication or the operation key board is damaged
B. main controller failure
C. solenoid valve or load relief valve cannot work normally< The oil level of oil tank is too low or the filter is blocked
e. the pressure setting value of the heightening safety valve is low or damaged
F. the height adjustment hydraulic pump is damaged
g. the hydraulic system enters too much air or injects unqualified oil
exclusion method:
A. connect the relevant circuit or replace the keyboard
B. replace the main controller or auxiliary board
C. observe the display light on the solenoid valve. When the power supply is on, the light will be on. If not, check the power supply circuit. Otherwise, check the suction force and valve core of the solenoid valve, and repair or replace the valve
D. It is required to add qualified hydraulic oil or clean the oil filter
E. readjust or replace
E. replace the hydraulic oil pump
F. exhaust the hydraulic system or change the oil< (3) analysis and elimination of automatic sinking fault of shearer drum after lifting; (a) hydraulic lock is not tight or valve core is stuck
B. the pipeline is damaged or the joint is loose
C. liquid flowing through the front and rear cavities of the heightening cylinder
exclusion methods:
A. repair or replacement
B. tighten or replace the pipeline
C. replace the oil cylinder< 4. Analysis and elimination of shearer non traction fault A. operation display station is not reset or main controller is faulty
B. the delay relay falls off or the air switch falls off< B / > < B / > C. The 36vac power supply for the coil of vacuum contactor is not connected
D. the output power of traction transformer is too high or too low
E. data failure of frequency conversion controller shall be handled according to the failure prompted by programmer
F. there is no 20Vdc or 115VAC power supply for the inverter controller
g. the inverter is faulty and K1 is not closed
elimination method:
A. power on and reset again, and replace the main controller if it does not reset after several tests< B. press the relay or close the air switch
C. check the control power supply to make it within the allowable range< Adjust the voltage or replace the damaged parts
E. frequency converter parameter error, correct data
F. replace fuse Fu5 and fuse fu6 of auxiliary power box
g. check the inverter circuit according to the fault content of the programmer< First, disconnect the load motor wiring and check with a digital multimeter. The outline of transistor IGBT is shown in Fig. 9-13 and IGBT schematic diagram 9-14. The parameters between collector (c) and emitter (E) are measured by diode of multimeter. In static detection, when the positive electrode is connected to emitter E and the negative electrode is connected to collector
electrode C, the good transistor display value should be between 0.28-0.8v DC; If the positive electrode is connected to collector C and the negative electrode is connected to emitter e, a good transistor should show a reading of 1 (overflow), that is, C and E are cut off or a rising number. Dynamic detection: when the negative pole is connected to B and the positive pole is connected to e, the reading of C and e should be 0.38-0.65v. When IGBT mole is working, base B is not allowed to open circuit, otherwise IGBT mole will be damaged< 6. Analysis of common faults of frequency converter. 1. Current fault 200% current; B. Phase to phase short circuit and grounding of motor wiring; C. The load is too large; D. The power mole is damaged
2. Voltage fault low link volt low DC line voltage A. check rectifier mole; B. Fu4, R1, R2.
low line voltage: if the line voltage is lower than 85% of the normal voltage, it can cause the fault. Fu2 burnout
high voltage fault of hi line volt line may be caused by: A. too fast deceleration; B. The input voltage is 10% higher than the normal voltage; C. Incorrect parameter input ring programming
3. High temperature fault
the causes of high temperature rise of drive overtmp inverter may be: A. poor heat dissipation; B load is too high; C. The connection between inverter and motor is virtual; D. The temperature switch is not qualified
motop overtmp shows that the causes of motor overheating are as follows: a. the glue of thermal plug is open or the temperature protection circuit is open; B. The load is too large; C. The motor load parameters are not set correctly. The results of dB over TEM show that the causes of high brake temperature rise may be as follows: A. too high power supply voltage; B. Too frequent speed change; C. Too much load
4. Charging fault
the following aspects can be checked: A. check whether the fuse is on or off; B. Check the rectifier bridge:; C. Measure the charging resistance. If it is burned, replace the main control board. Contact open contact off / charging FLT charging fault
5. Communication fault comm0-5
analysis: A. whether the plug of the connecting line between the main control board and the console is tightly inserted; B. Whether the communication wiring is too close to the power line; C. If remote operation is used, whether the shielding layer is grounded; D. If none of the above conditions exist, replace the controller or motherboard
6. The charging light is not on
analysis: A. check whether the input line is well connected; B. When the inverter is in the shutdown state, whether the DC voltage reading is 20V; C. Whether the inverter controller is in good condition
7. Fault of motor not running
analysis: A. whether the wiring on the motor is in good condition; B. Whether the wiring between motor and frequency converter is open circuit; C. Check whether the connector of control cable is inserted tightly
