Installation method and system of bucket elevator

Abstract

The invention discloses an installation method and system of a bucket elevator, and relates to the technical field of mechanical installation. Comprising the steps of investigating an installation environment, collecting installation data and establishing an installation preparation evaluation system; determining an assembly arrangement scheme of a transmission device, an upper section, a middle shell, a bucket chain guide rail and a lower section based on a preparation evaluation result, and formulating a step-by-step installation plan; performing deviation control and precision debugging on the equipment component, and constructing a performance evaluation standard; empty vehicle operation monitoring is carried out according to the performance indexes, and a maintenance quality evaluation system is established; and evaluation and optimization upgrading of the installation quality of the bucket elevator are realized. According to the method, the controllability and scientificity of the installation process are ensured by establishing an installation preparation evaluation system; classified installation is carried out on the equipment components based on the evaluation result, different precision grades are allocated to all the components, and the corresponding installation method is adopted, so that the installation precision is improved; and establishing a maintenance quality evaluation system through the performance indexes, and monitoring and optimizing the operation state of the equipment regularly.

Description

Technical Field

[0001] The invention relates to the technical field of mechanical installation, and in particular to an installation method and system for a bucket elevator. Background Art

[0002] The traditional installation method of bucket elevator mainly relies on manual experience, and usually uses visual inspection, manual adjustment and other methods for installation positioning and precision control. As an important bulk material vertical conveying equipment, bucket elevator is widely used in mining, metallurgy, ports, chemical industry, power production and other industries. With the improvement of industrial automation level, the installation accuracy and operation stability requirements of bucket elevator are becoming increasingly stringent. The traditional installation method of bucket elevator mainly relies on manual experience, and usually uses visual inspection, manual adjustment and other methods for installation positioning and precision control. In recent years, although some installation methods based on modern measuring tools such as laser ranging and digital level have emerged, there are still obvious deficiencies in the systematic evaluation of the installation process, the quantification of precision control, and the dynamic monitoring of the operating status. For example, in the actual installation process, due to the lack of a scientific installation preparation evaluation system, problems such as inaccurate installation condition evaluation and unreasonable component arrangement scheme often occur; at the same time, due to the lack of standardized performance evaluation standards and maintenance quality evaluation systems, the equipment has technical problems such as large verticality deviation, poor shaft coaxiality, and fast chain wear during the installation and commissioning and later operation and maintenance stages.

[0003] At present, the research on bucket elevators at home and abroad mainly focuses on structural optimization design, transmission efficiency improvement, etc., while there are relatively few systematic studies on its installation process. The existing installation technology generally has the following shortcomings: First, there is a lack of quantitative evaluation mechanism for the installation environment before installation, which leads to the lack of pertinence in the installation preparation work; second, there is no scientific deviation control model established during the installation process, which makes the adjustment of key parameters such as shell verticality and shaft coaxiality lack theoretical guidance; third, the performance evaluation after installation lacks a unified quantitative standard, making it difficult to objectively evaluate the installation quality; finally, the operation monitoring and maintenance optimization of the equipment lacks systematicity, and it is impossible to achieve continuous improvement in the installation quality. These technical problems seriously restrict the installation efficiency and operation reliability of bucket elevators, and it is urgent to develop a bucket elevator installation method based on quantitative evaluation and systematic control. Summary of the invention

[0004] In view of the problems existing in the prior art, the present invention is proposed.

[0005] Therefore, the problem to be solved by the present invention is how to overcome the shortcomings of the prior art such as inaccurate installation environment assessment, non-standard installation precision control, and lack of performance evaluation standards, and to provide a bucket elevator installation method and system based on quantitative data collection, systematic installation and debugging, and standardized quality evaluation.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0007] In a first aspect, an embodiment of the present invention provides a method for installing a bucket elevator, which includes investigating the installation environment, collecting installation data, and establishing an installation preparation evaluation system;

[0008] Determine the component arrangement plan of the transmission, upper section, middle casing, bucket chain guide, and lower section based on the results of the readiness assessment, and develop a step-by-step installation plan;

[0009] Conduct deviation control and precision debugging of equipment components and establish performance evaluation standards;

[0010] Monitor empty vehicle operation based on performance indicators and establish a maintenance quality evaluation system;

[0011] Realize the evaluation, optimization and upgrade of bucket elevator installation quality.

[0012] As a preferred solution of the installation method of the bucket elevator of the present invention, wherein: investigating the installation environment, collecting environmental data including installation position data, shell connection data, shaft system reference data and chain bucket installation data;

[0013] Among them, the installation position data include the relative position relationship between the upper section and the transmission sprocket group, the layout position of the standard section and the adjustment section of the middle casing, and the position relationship between the lower section and the feed port and the guide trough. The casing connection data include the thickness of the asbestos rubber pads between each section of the casing, the specifications of the bolts and washers at the casing connection, and the installation spacing between the casing inspection door and the guide rail. The shaft system reference data include the deviation value between the head shaft and the center line of the sprocket, the parallelism t value between the two sprockets, and the verticality of the tail shaft to the horizontal reference plane. The chain bucket installation data include the relative position of the two plate sleeve roller chains, the fixed spacing between the hopper and the chain plate, and the meshing clearance between the chain and the sprocket.

