I. Project Overview
The laneway of the No. 12 mining area for the construction of the third team is currently under construction of 210m . According to the project arrangement, the roadway lane in the 12th mining area is prepared by using a roadheader, and an EBZ160 -type roadheader and supporting DZQ80/30 are required for the new arrival of the mine. After the /11 belt loader is dismantled, it is loaded and transported to the intersection of the northwestern Union Lane and the northwest belt conveyor Shimen for installation. In order to ensure the safety of construction, this safety technical measure is specially formulated.
Second, the construction organization measures
1 ã€Construction unit: develop three teams
2. Chief of Construction: Chen Wanlong is responsible for the demolition work, the general command and coordination, and the first person responsible for construction safety.
3 , construction technology responsible person: by the mechanical and electrical team leader and on-site team leader, responsible for technical guidance and on-site inspection and supervision.
4. Construction workers: Three shifters, the on-site team captain shall be responsible for the deployment and safety production of on-duty personnel, organize safety inspections and confirmations, eliminate hidden dangers on site, and implement the on-site safety and technical measures, and be the first responsible person for safe production on-site.
Third, the construction content
1, removal of a EBZ160 Roadheader.
2. Demolition of supporting DZQ80/30/11 type belt conveyors.
3. After loading the parts, transport the parts to the northwest lane and install it.
Fourth, equipment structure overview
The EBZ160 boring machine is manufactured by SANY Heavy Equipment Co., Ltd. Its main components are: cutting section, shovel plate section, first transportation section, main body section, traveling section, rear support section, lubrication system, hydraulic system, and water system. Electrical system, guard plate and accessories and other components.
No. Component Name Quantity Weight ( kg )
Dimensions: length × width × height ( mm )
1 body frame 1 5210 3320 × 1190 × 1440
2 walking part 2 10000 3400 × 790 × 820
3 Turntable 1 1680 1550 × 1660 × 740
4 cutting part 1 8500 3900 × 1900 × 1100
5 Shovel part 1 3850 2900 × 2470 × 712
6 rear support bracket 1 2100 1800 × 2280 × 960
7 Rear support coupling 1 400 1100 × 740 × 560
8 rear support legs 2 740 1470 × 500 × 430
9 Second Movement Turntable 1 420 500 × 1200 × 500
10 electric control box 1 1100 1800 × 600 × 860
11 Operator Station 1 550 1800 × 980 × 960
12 tank 1 920 1650 × 750 × 730
13 1 chute before transport 1 980 3900 × 720 × 690
14 after the chute and other 1 1350 1570 × 680 × 630
15 cutting lift cylinder 2 520 1420 × 320 × 220
16 cutting rotary cylinder 2 450 1550 × 250 × 220
17 shovel lift cylinder 2 390 870 × 240 × 220
18 Rear support lift cylinder 2 360 1000 × 24
×220
19 Main Pump Station 1 1000 1630 × 750 × 730
Disassembly and installation sequence
Disassembly Order Installation Order Part Name
1 13 various types of cover
2 12 cutting section
3 11 First conveyor
4 10 side shovel plate
5 9 Shovel body
6 8 pump station
7 7 tank
8 6 console
9 5 Hydraulic System
10 4 electric control box
11 3 rear support
12 2 Walking Department
13 1 Main body
V. Preparation
1. All personnel involved in the operation must be familiar with the structure, performance and technical parameters of the equipment.
2, ready for large flatbed six, three large flower car, small flatbed 4, 5 tub, and 5t chain hoists, industrial equipment and so on.
3, at the installation point ahead is good special construction lifting bolt, bolt selection lifting Φ 20 × 2200mm bolting at the root using a high-strength bolt MSK2335 type (back side) and a MSZ2335 type (outer) anchoring agent, Design Anchorage 120kN .
4, ready to 5t four chain hoists (using two sets, two standby), stage 3T chain hoists 3 (adjustment made during lifting). And prepare hooks, duck Tsui and other hooks. Before using the chain hoist, it should be checked in advance whether the tonnage is appropriate or not, and whether the backstop device is completely intact.
