An automatic lubrication device and lubrication method for the lifting chain of a bucket unloader.

Abstract

This invention discloses an automatic lubrication device and method for the lifting chain of a bucket unloader. The system includes an X-axis moving device, a Y-axis moving device, an automatic lubrication device, and a controller. The automatic lubrication device is mounted on the Y-axis moving device, and the Y-axis moving device is mounted on the X-axis moving device. During operation, the controller can control the X-axis and Y-axis moving devices in real time based on data collected by a three-dimensional laser rangefinder, automatically adjusting the position of the three-dimensional laser rangefinder to ensure the lubrication nozzle is always in the appropriate lubrication position. This invention features X, Y, and Z-axis spatial movement and follow-up functions. If the chain sways during link switching, this can be detected by the three-dimensional laser rangefinder, and the controller will then control the X-axis and Y-axis moving devices to adjust the position of the lubrication nozzle, ensuring it is always in the accurate lubrication position for effective lubrication.

Description

Technical Field

[0001] This invention belongs to the technical field of unloading equipment, specifically relating to an automatic lubrication device and lubrication method for the lifting chain of a chain bucket unloader. Background Technology

[0002] Bucket unloaders are specialized unloading equipment used in bulk cargo terminals, characterized by high efficiency, energy saving, and environmental friendliness. During operation, the lifting chains are partially buried in fine ore, subject to prolonged erosion from mineral powder and moisture. Under these harsh conditions, chain link lubrication is crucial. The two bucket unloader chains are 97.5 meters long, with 800 links and a total of 1600 lubrication points. The typical lubrication cycle is 100,000 tons per cycle. The effectiveness of lubrication directly impacts the chain's lifespan, making lubrication maintenance extremely important.

[0003] Currently, chain lubrication at bulk ore terminal chain bucket unloaders mainly relies on manual oiling. Typically, with the lifting chain stopped, the operator lubricates a section of the chain below the material handling head, then starts the chain to rotate the un-maintained links to the ground, stops the lifting chain again, and continues lubricating. This cycle is repeated until all chain links and pins are lubricated. A single maintenance operation for the lifting chain usually requires four people working together for 3-4 hours, which is time-consuming, labor-intensive, and inefficient.

[0004] To address the issue of low efficiency, Chinese Patent Publication No. CN102180345A discloses an automatic chain lubrication device for a bucket elevator. This device includes a pneumatic control system consisting of an air compressor and piping, and a support frame with a U-shaped groove. The groove houses an air compressor and a lubricating oil pump, while the bottom is symmetrically equipped with horizontal adjustment seats and rubber universal wheels. Longitudinal moving guide rails are symmetrically mounted on the two walls of the U-shaped groove, supporting a longitudinal moving operating platform. A transverse moving guide rail is mounted on the longitudinal operating platform, supporting a transverse moving operating platform. A longitudinal positioning block and an oil gun are mounted on the transverse moving operating platform. A high-pressure gas nozzle is also mounted on the support frame. When the automatic chain lubrication device is placed 550mm below the bucket elevator, and the center line of the U-shaped groove of the support frame is aligned with the chain's running direction, the pneumatic control system drives the transverse moving operating platform to move and freely connect with the chain pins. The chain then propels the transverse moving platform forward a distance equal to one chain pitch, completing a cycle of cleaning and lubrication of a pair of chain pins.

[0005] The technical solution disclosed in the aforementioned patent (CN102180345A) requires manual adjustment of the refueling device position based on the height of the lifting transmission chain before refueling. The refueling nozzle must then be aligned with the chain before automatic refueling can be initiated. Furthermore, this refueling device can only move horizontally and repeatedly in the chain's rotation direction. In reality, wind vibrations in the chain bucket unloader's boom and chain vibrations cause the material handling head to sway, resulting in a constantly changing chain position. The refueling device cannot follow the chain's movement and refuel in real time, leading to poor refueling efficiency. Summary of the Invention

[0006] The purpose of this invention is to provide an automatic lubrication device and lubrication method for the lifting chain of a chain bucket unloader that has high lubrication efficiency, accurate positioning, and good effect.