[0014] As a preferred solution of the installation method of the bucket elevator of the present invention, the installation preparation evaluation system includes:

[0015] Evaluation based on installation position data: the gap deviation between the upper section and the transmission sprocket group is ≤1mm, the connection error between the middle casing sections is ≤±1.5mm, and the centering deviation between the lower section and the feed port is ≤2mm;

[0016] Evaluation based on shell connection data: the thickness error of asbestos pads between shell sections is ≤±0.5mm, the tightening torque of shell connection bolts reaches more than 95% of the design value, and the sealing integrity of the inspection door reaches more than 95%;

[0017] Evaluation based on shafting reference data: the deviation between the head shaft and the center line of the sprocket ≤ 0.8 mm, the parallelism t value of the two sprockets ≤ 2.5 mm, and the perpendicularity error of the tail shaft ≤ 1 mm;

[0018] Evaluation based on the installation data of the chain buckets: the installation clearance error of the plate sleeve chain ≤ ±0.8 mm, the tightening torque of the hopper fixing bolts reaches more than 90% of the design value, and the meshing clearance between the chain and the sprocket is within the range of 2 - 3 mm;

[0019] Among them, the key indicators include: the deviation between the head shaft and the center line of the sprocket, the parallelism t value of the two sprockets, the perpendicularity error of the tail shaft, and the meshing clearance between the chain and the sprocket;

[0020] When all the above indicators meet the requirements, the evaluation result is excellent; when no more than two of the other indicators except the key indicators slightly exceed the requirements, the evaluation result is qualified; when any key indicator fails to meet the requirements or more than two non - key indicators fail to meet the requirements, the evaluation result is unqualified.

[0021] As a preferred scheme of the installation method of the bucket elevator of the present invention, among them: when the evaluation result is excellent, assemble with a standard middle housing and a middle housing with an inspection door, and the height dimension of the standard middle housing is selected according to the complete set list;

[0022] When the evaluation result is qualified, install two pairs of guide rails on the standard middle housing to ensure the normal operation of the chain buckets;

[0023] When the evaluation result is unqualified, on - site rectification is required to meet the installation requirements;

[0024] The step - by - step installation plan includes the installation of the housing and the head shaft. When installing the housing, the offset in the x - direction and y - direction of the upper and lower housings is less than 2 mm. When installing the head shaft, the symmetry of the head wheel [m1 - m2] < 5 mm.

[0025] As a preferred scheme of the installation method of the bucket elevator of the present invention, among them: deviation control and precision debugging include the adjustment of the perpendicularity of the housing and the coaxiality of the shafting;

[0026] Among them, the adjustment of the perpendicularity of the housing includes detecting the perpendicularity of the tail housing to the horizontal plane in the x and y directions ≤ 1 mm, checking [X n - X1] < A and [y n - y1] < A, where the value of A is required to be 3 mm when the height of the bucket elevator is 10 - 40 m, 4 mm when the height of the bucket elevator is 40 - 60 m, and 5 mm when the height of the bucket elevator is greater than 60 m;

[0027] The adjustment of the coaxiality of the shafting includes detecting the coaxiality of the input shaft of the reducer and the motor shaft. The outer - circle clearance of the coupling is 0.5 mm, and use a steel ruler and feeler gauges to check the clearance at three points after 90°.

[0028] As a preferred solution of the installation method of the bucket elevator of the present invention, the maintenance quality evaluation system includes:

[0029] Comprehensively evaluate the equipment operation status, focusing on monitoring the verticality deviation of the head / tail housing, the deviation value at both ends of the sprocket, the bearing temperature rise value, the no-load current value of the main motor, and the chain pitch elongation;

[0030] Quality assessment based on monitoring data:

[0031] When the verticality deviation is ≤1mm, the sprocket deviation is ≤3mm, the bearing temperature rise is normal, the current value is stable, and the chain elongation is ≤2%, it is evaluated as excellent;

[0032] When the verticality deviation is between 1-2mm, the sprocket deviation is between 3-4mm, the bearing temperature rise is slightly higher, the current value fluctuates, and the chain elongation is between 2-4%, it is evaluated as meeting the standard;

[0033] When the verticality deviation is >2mm, the sprocket deviation is >4mm, the bearing temperature rise is too high, the current value is abnormal, and the chain elongation is >4%, it is assessed as not meeting the standard.

[0034] As a preferred solution of the installation method of the bucket elevator of the present invention, wherein: the evaluation and optimization of the installation quality includes an operation monitoring step and a maintenance optimization step;

[0035] The operation monitoring steps include running the empty vehicle for 4 hours and recording the no-load current value of the main motor, the temperature rise value of each bearing of the reducer, and the temperature rise value of the head and tail bearings;

[0036] Maintenance optimization steps include removing a set of chain buckets at the bottom when the chain elongation exceeds 2%, adding sodium-based or lithium-based grease to the bearings every week, replacing No. 50 gear oil in the reducer every six months, and regularly tightening and spot welding all connecting bolts;

[0037] Among them, the bolts are tightened by tightening them after the first 4-hour empty-car operation and then tightening them again after the second 4-hour empty-car operation.