5. Prepare a certain amount of square wood, lining boards, and level the machine to prevent it from tipping over.
6. Clean and clean the installation site so as not to affect the installation of the roadheader.
7. In order to satisfy the safe transportation of large pieces of equipment, it is necessary to carefully check the height, width, track, piping, cables, and other equipment passing through the equipment in advance to ensure that the roadway through which the equipment passes is unimpeded.
8. Inspect the track at the end of the northwest to the installation site. The track must be laid complete, firm and conform to the rail type. The track joint clearance shall not be greater than 5mm , the height difference shall be no more than 2mm , and the spacing between the sleepers shall not be greater than 0.7m , under the sleeper should be compacted, no suspension.
VI. Demolition work
When disassembling, special personnel are responsible for commanding work and dismantling into parts in accordance with the instructions for use and maintenance. Personnel engaged in disassembly work should familiarize themselves with the structure of the machine according to the technical documents, understand in detail the important joints, and prepare lifting appliances to ensure the safety of dismantling.
Under the action of the loading section and the supporting cylinder, the boring machine is lifted and a sleeper is laid on the main frame to support the entire boring machine. Under the effect of the hydraulic system, the support cylinder is stowed, the shovel blade is dropped, and the tribal land is cut.
Put the oil in the tank into a clean container.
Identify the parts that need to be disassembled to remove the necessary tubing. After the tubing is removed, the components are removed in the disassembly sequence.
In order to ensure the smooth dismantling, take several large parts as an example to illustrate the dismantling method.
The dismantling method of the cutting part:
7.1 When the cutting head lands, first remove the end of the lifting cylinder and the cutting arm with a special tool for pulling the shaft.
7.2, in the rear portion of the motor M30 has two threaded holes, two rings screwed into the screw holes as lifting the rear, cutting the front portion of the housing bore as lifting holes, with the cross-sectional rear chain hoists 5t cutting unit lifted, with In the above-mentioned method of 7.1 , one end of the connection between the lift cylinder and the turntable is dismantled, and finally, the pin shaft connecting the cutting arm and the turntable is removed.
7.3 . Under the lifting of the 5t chain hoist, the cutting section is mounted on a large flatbed truck prepared in advance.
Dismantling method for the first conveyor:
8.1 . Use a grease gun to tension the chain through the tensioning cylinder, pull out the clamping plate, and unload the cylinder. Remove the chain from the appropriate connection ring and remove it from the back of the chute.
8.2 . Unscrew the bolts connecting the tensioning device, the drive device and the chute, and remove the tensioning device and the drive device.
8.3 . Unscrew the connecting part bolts of the two chutes of the transporter, lift the transporter chute with a steel wire rope and pull it out from the rear of the roadheader and separate it from the main body frame . Install it under the lifting of the 5t chain hoist. Get ready for the big flatbed.
Demolition of the shovel plate:
9.1 . When the front end of the blade is fully in contact with the floor or the wood, remove the hydraulic cylinder for lifting and lowering the blade with a special tool for removing the pin.
9.2, the sides of the front portion of the shovel M30 has two threaded holes, two rings screwed into the screw hole as lifting the front portion, after the installation of the liner cylinder connecting hole as a connection hole in the rear portion, with the hoisting rope will spatulas , Remove the pinboard shaft connecting the blade to the main body.
9.3 . Under the hoisting of the 5t chain hoist, the shovel board is mounted on a large flower rack vehicle prepared in advance.
The dismantling method of the walking part:
10.1 . Disassemble one side of the walking part and then remove it.
Solve the other side of the walk.
10.2 . Underneath the track, use wood or wooden piers to prevent it from falling over. Unscrew the bolts that connect the walking part and the body part, and tie the two ends of the walking part with a wire rope to lift (by directly lifting the track plate), and under the hoisting of the 5t chain hoist, install the walking part in the large part prepared in advance. Flatbed.
10.3 . Use the same method to remove the other side of the walking part.
Precautions when dismantling:
The parts to be dismantled should be handled with care. The screws, washers, pins, etc. must be properly stored to prevent damage or loss. The inner screw hole is filled with cotton yarn. Plungers and other precision parts must be packaged to prevent damage during transportation.