[0007] The technical solution of this invention is as follows: An automatic lubrication device for the lifting chain of a chain bucket unloader, characterized in that it includes an X-axis moving device, a Y-axis moving device, an automatic lubrication device, and a controller; the automatic lubrication device includes a fixed bracket, a Z-axis moving seat movably mounted on the fixed bracket, two sets of tracking lubrication components, and a three-axis laser rangefinder limiter for determining the position of chain links; the tracking lubrication components include a lubrication cylinder, a tracking cylinder, and a control valve, wherein the piston rod end of the lubrication cylinder is connected to a lubrication nozzle, and the piston rod end of the tracking cylinder is connected to a following stop for intercepting the chain pin; the lubrication cylinder and the tracking cylinder... The tracking cylinders are arranged side by side and fixedly mounted on the Z-axis moving base. A reset spring is also connected to the Z-axis moving base. The three-axis laser rangefinder limiter is fixedly mounted on the fixed bracket via the sensing bracket. The fixed bracket is mounted on the Y-axis moving device and can move longitudinally under the drive of the Y-axis moving device. The Y-axis moving device is mounted on the X-axis moving device and can move laterally under the drive of the X-axis moving device. During operation, the controller can control the X-axis moving device and the Y-axis moving device in real time according to the data collected by the three-axis laser rangefinder limiter, and automatically adjust the position of the three-axis laser rangefinder limiter.

[0008] Furthermore, the X-axis moving device includes a base, an X-axis slide rail mounted on the base, an X-axis moving seat mounted on the X-axis slide rail, and an X-axis drive cylinder capable of driving the X-axis moving seat to move. The Y-axis moving device includes a stand mounted on the X-axis moving seat, a Y-axis slide rail mounted on the stand, a Y-axis moving seat mounted on the Y-axis slide rail, and a Y-axis drive cylinder capable of driving the Y-axis moving seat to move.

[0009] Furthermore, the following stop includes a connecting rod connected to the end of the piston rod and an arc-shaped baffle installed at the front end of the connecting rod.

[0010] Furthermore, the control valve is a mechanically controlled valve. The valve body of the mechanically controlled valve is fixedly mounted on the fixed bracket, and the stop assembly of the mechanically controlled valve is mounted on the Z-axis moving seat. When the chain drives the Z-axis moving seat to move, the stop assembly can follow the movement and drive the mechanically controlled valve plunger to move up and down, so that the piston rods of the tracking cylinder and the refueling cylinder extend or retract.

[0011] The present invention also provides a lubrication method for an automatic lubrication device based on the lifting chain of the above-mentioned bucket unloader, characterized by comprising the following steps:

[0012] (1) Install two sets of the automatic lubrication equipment to lubricate and maintain the lifting chains on both sides of the chain bucket unloader; in the initial state, the lifting chains on both sides of the chain bucket unloader are waiting for lubrication in the maintenance position, and the lubrication nozzles of the two sets of automatic lubrication equipment are ready at the initial zero position.

[0013] (2) When refueling, first manually control the X-axis moving device and Y-axis moving device of the automatic lubrication equipment to make the three-axis laser rangefinder reach the monitoring zero position of the first link to be refueled;

[0014] (3) The piston rods of the tracking cylinders of the two sets of tracking refueling components extend simultaneously, and the corresponding two following stops contact the two chain pin ends of the chain link to be refueled. The chain is started to rotate at the maintenance speed. When it rotates, it drives the Z-axis moving seat to move synchronously. At this time, the piston rod of the refueling cylinder extends, the refueling nozzle connects to the chain pin and performs oil injection.

[0015] (4) After the first link is lubricated, the piston rods of the lubrication cylinder and the tracking cylinder retract. Under the action of the reset spring, the tracking lubrication component resets with the Z-axis moving seat; waiting to lubricate the next link.

[0016] (5) After the tracking refueling component is reset, the three-way laser rangefinder collects the distance data between the chain plate and the pin on both sides of the chain link in real time, and determines whether it is at the monitoring zero position. If it is at the monitoring zero position, repeat steps (3)-(4) until all chain links and pins are refueled; if it is not at the monitoring zero position, execute step (6).

[0017] (6) The controller controls the X-axis moving device and Y-axis moving device to move in real time according to the distance data collected in real time by the three-axis laser rangefinder limiter, and adjusts the three-axis laser rangefinder limiter to move to the monitoring zero position; then repeat steps (3)-(4) until all chain pins are lubricated.

[0018] Furthermore, the controller has a built-in counter. At the beginning of refueling, the total number of chain links is set. Each time a chain link is refueled, it counts once. When all chain links are refueled, the refueling stops automatically.