[0038] In a second aspect, an embodiment of the present invention provides an installation system for a bucket elevator, which includes an installation preparation assessment module, an equipment installation and debugging module, and an installation quality assessment module;

[0039] The installation preparation assessment module is used to collect installation position data, shell connection data, shaft system reference data, and chain bucket installation data to establish an installation preparation assessment system;

[0040] The equipment installation and debugging module is used to adjust the verticality of the bucket elevator shell and the coaxiality of the shaft system based on the installation preparation assessment results, and to conduct an empty car running test on the bucket elevator;

[0041] The installation quality evaluation module is used to monitor the performance parameters of the bucket elevator. A maintenance quality evaluation system is established through the verticality deviation of the head / tail housing, the deviation value at both ends of the sprocket, the bearing temperature rise value, the no-load current value of the main motor, and the chain pitch elongation, and the bucket elevator is regularly maintained and optimized.

[0042] In a third aspect, an embodiment of the present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, wherein: when the computer program instructions are executed by the processor, the steps of the bucket elevator installation method as in the first aspect of the present invention are implemented.

[0043] In a fourth aspect, an embodiment of the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program instructions are executed by a processor, the steps of the method for installing a bucket elevator according to the first aspect of the present invention are implemented.

[0044] The beneficial effects of the present invention are as follows: the bucket elevator installation method and system provided by the present invention ensure the controllability and scientific nature of the installation process by establishing an installation preparation evaluation system, thereby improving installation efficiency, reducing rework, and improving the reliability and stability of the final installation quality; by performing graded installation of equipment components based on evaluation results, each component is assigned a different level of accuracy, and a corresponding installation method is adopted, thereby improving the accuracy of installation, reducing installation costs and operating risks, and ensuring the economy and long-term stability of equipment installation; a maintenance quality evaluation system is established through performance indicators, and the operating status of the equipment is regularly monitored and optimized, thereby improving operating reliability, reducing equipment failures, and ensuring the standardization and efficiency of maintenance work. The present invention achieves better results in terms of installation accuracy, operating stability, and maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0046] Figure 1 A flowchart of the installation method of a bucket elevator;

[0047] Figure 2 The schematic diagram of the installation method of the bucket elevator in the x direction;

[0048] Figure 3 The y direction schematic diagram of the installation method of the bucket elevator;

[0049] Figure 4 It is a schematic diagram of the x-direction offset of the installation method of the bucket elevator;

[0050] Figure 5 It is a schematic diagram of the y-direction offset of the installation method of the bucket elevator;

[0051] Figure 6 Schematic diagram of the head wheel symmetry of the bucket elevator installation method. DETAILED DESCRIPTION

[0052] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0053] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0054] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0055] Example 1

[0056] Reference Figure 1 to Figure 6 , which is the first embodiment of the present invention, provides a method for installing a bucket elevator, comprising:

[0057] S1, investigate the installation environment, collect installation data and establish an installation preparation assessment system;

[0058] In the embodiment of the present application, the installation environment is investigated and the environmental data collected includes installation position data, housing connection data, shaft system reference data and chain bucket installation data;

[0059] Among them, the installation position data include the relative position relationship between the upper section and the transmission sprocket group, the layout position of the standard section and the adjustment section of the middle casing, and the position relationship between the lower section and the feed port and the guide trough. The casing connection data include the thickness of the asbestos rubber pads between each section of the casing, the specifications of the bolts and washers at the casing connection, and the installation spacing between the casing inspection door and the guide rail. The shaft system reference data include the deviation value between the head shaft and the center line of the sprocket, the parallelism t value between the two sprockets, and the verticality of the tail shaft to the horizontal reference plane. The chain bucket installation data include the relative position of the two plate sleeve roller chains, the fixed spacing between the hopper and the chain plate, and the meshing clearance between the chain and the sprocket.

[0060] It should be noted that the equipment before the installation of the bucket elevator is: cleaning the site: first clean the site before installation, and clean up the debris from the foundation to each floor slab; prepare the necessary installation tools and equipment (crane, electric winch, manual hoist, electric welder, gas cutting equipment, theodolite, level and related tools); personnel preparation: technicians and welders, installers, fitters, etc.

[0061] It should be noted that the bucket elevator (abbreviated as bucket elevator) uses two plate-type sleeve roller chains as traction components. The two sides of the bucket are fixed on the chain plates and arranged continuously. It is a bucket elevator that uses inflow loading and low-speed gravity unloading.

[0062] It should also be noted that the platform is divided into integral platform and split platform; integral platform: railings and hangers are welded on site; split platform: split platforms are generally designed to be split due to their large area and for the convenience of transportation, and then assembled and welded on site; the supports of the split platforms are generally also welded on site, and the welding steps are: welding the platform; welding the supports; welding the guardrails and hangers.

[0063] It should also be noted that the installation position data directly affects the overall layout and operating efficiency of the equipment. Accurate position relationship evaluation helps to select the optimal installation solution; the shell connection data is related to the stability and sealing of the equipment. Scientific connection parameters can ensure the long-term stable operation of the equipment; the shaft system benchmark data is the key to ensuring the operating accuracy of the transmission system and has a significant impact on the overall performance of the equipment; the chain bucket installation data involves the core components of material transportation. The precise control of these parameters can improve the transportation efficiency and reduce component wear. The weight coefficient in the evaluation model allows adjustment according to different installation environments and requirements to achieve the optimization of the installation solution.

