Guard module for a waste rock hopper

Abstract

This utility model discloses a protective module for a gangue hopper, belonging to the field of mining machinery technology. This module aims to solve the problem of severe impact wear on the hopper bottom plate in high-gas environments and the safety risks associated with replacement operations. Its core components include a support plate fixed to the hopper bottom plate with bolts, multiple wedge-shaped wear-resistant support side plates arranged parallel to each other on the support plate, with the lower ends of the side plates connected to the wear-resistant support bottom plate, forming multiple parallel wear-resistant grooves. Below the wear-resistant support bottom plate is a support block with a buffer groove on its top surface, and the support plate, wear-resistant support side plates, wear-resistant support bottom plate, and support block form a T-shaped integral support structure. This utility model achieves rapid and safe hot-work-free replacement through modular design. Simultaneously, by utilizing the T-shaped structure and wear-resistant and buffer grooves to form a multi-level buffer system, it guides the formation of a "material-to-material" protective layer, greatly reducing direct impact and wear, and significantly improving overall economic benefits and safety.

Description

Technical Field

[0001] This utility model belongs to the field of mining machinery and material conveying technology, specifically relating to a protective module for gangue hoppers. Background Technology

[0002] In waste rock processing plants, the top of waste rock silos is typically equipped with an inverted Y-shaped funnel to transfer waste rock from the conveyor belt to designated silos. Due to the large flow rate, high hardness, and sharp edges of the waste rock, severe impact wear can occur on the bottom plate of the funnel, especially in areas directly impacted when the flow direction changes. For example, in one waste rock processing plant, approximately 620,000 tons of waste rock pass through annually, resulting in extremely severe wear in specific areas of the silo funnel bottom plate.

[0003] Currently, the main solution to this problem is to replace the severely worn hopper bottom plate. However, this operation poses significant safety hazards: First, the work site is located at the top of the silo, below which is a gangue bin filled with high concentrations of methane. According to mandatory standards such as the "Coal Mine Safety Regulations," hot work such as welding and cutting in such areas carries an extremely high risk of methane explosion and is usually strictly prohibited or requires significant manpower and resources to develop safety measures. Second, the replacement process is complex and time-consuming, affecting normal production. Therefore, there is an urgent need for a solution that can effectively extend the service life of the hopper bottom plate and avoid or reduce hot work operations in hazardous areas. Utility Model Content

[0004] The present invention aims to address the shortcomings of the prior art and provide a protective module for gangue funnels.

[0005] The technical solution adopted in this utility model is:

[0006] A protective module for a gangue hopper includes a support plate, several wear-resistant support side plates, a wear-resistant support base plate, and a support block. The support plate is bolted to the bottom plate of the hopper near the material impact area of ​​the conveyor belt. The cross-section of the wear-resistant support side plates is wedge-shaped. The tips of the several wear-resistant support side plates are fixed parallel to the support plate with their tips facing the conveyor belt. The wear-resistant support base plate is fixedly connected to the lower end faces of the several wear-resistant support side plates. The several wear-resistant support side plates and the wear-resistant support base plate together form several parallel wear-resistant grooves. The support block is fixedly connected to the bottom surface of the wear-resistant support base plate and the support plate. At least one buffer groove is formed on the top surface of the support block. The support plate, wear-resistant support side plates, wear-resistant support base plate, and support block are fixedly connected to each other to form a rigid T-shaped integral support structure.

[0007] Furthermore, the support block is an I-beam, an H-beam, or a box girder.

[0008] Furthermore, the cross-sectional shape of the buffer groove is V-shaped, U-shaped, or rectangular.

[0009] Furthermore, the wear-resistant support side plate and wear-resistant support bottom plate are made of high-strength wear-resistant steel with a Brinell hardness of not less than 400HBW.

[0010] Furthermore, the support plate, wear-resistant support side plate, wear-resistant support bottom plate, and support block are connected to form a T-shaped integral support structure by welding.

[0011] Compared with the prior art, the beneficial effects of this utility model are:

[0012] 1. This utility model uses bolts to fix the entire wear-resistant module to the impact area of ​​the funnel bottom plate. When the module is worn, it can be replaced by simply removing the bolts. This completely avoids hot work on the top of the gas-filled silo, greatly reduces safety risks, and simplifies the maintenance process.