It is strictly forbidden to dismantle the parts of equipment savagely to prevent damage to the body. After dismantling, the 5t chain hoists are used to load the parts.
When dismantling, it is strictly forbidden for anyone to place any part of the body under the removed part. After heavy objects are hoisted, personnel are forbidden to perform other work within 3m of the surroundings .
In order to avoid installation difficulties and unnecessary failure due to excessive decomposition, the machine should be removed as little as possible according to the actual situation.
When dismantling, the application of plugs such as tubings and fittings is closed or wrapped with a clean cloth to prevent the entry of dirt.
The surface of all unpainted parts, especially the joint surfaces, shall be covered with lubricating grease after dismantling.
Electrical equipment must be covered with moisture-proof material to prevent water ingress.
Small pieces of dismantled parts and bolts, gaskets, etc. that are easily lost are placed in a special container to prevent loss.
VII. Equipment transportation
The boring machine transport sequence is as follows: cutting part → side shovel plate → shovel plate body → walking part → main body part → rear support part → first conveyor → electric control box → hydraulic system → fuel tank → pump station → control console → various types of covers board.
Before loading, check whether the hooks and duck hooks used are safe and reliable.
When loading the vehicle, it is forbidden that the vehicle is ultra-high, extra-wide or partial load. The use of wire rope tied, and flatbed, flower carts and other body fastening places, shall not be less than four . All loading must ensure the balance between front and rear, left and right, to prevent skewed overturned or can not enter the cage, to prevent equipment damage and scratch when tightened with wire rope.
In the process of transportation, the key parts of the equipment, such as handles, handles, nozzles, nozzles, etc., that may collide, must be reliably protected.
Pieces and small pieces are placed in the mine car, and large pieces are placed on flatbeds or flower racks. Put planks under the car to prevent the device from sliding with the car.
All parts should be categorized and divided for inventory, centralized loading into the well, and special persons responsible for transportation to avoid loss.
Special escort is required during delivery, low speed operation, finding a drop or other situation, and immediately sending a parking signal.
Before transporting goods to and from the mountains, it is necessary to carry out a careful inspection of the lashings of the vehicles to ensure that they are firm and reliable before being transported.
Equipment transportation route: ground → auxiliary shaft → underground parking yard → -495m horizontal rail transportation Shimen → west wing rail transportation lane → northwest rail transit Shimen → northwest north alley lane → northwestern belt transport Shimen.
Eight, equipment installation
1. The installation procedure of the roadheader is contrary to the disassembly sequence. To ensure a smooth installation, take a few large parts as an example to illustrate how to install it.
2 , the installation of the walking part:
2.1 . First install one side of the walking part and then install the other side of the walking part. Raise the main body with wood or wooden piers so that the mounting surface of the bottom plate is 500 mm or more from the track section .
2.2 . Use a wire rope to tie the crawler on one side of the walking part and lift it (the three lifting rings on the crawler frame can be hung directly ), and connect with the body part. The tightening torque is 1500 N · m .
2.3 . Use road wood or wood piers under the mounted track to prevent it from falling over. Use the same method to install the track on the other side.
3 , shovel board installation method:
3.1 . There are 2 lifting rings on both sides of the front side of the shovel plate , and two rings are screwed into the front lifting holes. After the liner is attached to the cylinder, the back holes are used as connecting holes. The shovel plate is lifted with wire ropes. The chassis of the body is connected.
3.2 . Install the hydraulic cylinder for lifting and lowering the blade. After the installation, ground the front end of the shovel board and the floor, or put a log.
3.3 . The star wheel is directly driven by a low-speed, high-torque hydraulic motor. When assembling the star wheel, care should be taken to place the two three-claw star wheels in the wrong position to facilitate work.
4. Installation method of the first conveyor:
4.1 . Lift the transporter with steel wire rope and insert it into the main body frame from behind.
4.2 When the chute of the first conveyor is connected with the main body, the chain is loaded and the scraper chain is adjusted.
4.3 . Fasten one end of the chain with long wire, lead it from the upper part forward, reverse at the front guide wheel, and pull out the wire from the return side of the chain.