[0064] S2, based on the results of the preparation assessment, determine the component arrangement plan of the transmission device, upper section, middle casing, bucket chain guide, and lower section, and formulate a step-by-step installation plan;

[0065] Furthermore, the Installation Readiness Assessment System includes:

[0066] Evaluation based on installation position data: the gap deviation between the upper section and the transmission sprocket group is ≤1mm, the connection error between the middle casing sections is ≤±1.5mm, and the centering deviation between the lower section and the feed port is ≤2mm;

[0067] Evaluation based on shell connection data: the thickness error of asbestos pads between shell sections is ≤±0.5mm, the tightening torque of shell connection bolts reaches more than 95% of the design value, and the sealing integrity of the inspection door reaches more than 95%;

[0068] Evaluation based on shaft system benchmark data: deviation between head shaft and sprocket centerline ≤0.8mm, parallelism t value of two sprockets ≤2.5mm, verticality error of tail shaft ≤1mm;

[0069] Evaluation based on chain bucket installation data: the plate sleeve chain installation gap error is ≤±0.8mm, the hopper fixing bolt tightening torque reaches more than 90% of the design value, and the chain and sprocket meshing gap is within the range of 2-3mm;

[0070] The key indicators include: the deviation between the center line of the head shaft and the sprocket, the parallelism t value of the two sprockets, the verticality error of the tail shaft and the meshing clearance between the chain and the sprocket;

[0071] When all the above indicators meet the requirements, the evaluation result is excellent; when no more than two indicators other than the key indicators slightly exceed the requirements, the evaluation result is qualified; when any key indicator does not meet the requirements or more than two non-key indicators do not meet the requirements, the evaluation result is unqualified.

[0072] Furthermore, when the evaluation result is excellent, the standard middle casing and the middle casing with inspection door are used for assembly, and the height dimension of the standard middle casing is selected according to the set table;

[0073] When the evaluation results are qualified, two pairs of guide rails are installed on the standard middle casing to ensure the normal operation of the chain bucket;

[0074] When the evaluation results are unsatisfactory, on-site rectification is required to meet the installation requirements;

[0075] The step-by-step installation plan includes shell installation and head shaft installation. When the shell is installed, the offset of the upper and lower shells in the x and y directions is less than 2mm, and when the head shaft is installed, the head wheel symmetry [m1-m2] is less than 5mm.

[0076] It should be noted that the installation sequence of the bucket elevator shell is as follows: first install the tail on the foundation, make the tail shell perpendicular to the horizontal plane, and the verticality of the x and y directions to the horizontal plane should be ≤1mm, and tighten the anchor bolts (or weld the embedded iron); ② After confirming that the tail is installed correctly, install the first section. When installing, first put the asbestos pad, hoist the shell to align, and use the outer wall of the shell as the reference. The offset of the upper and lower shells in the x and y directions should be less than 2mm, see Figure 2; When [x2 - x1] < 2 mm and [y2 - y1] < 2 mm and the inspection is correct, then tighten the nut. Note that a flat washer and a spring washer must be added under the nut; ③ Lift the intermediate housing in sequence according to the above method. Pay attention to the positions of the non-standard section and the adjustment section (each section of our company has a number when leaving the factory, and it should be installed according to the number during assembly), so that all connection positions of the bucket elevator are convenient for disassembly and maintenance. During the process of lifting in sequence, check at any time that [xn - x1] < A and [yn - y1] < A. n (the number of sections from the tail to the head, including the head, the tail, the standard section, and the adjustment section). When installing and inspecting, two theodolites can be used to align simultaneously from the X direction and the Y direction (there are many methods, which can be selected by the installers themselves). No matter what method is used, it must meet the installation technical requirements in order to make the machine work smoothly and normally. For bucket elevators of different heights, the specific installation accuracy requirements are as follows: that is, for [xn - x1] < A and [yn - y1] < A, the requirements for the A value are shown in the following table:

[0077] Bucket elevator height Deviation value A 10—40m 3mm 40—60 4mm ＞60m 5mm

[0078] It should be noted that the step-by-step installation plan includes the installation of the housing and the head shaft. Among them, when installing the housing, the offset in the x direction and the y direction between the upper and lower housings is less than 2 mm, and when installing the head shaft, the symmetry degree of the head wheel [m1 - m2] < 5 mm. Use two theodolites to align simultaneously from the X direction and the Y direction. For bucket elevators of different heights, the specific installation accuracy requirements are: when the height is 10 - 40 m, the deviation value A is 3 mm; when the height is 40 - 60 m, the deviation value A is 4 mm; when the height is greater than 60 m, the deviation value A is 5 mm.

[0079] It should also be noted that the excellent evaluation results indicate that the installation conditions fully meet the requirements and the standard installation plan can be directly adopted; the qualified evaluation results require additional protective measures to ensure the installation quality; the unqualified evaluation results require re-evaluation after environmental improvement. The accuracy requirements in the step-by-step installation plan are classified according to the equipment height. This classification control method not only ensures the installation quality but also avoids the cost increase caused by excessive requirements.

[0080] S3. Conduct deviation control and precision debugging on the equipment components to establish performance evaluation criteria;

[0081] In the embodiment of the present application, the deviation control and precision debugging include the adjustment of the housing verticality and the coaxiality adjustment of the shafting;

[0082] Among them, the adjustment of the housing verticality includes detecting that the verticality of the tail housing in the x and y directions with respect to the horizontal plane is ≤ 1 mm, and checking [X n - X1] < A and [y n - y1] < A, where the requirement for the A value is: when the height of the bucket elevator is 10 - 40 m, A is 3 mm; when the height of the bucket elevator is 40 - 60 m, A is 4 mm; when the height of the bucket elevator is greater than 60 m, A is 5 mm;

[0083] The shaft coaxiality adjustment includes checking the coaxiality of the reducer input shaft and the motor shaft. The outer circle clearance of the coupling is 0.5mm, and the three-point clearance after 90° is checked using a steel ruler and a thickness gauge.