[0019] The beneficial effects of this invention are: the automatic lubrication system of this invention has three-way movement and follow-up functions in X, Y, and Z space. If the chain shakes during the switching of chain links, it can be detected by the monitoring of the three-way laser rangefinder limiter. The controller controls the X-axis movement device and the Y-axis movement device to adjust the position of the lubricating nozzle, ensuring that the lubricating nozzle is always in the accurate lubrication position for lubrication, resulting in good lubrication effect. Attached Figure Description

[0020] The present invention will be further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present invention. For those skilled in the art, other drawings can be obtained based on the following drawings without creative effort.

[0021] Figure 1 This is a schematic diagram showing the state of two sets of automatic lubrication equipment of the present invention lubricating the lifting chain.

[0022] Figure 2 This is a schematic diagram of the automatic lubrication device of the present invention.

[0023] Figure 3 This is a schematic diagram of the automatic refueling device in this invention.

[0024] Figure 4 This is a schematic diagram showing the state of the follower stop and the oil nozzle in conjunction with the chain in this invention.

[0025] Figure 5 This is a schematic diagram of the timing valve in the refueling state of the present invention. Detailed Implementation

[0026] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of this application can be combined with each other.

[0027] like Figure 1 As shown, the present invention provides an automatic lubrication device for the lifting chain of a chain bucket unloader, comprising an X-axis moving device 100, a Y-axis moving device 200, an automatic refueling device 300, a lubrication station 400, and a controller; the controller is a PLC control cabinet, installed inside the control cabinet 500.

[0028] like Figure 2 As shown, the X-axis moving device 100 includes a base 101, an X-axis slide rail 102 mounted on the base, an X-axis moving seat 103 mounted on the X-axis slide rail, and an X-axis drive cylinder 104 capable of driving the X-axis moving seat to move. A lateral limit switch 105 is provided on each of the left and right sides of the X-axis slide rail 102. The extension and retraction of the piston rod of the X-axis drive cylinder 104 can drive the X-axis moving seat to move along the X-axis slide rail 102.

[0029] The Y-axis moving device 200 includes a stand 201 mounted on an X-axis moving seat 103, a Y-axis slide rail 202 mounted on the stand, a Y-axis moving seat 203 mounted on the Y-axis slide rail, and a Y-axis drive cylinder 204 capable of driving the Y-axis moving seat to move. Two longitudinal limit switches 205 are provided on the Y-axis slide rail 202. The extension and retraction of the piston rod of the Y-axis drive cylinder 204 can drive the Y-axis moving seat to move along the Y-axis slide rail 202.

[0030] like Figure 2-4 As shown, the automatic refueling device 300 includes a fixed bracket 301, a Z-axis movable seat 302 movably mounted on the fixed bracket, two sets of tracking refueling components, and a three-axis laser rangefinder 303 for determining the position of chain links. The tracking refueling components include a refueling cylinder 304, a tracking cylinder 305, and a control valve 306. A refueling nozzle 307 is connected to the piston rod end of the refueling cylinder, and the nozzle 307 is connected to the lubrication station 400 via a pipeline. A follower stop 308 for intercepting chain pins is connected to the piston rod end of the tracking cylinder. The refueling cylinder 304 and the tracking cylinder 305 are arranged side-by-side and fixedly mounted on the Z-axis movable seat 302. A return spring 309 is also connected to the Z-axis movable seat 302. The three-axis laser rangefinder 303 is fixedly mounted on the fixed bracket 301 via a sensing bracket 310. The fixed bracket 301 is mounted on the Y-axis movable seat 203 and can move longitudinally under the drive of the Y-axis drive cylinder 204. The Y-axis moving device can move laterally under the drive of the X-axis drive cylinder 104. During operation, the controller can control the X-axis and Y-axis moving devices to automatically adjust the position of the three-axis laser rangefinder limiter after real-time calculation and processing based on the data collected by the three-axis laser rangefinder limiter 303.

[0031] Specifically, the follower stop 308 includes a connecting rod connected to the end of the piston rod and an arc-shaped baffle installed at the front end of the connecting rod. The arc-shaped baffle is designed to not only block the follower movement but also to limit the pin shaft from moving up and down.

[0032] The aforementioned control valve 306 can be a solenoid valve, controlled to open or close via a controller. Alternatively, a mechanically controlled valve can be used. Specifically, the valve body 3061 of the mechanically controlled valve is fixedly mounted on the fixed bracket 301, and the stop assembly 3062 of the mechanically controlled valve is mounted on the Z-axis moving seat 302. The valve body has an air inlet P1, a first air outlet E1, a second air outlet E2, and a vent. The air inlet P1 is connected to an external air source, the first air outlet E1 is connected to the refueling cylinder 304, and the second air outlet E2 is connected to the tracking cylinder 305. When the chain drives the Z-axis moving seat to move, the stop assembly 3062 moves accordingly, causing the piston 3063 of the mechanically controlled valve to move up and down, thereby controlling the opening or closing of the first air outlet E1 and the second air outlet E2 of the mechanically controlled valve, and consequently controlling the extension or retraction of the piston rods of the tracking cylinder and the refueling cylinder.