[0013] 2. This utility model constructs a multi-level buffer wear-resistant system by setting wear-resistant grooves formed by wedge-shaped wear-resistant side plates and wear-resistant bottom plates, as well as buffer grooves on the support blocks. The gangue first impacts and accumulates in the wear-resistant grooves and buffer grooves, forming a protective layer of "material abrasion material", which greatly reduces the direct impact and wear of gangue on the module itself and the bottom plate of the funnel behind it, extending the service life of the bottom plate of the funnel from 5 months to more than 15 months;

[0014] 3. The support plate, wear-resistant support side plate, wear-resistant support bottom plate and support block of this utility model are fixedly connected to each other to form a stable T-shaped structure with strong overall rigidity, which can withstand the continuous impact of large flow and high drop gangue.

[0015] 4. Although this utility model increases the manufacturing cost of the module, it avoids the high material and labor costs required for frequent replacement of the entire funnel bottom plate, as well as the time and safety costs caused by production stoppages and hot work permits, resulting in significant overall economic benefits. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the installation structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the structure of this utility model;

[0018] In the diagram: 1. Conveyor belt; 2. Hopper bottom plate; 3. Silo; 4. Support plate; 5. Wear-resistant support side plate; 6. Wear-resistant support bottom plate; 7. Support block; 8. Gangue; 9. Bolt; 10. Buffer trough; 11. Wear-resistant trough. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0020] like Figure 1 and Figure 2 As shown, a protective module for a gangue hopper has a core component including a rectangular support plate 4, which is fastened to the bottom plate 2 of the hopper by multiple bolts 9, facing the impact area of ​​the material drop point of the conveyor belt 1.

[0021] On the upper surface of the support plate 4, four wedge-shaped, triangular, or trapezoidal wear-resistant support side plates 5 are welded in parallel, with their tips all pointing towards the material inlet direction of the conveyor belt 1. The bottom edges of all the wear-resistant support side plates 5 are welded together with a flat wear-resistant support base plate 6. These side plates 5 and the base plate 6 together form three parallel wear-resistant grooves 11 with approximately triangular cross-sections.

[0022] Below the wear-resistant support base plate 6, a support block 7 is centrally located, preferably an I-beam in this embodiment. One or more longitudinal buffer grooves 10 are formed on the top surface of the upper flange of the I-beam, the surface that contacts the wear-resistant support base plate 6. The upper flange of the support block 7 is welded to the wear-resistant support base plate 6, and its web or lower flange is welded to the support plate 4 below, thereby firmly connecting the support plate 4, the wear-resistant support base plate 6, and the support block 7 into a rigid T-shaped integral structure.

[0023] The wear-resistant support side plate 5 and wear-resistant support bottom plate 6 are preferably made of high-strength wear-resistant steel plate to cope with the severe wear of gangue.

[0024] The materials used in this embodiment are as follows:

[0025] 1. One piece of steel plate, 300*600*16mm, for the base structure area;

[0026] 2. Five pieces of diagonal triangular steel plates, 100*280*16mm.

[0027] 3. I-beam, 600*100*100mm, 1 piece;

[0028] 4. One steel plate, 300*150*16mm.

[0029] 5. Bolts, M16*80, 2 sets.

[0030] Comparison experiment of wear resistance and service life

[0031] This embodiment was compared with existing technologies using accelerated wear testing. The test conditions simulated actual working conditions in a coal gangue processing plant, using gangue with a particle size of 50-150mm and a Protodyakonov hardness of f=8-10. The impact was continuous at a flow rate of 80 tons per hour from a drop of 3 meters above the impact point. Using gangue of the same material, particle size, and flow rate, the test was conducted for 500 hours under the same impact conditions. The test data are as follows:

[0032] Ordinary steel plate (Q235) 20 11.5 8.5 5 Traditional wear-resistant lining 20 15.2 4.8 8 This utility model T-shaped module Side panels 20, bottom panel 15 Side panels 18.1, bottom panel 14.3 Side panels 1.9m, bottom panel 0.7m 15

[0033] Structural stability and impact resistance test

[0034] A physical impact test was conducted on the T-shaped module, simulating the impact of a 50kg chunk of gangue falling from a height of 5 meters. Under the maximum impact load, the maximum stress in the overall T-shaped structure was 185MPa, far lower than the yield strength of Q345 steel (≥345MPa), achieving a safety factor of 1.86. Compared to a solution that only uses bolts to fix a large wear-resistant plate, the maximum deformation of this invention is reduced by more than 70%.