[0084] It should be noted that the installation and inspection specifications of the head shell are the same as those of the intermediate shell. After the head shell is installed, the head shaft assembly begins. When installing the head shaft, the following three key requirements must be met. Use a frame level to preliminarily adjust the level of the head shaft, and install two steel wires ( Left and right) until it is below the centerline of the tail wheel. Hang a large plumb line at the lower end of each wire and immerse it in two oil barrels. After it stabilizes, measure the t value between the left and right wheels. If [t1-t2] < 3mm, loosen the head shaft bearing seat fastening bolts and adjust the head shaft position to ensure [t1-t2] < 3mm, so as to control the two shafts in the same plane.

[0085] Adjust the head axis so that the steel wire located at the center of the two wheels is also located at the center of the two tail wheels at the same time. The deviation adjustment method is the same as using a frame level to preliminarily adjust the level of the head axis. In actual adjustment, the two adjustments of preliminarily adjusting the level of the head axis with a frame level and adjusting the head axis can be carried out at the same time;

[0086]

[0087] The symmetry of the head wheel [m1-m2] is less than 5mm. However, when the symmetry of the head wheel cannot be guaranteed in order to ensure the preliminary adjustment of the head axis level and the adjustment of the head axis with a frame level, the symmetry of the head wheel can be relaxed. It should be noted that the above is mainly based on the adjustment of the head axis. If the adjustment of the head axis on site cannot meet its main parameters, you can consider adjusting the tail shaft or adjusting the head shell (loosen the connecting bolts on the head to move or rotate the position of the shell to solve the problem).

[0088] Adjustment of the coaxiality between the motor and the reducer input shaft. The following is the method for on-site replacement: When checking the coaxiality, the elevation of the motor seat plane should be 1-1.5mm smaller than the nominal size. This is to facilitate the adjustment of the coaxiality between the reducer input shaft and the motor shaft. Generally, the reducer is not moved (because it is too troublesome to have too many pads on the reducer base, the reducer is also heavy, and the motor is relatively light), and the number of pads is also small. The motor can be moved in the X and Y directions or the thickness of the pad can be used to change the size in the Z direction. Generally, the reducer is not moved. The method is to adjust the motor first, and check it with a steel ruler and a thickness gauge (also called a plug gauge). When checking, put the steel ruler on the large outer circle of the coupling (parallel to the axis) and check it once at 90°. If the clearances of the three points checked, the steel ruler and the outer circles of the two couplings are the same, it means that the coaxiality of the motor shaft and the reducer has reached the requirements. If the three outer clearances are different, the plug gauge can be used to measure the size of the clearance. If the clearance at the motor end is large when measuring at the top of the outer circle of the coupling, it means that the motor is low and needs to be padded from the bottom of the motor. The thickness of the pad depends on the size of the gap. For example, if the gap is 0.5mm, a 0.5mm pad should be used.

[0089] It should also be noted that the installation accuracy of the equipment directly affects its operating stability and service life. Verticality control ensures the smoothness of material transportation, and coaxiality adjustment ensures the efficient operation of the transmission system. Differentiated accuracy standards are used for different equipment heights, which not only ensures the installation quality, but also avoids the increased construction difficulty and cost caused by excessive accuracy requirements. Through scientific measurement methods and standardized adjustment processes, the controllability and consistency of equipment installation accuracy are achieved.

[0090] S4, monitor empty vehicle operation based on performance indicators and establish a maintenance quality evaluation system;

[0091] In the embodiment of the present application, the maintenance quality evaluation system includes:

[0092] Comprehensively evaluate the equipment operation status, focusing on monitoring the verticality deviation of the head / tail housing, the deviation value at both ends of the sprocket, the bearing temperature rise value, the no-load current value of the main motor, and the chain pitch elongation;

[0093] Quality assessment based on monitoring data:

[0094] When the verticality deviation is ≤1mm, the sprocket deviation is ≤3mm, the bearing temperature rise is normal, the current value is stable, and the chain elongation is ≤2%, it is evaluated as excellent;

[0095] When the verticality deviation is between 1-2mm, the sprocket deviation is between 3-4mm, the bearing temperature rise is slightly higher, the current value fluctuates, and the chain elongation is between 2-4%, it is evaluated as meeting the standard;

[0096] When the verticality deviation is >2mm, the sprocket deviation is >4mm, the bearing temperature rise is too high, the current value is abnormal, and the chain elongation is >4%, it is assessed as not meeting the standard.

[0097] It should be noted that manual or jog test run is required before empty vehicle operation. The chain should rotate on the sprocket for more than two weeks. Only when there is no jamming or abnormal sound can the empty vehicle be operated continuously. During the empty vehicle operation, the current and voltage of the main motor should be measured and recorded in time. At the same time, the temperature rise of each bearing part of the reducer and the temperature rise of the head and tail bearings of the bucket elevator should be measured. After the empty vehicle runs for 4 hours, if there is no abnormal phenomenon, it can be stopped and all the bolts fixing the bucket should be tightened once. Because the bucket is in the right position during the empty vehicle operation at this time, tighten the screws and stop the empty vehicle for more than 4 hours, tighten the bucket connection bolts again, and spot weld the bolts and nuts with electric welding after tightening the bolts.