8. Main board fault data fault, replace the frequency conversion main controller.
3. Generally, every Mining Bureau has an organic repair plant, which can be repaired. Some of them can be repaired in this mine. For example, Nantun mine of our bureau can repair shearers and roadheader
4. 1. The maintenance workers of the shearer must strictly implement the operation regulations, operation regulations, coal mine safety regulations, safety proction responsibility system and post responsibility system, carefully overhaul all parts of the shearer, strictly implement the relevant provisions of daily inspection, weekly inspection and monthly inspection, and ensure that all parts are in good condition. If the maintenance is not in place, the mechanical accident should be investigated according to its nature, Take it seriously
2. If the overhaul is not in place and affects the procer, the repairman will be fined according to the ration of the influence and the degree of responsibility. In principle, the penalty is 5 yuan per minute
3. The maintenance workers of the shearer should strictly implement the consumption of various materials of the shearer, and carry out quarterly assessment according to the material cost given by the team. The team leader should bear 1% of the overrun and the team members should bear 0.5%
4. Common tools and materials, accessories and all kinds of oil are often enough and placed in the specified place. If the proction is affected e to the lack of accessories, the responsible person will be fined 30-50 yuan according to the length of time
5. The maintenance worker shall ensure that the shearer is clean and hygienic, otherwise, a fine of 20 yuan will be imposed if the shearer is found to have poor sanitation once. After the maintenance of each shift is completed, the machine must be tested, and the equipment can only be hoisted after it is in normal operation, and a fine of 10 yuan will be imposed on each maintenance worker if the shearer is not tested once
6. Others shall be carried out according to the relevant regulations of the maintenance team
7. Fill in the delivery form and maintenance record of Shearer in time, and fine 10 yuan for not filling in one time.
2. If the overhaul is not in place and affects the procer, the repairman will be fined according to the ration of the influence and the degree of responsibility. In principle, the penalty is 5 yuan per minute
3. The maintenance workers of the shearer should strictly implement the consumption of various materials of the shearer, and carry out quarterly assessment according to the material cost given by the team. The team leader should bear 1% of the overrun and the team members should bear 0.5%
4. Common tools and materials, accessories and all kinds of oil are often enough and placed in the specified place. If the proction is affected e to the lack of accessories, the responsible person will be fined 30-50 yuan according to the length of time
5. The maintenance worker shall ensure that the shearer is clean and hygienic, otherwise, a fine of 20 yuan will be imposed if the shearer is found to have poor sanitation once. After the maintenance of each shift is completed, the machine must be tested, and the equipment can only be hoisted after it is in normal operation, and a fine of 10 yuan will be imposed on each maintenance worker if the shearer is not tested once
6. Others shall be carried out according to the relevant regulations of the maintenance team
7. Fill in the delivery form and maintenance record of Shearer in time, and fine 10 yuan for not filling in one time.
5. Come to Inner Mongolia Bayannaoer Ulat rear banner
6. The process and equipment maintenance of pithead (mine) coal preparation plant and other coal preparation plants are basically the same. There are only slight differences. The coal preparation plant at the mouth of the pit can be directly lifted from the raw coal mining area at one time, and enter the coal washing equipment directly through the buffer bin. The control of ash content depends on the adjustment of wind and water and the level of frequency. Different coal quality uses different methods, and it takes a long time to reach the requirement of ash content. Generally, adding medium in heavy medium coal washing is controlled automatically, which can be increased or decreased according to the ash content required by the proct. Please forgive me for the mistakes.
7. You can repair the shearer. Do you want to be introced? Coal mine is dirty, messy, poor, mainly tired!
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