[0035] Simulation results demonstrate that the "T-shaped integral structure" formed by welding the support plate, wear-resistant components, and support block solves the technical problem of "insufficient overall rigidity and easy deformation and damage after modular design." This indicates that the structure is not a simple assembly, but a creative design to achieve the goal of "long-term maintenance-free operation."

[0036] By installing the funnel bottom plate 2 on the original hopper in this embodiment, the risk of wear and tear on the funnel bottom plate 2 in the gangue silo 3 is reduced. Secondly, it extends the service life of the funnel bottom plate 2, reduces the frequency of hot work operations on the top of the gangue silo 3, and lowers the safety risks of working in hazardous environments. Through the implementation of this embodiment, the service life of the funnel bottom plate 2 is extended from 5 months to 15 months, and the average accident handling time is reduced by 120 minutes.

[0037] Economic benefits: △S = S1 - S2 = (A + B + C) - D + E

[0038] ={120*30+5000+50000+12*125}-{2500+6*125}=56850 yuan

[0039] S1 represents the cost of generating benefits, and S2 represents the cost of input. 120*30 represents the value generated by saving 120 minutes of accident time, 5000 represents the budgeted cost of materials input in the previous year before the renovation, 50000 represents the accident cost caused by hot work hazards, 12*125 represents the labor cost in the previous year before the renovation, 2500 represents the cost of materials used after the renovation, and 6*125 represents the labor cost of the renovation.

[0040] The working process of this utility model:

[0041] After installation, the gangue 8 falling from the conveyor belt 1 first impacts the wedge-shaped tip of the module. Some of the gangue splashes up and falls into the wear-resistant groove 11 and the buffer groove 10, where it accumulates. The subsequent continuous falling gangue 8 will mainly impact these accumulated gangue, achieving a "material-on-material" buffering effect. The hard wear-resistant module body bears the indirect, mitigated impact and friction, while the funnel bottom plate 2 below it is completely protected.

[0042] When the wear-resistant module wears down after long-term use and needs to be replaced, simply loosen bolt 9 to remove the old module as a whole, replace it with a new module, and tighten it again. The whole process is quick, safe, and requires no open flame.

Claims

1. A protective module for a gangue funnel, characterized in that, The system includes a support plate (4), several wear-resistant support side plates (5), a wear-resistant support base plate (6), and a support block (7). The support plate (4) is fixedly installed on the bottom plate (2) of the funnel near the material impact area of ​​the conveyor belt (1) by bolts (9). The cross-section of the wear-resistant support side plates (5) is a wedge-shaped structure. The tips of the several wear-resistant support side plates (5) are fixed parallel to the support plate (4) with the conveyor belt (1) facing the tip. The wear-resistant support base plate (6) and the several wear-resistant support side plates (5) are also connected. The lower end face is fixedly connected, and several wear-resistant support side plates (5) and wear-resistant support base plate (6) together form several parallel wear-resistant grooves (11). The support block (7) is fixedly connected to the bottom surface of the wear-resistant support base plate (6) and the support plate (4). At least one buffer groove (10) is opened on the top surface of the support block (7). The support plate (4), wear-resistant support side plates (5), wear-resistant support base plate (6) and support block (7) are fixedly connected to each other to form a rigid T-shaped integral support structure.

2. A protective module for a gangue funnel according to claim 1, characterized in that, The support block (7) is an I-beam, an H-beam, or a box beam.

3. A protective module for a gangue funnel according to claim 1, characterized in that, The cross-sectional shape of the buffer groove (10) is V-shaped, U-shaped or rectangular.

4. A protective module for a gangue funnel according to any one of claims 1 to 3, characterized in that, The wear-resistant support side plate (5) and wear-resistant support bottom plate (6) are made of high-strength wear-resistant steel with a Brinell hardness of not less than 400HBW.

5. A protective module for a gangue funnel according to any one of claims 1 to 3, characterized in that, The support plate (4), wear-resistant support side plate (5), wear-resistant support bottom plate (6) and support block (7) are connected by welding to form a T-shaped integral support structure.

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