[0098] It should also be noted that lubrication is carried out according to the following table in daily work:

[0099]

[0100]

[0101] It should also be noted that this evaluation system achieves comprehensive monitoring of the equipment's operating status through comprehensive evaluation of multiple key performance indicators. Verticality deviation and sprocket deviation reflect the geometric accuracy of the equipment, bearing temperature rise and current value characterize the equipment's operating status, and chain elongation reflects the degree of wear of key components. Through this multi-dimensional evaluation system, potential problems in equipment operation can be discovered in a timely manner, providing a scientific basis for maintenance decisions.

[0102] S5, to evaluate, optimize and upgrade the installation quality of bucket elevators;

[0103] In the embodiment of the present application, the evaluation and optimization of installation quality includes an operation monitoring step and a maintenance optimization step;

[0104] The operation monitoring steps include running the empty vehicle for 4 hours and recording the no-load current value of the main motor, the temperature rise value of each bearing of the reducer, and the temperature rise value of the head and tail bearings;

[0105] Maintenance optimization steps include removing a set of chain buckets at the bottom when the chain elongation exceeds 2%, adding sodium-based or lithium-based grease to the bearings every week, replacing No. 50 gear oil in the reducer every six months, and regularly tightening and spot welding all connecting bolts;

[0106] Among them, the bolts are tightened by tightening them after the first 4-hour empty-car operation and then tightening them again after the second 4-hour empty-car operation.

[0107] It should be noted that the required amount of spare parts should be prepared based on experience and daily inspections. The following table lists the commonly used spare parts:

[0108]

[0109]

[0110] It should also be noted that this systematic evaluation and optimization mechanism extends installation quality control to the entire life cycle of the equipment. Through standardized monitoring methods and maintenance processes, continuous improvement of equipment performance is achieved, ensuring long-term stable operation of the equipment. At the same time, by accumulating operating data and maintenance experience, the installation process can be continuously improved and the installation quality of subsequent projects can be improved.

[0111] Furthermore, the present embodiment also provides a bucket elevator installation system, including an installation preparation assessment module, an equipment installation and debugging module, and an installation quality assessment module;

[0112] The installation preparation assessment module is used to collect installation position data, shell connection data, shaft system reference data, and chain bucket installation data to establish an installation preparation assessment system;

[0113] The equipment installation and debugging module is used to adjust the verticality of the bucket elevator shell and the coaxiality of the shaft system based on the installation preparation assessment results, and to conduct an empty car running test on the bucket elevator;

[0114] The installation quality evaluation module is used to monitor the performance parameters of the bucket elevator. A maintenance quality evaluation system is established through the verticality deviation of the head / tail housing, the deviation value at both ends of the sprocket, the bearing temperature rise value, the no-load current value of the main motor, and the chain pitch elongation, and the bucket elevator is regularly maintained and optimized.

[0115] This embodiment also provides a computer device suitable for the installation method of a bucket elevator, including a memory and a processor; the memory is used to store computer executable instructions, and the processor is used to execute computer executable instructions to implement the installation method of the bucket elevator proposed in the above embodiment.

[0116] The computer device may be a terminal, and the computer device includes a processor, a memory, a communication interface, a display screen and an input device connected via a system bus. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The communication interface of the computer device is used to communicate with an external terminal in a wired or wireless manner, and the wireless manner can be achieved through WIFI, an operator network, NFC (near field communication) or other technologies. The display screen of the computer device may be a liquid crystal display screen or an electronic ink display screen, and the input device of the computer device may be a touch layer covering the display screen, or a key, trackball or touchpad provided on the housing of the computer device, or an external keyboard, touchpad or mouse, etc.

[0117] This embodiment also provides a storage medium on which a computer program is stored. When the program is executed by a processor, the method for installing a bucket elevator as proposed in the above embodiment is implemented.

[0118] In summary, the bucket elevator installation method and system provided by the present invention ensure the controllability and scientificity of the installation process by establishing an installation preparation evaluation system, improve installation efficiency, reduce rework, and improve the reliability and stability of the final installation quality; by performing graded installation of equipment components based on the evaluation results, each component is assigned a different level of accuracy, and a corresponding installation method is adopted, which improves the installation accuracy, reduces the installation cost and operation risk, and ensures the economy and long-term stability of the equipment installation; a maintenance quality evaluation system is established through performance indicators, and the equipment operation status is regularly monitored and optimized, which improves the operation reliability, reduces equipment failures, and ensures the standardization and efficiency of maintenance work. The present invention achieves better results in installation accuracy, operation stability and maintenance efficiency.

[0119] Example 2

[0120] Reference Figure 1-Figure 6 , which is the second embodiment of the present invention, and this embodiment provides an installation method for a bucket elevator. In order to verify the beneficial effects of the present invention, scientific demonstration is carried out through economic benefit calculation and simulation experiments.

[0121] A newly built TD800 bucket elevator in a mine was selected as the test object. The total height of the elevator was 45 meters and the designed conveying capacity was 500t / h. In order to verify the effectiveness of the method of the present invention, a comparative test was carried out using the traditional installation method and the installation method proposed by the present invention.