[0033] The automatic refueling process using a mechanically controlled valve is as follows: In the initial state, the roller at the lower end of the plunger 3063 is located at position A1, which is the refueling waiting state. Figure 5(As shown in the diagram). At this time, the air inlet P1 is connected to the second air outlet, and the piston rod of the tracking cylinder 305 extends. When it moves to position A2, it is in the refueling state. At this time, the air inlet P1 is simultaneously connected to both the first and second air outlets, and the piston rods of both the refueling cylinder 304 and the tracking cylinder 305 are extended. When it moves to position A3, it is in the open reset state. At this time, the first air outlet E1 and the second air outlet E2 are simultaneously connected to the vent, and the piston rods of both the refueling cylinder 304 and the tracking cylinder 305 retract. As the stop assembly 3062 resets, it returns to the refueling waiting state at position A1.

[0034] The following details the lubrication method for the automatic lubrication equipment of the lifting chain of the aforementioned chain bucket unloader, including the following steps.

[0035] Two sets of the aforementioned automatic lubrication equipment are installed to lubricate and maintain the lifting chains on both sides of the chain bucket unloader. Initially, the lifting chains on both sides of the chain bucket unloader are in the maintenance position awaiting lubrication, and the lubrication nozzles of the two sets of automatic lubrication equipment are ready at the initial zero position. The initial zero position of the lubrication nozzle refers to the X-axis moving seat being at the left limit and the Y-axis moving seat being at the lower limit.

[0036] (2) When refueling, first manually control the X-axis moving device 100 and Y-axis moving device 200 of the automatic lubrication equipment to make the three-axis laser rangefinder limiter 303 reach the monitoring zero position of the first link to be refueled, and the status is as follows. Figure 1 As shown, when the three-dimensional laser rangefinder 303 is at the monitoring zero position, and the piston rod of the refueling cylinder extends into place, the refueling nozzle is just aligned with the chain pin.

[0037] (3) The piston rods of the tracking cylinders 305 of the two sets of tracking refueling components extend simultaneously, and the corresponding two following stops contact the two chain pin ends of the chain link to be refueled, start the chain to rotate at the maintenance speed, and drive the Z-axis moving seat 302 to move synchronously. At this time, the piston rod of the refueling cylinder 304 extends, and the refueling nozzle 307 connects to the chain pin and performs oil injection.

[0038] (4) After the first link is lubricated, the piston rods of the lubrication cylinder 304 and the tracking cylinder 305 retract. Under the action of the reset spring 309, the tracking lubrication component resets with the Z-direction moving seat 302; waiting to lubricate the next link.

[0039] (5) After the tracking refueling component is reset, the three-way laser rangefinder 303 collects the distance data between the chain plate and the pin on both sides of the chain link in real time, and determines whether it is at the monitoring zero position. If it is at the monitoring zero position, repeat steps (3)-(4) until all chain links and pins are refueled; if it is not at the monitoring zero position, execute step (6).

[0040] (6) The controller controls the X-axis moving device 100 and Y-axis moving device 200 to move in real time according to the distance data collected in real time by the three-axis laser rangefinder limiter 303, and adjusts the three-axis laser rangefinder limiter 303 to move to the monitoring zero position; then repeat steps (3)-(4) until all chain pins are lubricated.

[0041] Furthermore, the controller has a built-in counter. At the beginning of refueling, the total number of chain links is set. Each time a chain link is refueled, it counts once. When all chain links are refueled, the refueling stops automatically.

[0042] The solution of this invention can automatically lubricate the chain pins, achieving a high degree of automation. It also effectively solves the problem of misalignment of the lubrication nozzle with the pins caused by chain shaking during operation, realizing automatic lubrication of the lifting chain pins of the chain bucket unloader. It has broad application prospects in the field of chain drive.

[0043] In summary, although the present invention has listed the above preferred embodiments, it should be noted that various changes and modifications can be made by those skilled in the art, and such changes and modifications should be included within the scope of protection of the present invention unless they deviate from the scope of the present invention.