[0122] The traditional installation method mainly relies on the experience of construction personnel for installation, lacking systematic evaluation and precise control; the method of the present invention first uses a high-precision laser theodolite and a digital level to comprehensively measure the installation environment and obtain installation position data: relative position deviation between the upper section and the transmission sprocket group (0.8mm), spacing error between the middle casing sections (±1.2mm), and centering between the lower section and the feed port (1.5mm); shell connection data: asbestos rubber pad thickness deviation (±0.3mm), bolt tightening torque (reaching 95% of the design value), inspection door sealing integrity (98%); shaft system reference data: head shaft and sprocket centerline deviation (0.6mm), two sprocket parallelism t value (2.1mm), tail shaft verticality (0.8mm); chain bucket installation data: two plate sleeve roller chain spacing error (±0.5mm), bucket fixing bolt tightness (reaching 96% of the design value), chain and sprocket meshing clearance (2.2mm).

[0123] Through comprehensive evaluation of the above indicators, it was determined that the installation conditions of the equipment were within the qualified range. Based on this evaluation result, two pairs of guide rails were added to the standard middle casing, and the installation was carried out by segmented lifting. During the installation process, dual theodolites were used to align from both the X and Y directions, and a digital micrometer was used to monitor the connection accuracy of each section of the casing in real time. In the head shaft installation process, the wire drop method was innovatively used in combination with a laser centering instrument to adjust the head wheel symmetry within 3mm.

[0124] After the mechanical installation was completed, an 8-hour segmented empty vehicle trial run was carried out, and the key operating parameters of the equipment were recorded every 4 hours, including the no-load current of the main motor, bearing temperature rise, chain elongation and other data. A scientific maintenance quality evaluation system was established based on these data.

[0125]

[0126] The comparative test data analysis shows that the method of the present invention is significantly superior to the traditional installation method in many key technical indicators:

[0127] In terms of installation accuracy: for the equipment installed by the traditional method, the average vertical deviation of the shell is 2.65mm, and the average deviation of the sprocket is 4.05mm; while for the equipment installed by the method of the present invention, these two indicators are reduced to 0.8mm and 1.93mm, respectively, with an improvement of 69.8% and 52.3%, respectively. This improvement in accuracy is mainly due to the innovative solution of the dual theodolite synchronous alignment method and the steel wire drop combined with laser alignment proposed by the present invention.

[0128] In terms of operating status: under the traditional installation method, the average bearing temperature rise reached 43.5°C, and the no-load current fluctuation range reached ±8.15%; after adopting the method of the present invention, the bearing temperature rise was reduced to 26.3°C, and the no-load current fluctuation was narrowed to ±2.13%, which were improved by 39.5% and 73.8% respectively. This shows that the precision control method of the present invention significantly improves the operating stability of the equipment.

[0129] Service life index: For the equipment installed by the traditional method, the chain elongation is 3.65% on average, and the first maintenance cycle is only 6.5 months; while for the equipment installed by the method of the present invention, the chain elongation is reduced to 1.1%, and the first maintenance cycle is extended to 19.7 months, which are improved by 69.9% and 203% respectively. This fully proves the effectiveness of the installation preparation evaluation system and maintenance quality evaluation system proposed by the present invention.

[0130] Economic benefit analysis: By extending the maintenance cycle and reducing the maintenance frequency, it is estimated that each device will save about 150,000 yuan in annual maintenance costs, reduce equipment downtime by 180 hours, and create additional economic benefits of about 1.2 million yuan. At the same time, the improved stability of equipment operation also reduces the loss during material transportation, further improving economic benefits.

[0131] These data fully prove that the installation method proposed in the present invention has significant technical innovation and practical application value in improving installation accuracy, improving operating conditions, and extending service life.

[0132] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for installing a bucket elevator, characterized in that: include, Investigate the installation environment, collect installation data and establish an installation preparation assessment system; Determine the component arrangement plan of the transmission, upper section, middle casing, bucket chain guide, and lower section based on the results of the readiness assessment, and develop a step-by-step installation plan; Conduct deviation control and precision debugging of equipment components and establish performance evaluation standards; Monitor empty vehicle operation based on performance indicators and establish a maintenance quality evaluation system; Realize the evaluation, optimization and upgrade of bucket elevator installation quality.

2. The method for installing a bucket elevator according to claim 1, characterized in that: The survey of the installation environment and the collection of environmental data include installation position data, housing connection data, shaft system reference data and chain bucket installation data; Among them, the installation position data include the relative position relationship between the upper section and the transmission sprocket group, the layout position of the standard section and the adjustment section of the middle casing, and the position relationship between the lower section and the feed port and the material guide trough. The casing connection data include the thickness of the asbestos rubber pads between each section of the casing, the specifications of the bolts and washers at the casing connection, and the installation spacing between the casing inspection door and the guide rail. The shaft system reference data include the deviation value between the head shaft and the center line of the sprocket, the parallelism t value between the two sprockets, and the verticality of the tail shaft to the horizontal reference plane. The chain bucket installation data include the relative position of the two plate sleeve roller chains, the fixed spacing between the bucket and the chain plate, and the meshing clearance between the chain and the sprocket.

3. The method for installing a bucket elevator according to claim 2, characterized in that: The installation readiness assessment system includes: Evaluation based on installation position data: the gap deviation between the upper section and the transmission sprocket group is ≤1mm, the connection error between the middle casing sections is ≤±1.5mm, and the centering deviation between the lower section and the feed port is ≤2mm; Evaluation based on shell connection data: the thickness error of asbestos pads between shell sections is ≤±0.5mm, the tightening torque of shell connection bolts reaches more than 95% of the design value, and the sealing integrity of the inspection door reaches more than 95%; Evaluation based on shaft system benchmark data: deviation between head shaft and sprocket centerline ≤0.8mm, parallelism t value of two sprockets ≤2.5mm, verticality error of tail shaft ≤1mm; Evaluation based on chain bucket installation data: the plate sleeve chain installation gap error is ≤±0.8mm, the hopper fixing bolt tightening torque reaches more than 90% of the design value, and the chain and sprocket meshing gap is within the range of 2-3mm; The key indicators include: the deviation between the center line of the head shaft and the sprocket, the parallelism t value of the two sprockets, the verticality error of the tail shaft and the meshing clearance between the chain and the sprocket; When all of the above indicators meet the requirements, the evaluation result is excellent; when no more than two indicators other than the key indicators slightly exceed the requirements, the evaluation result is qualified; when any key indicator does not meet the requirements or more than two of the non-key indicators do not meet the requirements, the evaluation result is unqualified.

4. The method for installing a bucket elevator according to claim 3, characterized in that: When the evaluation result is good, the standard middle casing and the middle casing with inspection door are used for assembly, and the height size of the standard middle casing is selected according to the set table; When the evaluation results are qualified, two pairs of guide rails are installed on the standard middle casing to ensure the normal operation of the chain bucket; When the evaluation results are unsatisfactory, on-site rectification is required to meet the installation requirements; The step-by-step installation plan includes shell installation and head shaft installation, wherein when the shell is installed, the offset of the upper and lower shells in the x and y directions is less than 2 mm, and when the head shaft is installed, the head wheel symmetry [m1-m2] is less than 5 mm.

5. The method for installing a bucket elevator according to claim 4, characterized in that: The deviation control and precision adjustment include shell verticality adjustment and shaft coaxiality adjustment; Among them, the adjustment of the shell verticality includes detecting that the verticality of the tail shell in the two directions of the horizontal plane x and y is ≤ 1 mm, and checking [X n - X1] < A and [y n - y1] < A, where the value of A is required to be 3 mm when the height of the bucket elevator is 10 - 40 m, 4 mm when the height of the bucket elevator is 40 - 60 m, and 5 mm when the height of the bucket elevator is greater than 60 m; The shaft coaxiality adjustment includes checking the coaxiality of the reducer input shaft and the motor shaft. The outer circle clearance of the coupling is 0.5mm, and the three-point clearance after 90° is checked using a steel ruler and a thickness gauge.

6. The method for installing a bucket elevator according to claim 5, characterized in that: The maintenance quality evaluation system includes: Comprehensively evaluate the equipment operation status, focusing on monitoring the verticality deviation of the head / tail housing, the deviation value at both ends of the sprocket, the bearing temperature rise value, the no-load current value of the main motor, and the chain pitch elongation; Quality assessment based on monitoring data: When the verticality deviation is ≤1mm, the sprocket deviation is ≤3mm, the bearing temperature rise is normal, the current value is stable, and the chain elongation is ≤2%, it is evaluated as excellent; When the verticality deviation is between 1-2mm, the sprocket deviation is between 3-4mm, the bearing temperature rise is slightly higher, the current value fluctuates, and the chain elongation is between 2-4%, it is evaluated as meeting the standard; When the verticality deviation is >2mm, the sprocket deviation is >4mm, the bearing temperature rise is too high, the current value is abnormal, and the chain elongation is >4%, it is assessed as not meeting the standard.

7. The method for installing a bucket elevator according to claim 6, characterized in that: The evaluation and optimization of the installation quality includes an operation monitoring step and a maintenance optimization step; The operation monitoring step includes running the empty vehicle for 4 hours and recording the no-load current value of the main motor, the temperature rise value of each bearing of the reducer, and the temperature rise value of the head and tail bearings; The maintenance optimization steps include removing a set of chain buckets at the bottom when the chain elongation exceeds 2%, adding sodium-based or lithium-based grease to the bearings every week, replacing No. 50 gear oil in the reducer every six months, and regularly tightening and spot welding all connecting bolts; Among them, the bolts are tightened by tightening them after the first 4-hour empty-car operation and then tightening them again after the second 4-hour empty-car operation.

8. A bucket elevator installation system, based on the bucket elevator installation method according to any one of claims 1 to 7, characterized in that: It also includes, installation preparation assessment module, equipment installation and commissioning module, and installation quality assessment module; The installation preparation assessment module is used to collect installation position data, housing connection data, shaft system reference data, and chain bucket installation data to establish an installation preparation assessment system; The equipment installation and debugging module is used to adjust the verticality of the bucket elevator shell and the coaxiality of the shaft system based on the installation preparation assessment results, and to perform an empty car running test on the bucket elevator; The installation quality evaluation module is used to monitor the performance parameters of the bucket elevator. A maintenance quality evaluation system is established through the verticality deviation of the head / tail shell, the deviation value at both ends of the sprocket, the bearing temperature rise value, the no-load current value of the main motor, and the chain pitch elongation, so as to regularly perform maintenance and optimization on the bucket elevator.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the bucket elevator installation method according to any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the bucket elevator installation method according to any one of claims 1 to 7 are implemented.

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