Claims

1. An automatic lubrication device for the lifting chain of a bucket unloader, characterized in that, It includes an X-axis moving device, a Y-axis moving device, an automatic refueling device, and a controller; The automatic refueling device includes a fixed bracket, a Z-axis movable seat movably mounted on the fixed bracket, two sets of tracking refueling components, and a three-axis laser rangefinder limiter for determining the position of chain links. The tracking refueling components include a refueling cylinder, a tracking cylinder, and a control valve. The piston rod end of the refueling cylinder is connected to a refueling nozzle, and the piston rod end of the tracking cylinder is connected to a following stop for intercepting the chain pin. The refueling cylinder and the tracking cylinder are arranged side by side and fixedly mounted on the Z-axis movable seat. A reset spring is also connected to the Z-axis movable seat. The three-axis laser rangefinder limiter is fixedly mounted on the fixed bracket through a sensing bracket. The fixed bracket is installed on the Y-axis moving device and can move longitudinally under the drive of the Y-axis moving device; the Y-axis moving device is installed on the X-axis moving device and can move laterally under the drive of the X-axis moving device. During operation, the controller can control the X-axis and Y-axis moving devices in real time based on the data collected by the three-axis laser rangefinder limiter, and automatically adjust the position of the three-axis laser rangefinder limiter. The following stop includes a connecting rod connected to the end of the piston rod and an arc-shaped baffle installed at the front end of the connecting rod; The control valve is a mechanically controlled valve. The valve body of the mechanically controlled valve is fixedly mounted on the fixed bracket. The stop assembly of the mechanically controlled valve is mounted on the Z-axis moving seat. When the chain drives the Z-axis moving seat to move, the stop assembly can follow the movement and drive the mechanically controlled valve plunger to move up and down, so that the piston rods of the tracking cylinder and the refueling cylinder extend or retract.

2. The automatic lubrication device for the lifting chain of the chain bucket unloader according to claim 1, characterized in that: The X-axis moving device includes a base, an X-axis slide rail mounted on the base, an X-axis moving seat mounted on the X-axis slide rail, and an X-axis driving cylinder capable of driving the X-axis moving seat to move.

3. The automatic lubrication device for the lifting chain of the chain bucket unloader according to claim 2, characterized in that: The Y-axis moving device includes a stand mounted on the X-axis moving seat, a Y-axis slide rail mounted on the stand, a Y-axis moving seat mounted on the Y-axis slide rail, and a Y-axis driving cylinder capable of driving the Y-axis moving seat to move.

4. The automatic lubrication device for the lifting chain of the chain bucket unloader according to claim 1, characterized in that: The controller has a built-in counter. At the beginning of refueling, the total number of chain links is set. Each time a chain link is refueled, it counts once. When all chain links are refueled, it automatically stops.

5. A lubrication method for an automatic lubrication device for the lifting chain of a bucket unloader according to any one of claims 1-4, characterized in that, Includes the following steps: (1) Install two sets of the automatic lubrication equipment to lubricate and maintain the lifting chains on both sides of the chain bucket unloader; in the initial state, the lifting chains on both sides of the chain bucket unloader are waiting for lubrication in the maintenance position, and the lubrication nozzles of the two sets of automatic lubrication equipment are ready at the initial zero position. (2) When refueling, first manually control the X-axis moving device and Y-axis moving device of the automatic lubrication equipment to make the three-axis laser rangefinder reach the monitoring zero position of the first link to be refueled; (3) The piston rods of the tracking cylinders of the two sets of tracking refueling components extend simultaneously, and the corresponding two following stops contact the two chain pin ends of the chain link to be refueled. The chain is started to rotate at the maintenance speed. When it rotates, it drives the Z-axis moving seat to move synchronously. At this time, the piston rod of the refueling cylinder extends, the refueling nozzle connects to the chain pin and performs oil injection. (4) After the first link is lubricated, the piston rods of the lubrication cylinder and the tracking cylinder retract. Under the action of the reset spring, the tracking lubrication component resets with the Z-axis moving seat; waiting to lubricate the next link. (5) After the tracking refueling component is reset, the three-way laser rangefinder collects the distance data between the chain plate and the pin on both sides of the chain link in real time, and determines whether it is at the monitoring zero position. If it is at the monitoring zero position, repeat steps (3)-(4) until all chain links and pins are refueled. If the zero position is not being monitored, proceed to step (6). (6) The controller controls the X-axis moving device and Y-axis moving device to move in real time according to the distance data collected in real time by the three-axis laser rangefinder limiter, and adjusts the three-axis laser rangefinder limiter to move to the monitoring zero position; then repeat steps (3)-(4) until all chain pins are lubricated.

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