4.4 . At the sprocket at the rear end of the chute, after the chain is bent upwards to mesh with the teeth of the sprocket, connect the chain with the connecting ring.
4.5 . Connect the tensioning device with the drive device and the chute with bolts, adjust the chain to the required degree of tension with the oil gun through the tensioning cylinder (the sag value of the chain is 50 to 70m ), and install the clamping plate and cylinder. Uninstall.
5 , installation method of cutting part:
5.1, in the rear portion of the motor M30 has two threaded holes, two rings screwed into the screw holes as lifting the rear, cutting the front portion of the housing bore as lifting holes, with the hoisting rope and the cutting portion coupled to the turntable.
5.2 . Install lifting cylinders of cutting section. After installation, the front end of the cutting head is connected to the bottom plate.
6. Precautions during installation:
6.1 When hoisting each part, the steel wire rope must be hung in accordance with the position of lifting hole and hanging ring.
6.2 When installing pins and bolts, it must be coated with anti-rust agent or grease.
6.3 When installing the pin in the area with a dust ring, care must be taken not to scratch the dust ring. Therefore, when inserting a pin, insert it while turning slightly.
6.4 , in the exposed part of the adjustment bolt, to prevent rust, grease should be applied.
6.5 . Tightening torques of fastening bolts should be tightened according to the specified tightening torque and should be tightened evenly to prevent deflection due to uneven fastening.
6.6 , replacement of wearing parts, should be washed with washing oil, and then loaded as required.
6.7 . Choose a steel wire rope with enough strength according to the lifting load and angle when lifting.
Nine, installation technical requirements and debugging
When the boring machine is installed downhole, it is assembled in strict accordance with the installation sequence. It is assembled according to the requirements of the roadheader installation instructions. In principle, whoever disassembles the equipment is installed to ensure that the assembly is qualified and meets the quality standards.
All kinds of bolts and connecting screws, to the number of seats, all kinds of seals, tubing, water pipes, cables must be assembled in order, with particular attention to the cable connection can not have the phenomenon of explosion, the connection of the equipment to be flexible without resistance.
All parts and components should be fully installed, spring washers, bolts, pins, etc. must be fully installed, and any mechanism and protective device must not be arbitrarily thrown away.
The fittings of the hydraulic and waterway systems must be wiped clean before installation.
When installing each coupling pin, pay attention to the position of the pin stop notch and the locking tab.
Before the assembly was completed, the equipment was not allowed to connect to the electricity to perform the commissioning work.
The tension of the chain of the conveyor is appropriate, and the chain sag is about 50 to 70mm after the tension .
The tightness of the track is appropriate, and the sag is about 70 to 100mm after the tension .
Before commissioning, inform the relevant departments in advance to do a good job of setting the protection, and carefully and carefully check the machine. The commissioning can be carried out under the condition that the cable connection, hydraulic and water system loops are correctly taken over. Start the test, if there is any abnormality, you must stop the machine immediately. Check the cause and troubleshoot before starting the test again.
After the pump station motor work, the oil pump should be under pressure, and the operation of any handle machine should have corresponding actions. There should be no oil leakage in the joints of pipelines, valves, oil pumps, oil motors, etc.
According to the operation signboard on the operation table, each handle is operated to observe that the action direction of the actuator should be consistent with the direction indicated by the signboard, and an error should be promptly adjusted.
The cutting head should be turned clockwise (from the driver's position).
The inside and outside spraying should be smooth, the spray should be normal, and the waterway and joints should be free from leakage.
The pressure of each circuit of the hydraulic system meets the requirements. Cylinder: 16MPa ; Walking: 25MPa ; First conveyor: 18MPa ; Starwheel : 18MPa .
Before the boring machine is opened to the work, the debris from the front of the boring machine to the working surface shall be cleaned. When the boring machine is walking, special personnel shall be assigned to supervise the cables. Stations within 10m on both sides of the roadheader and in front shall be forbidden. When the roadheader is opened to the working surface, the bridge loader is hauled to the work surface with a φ 12.5mm wire rope hung on the support frame of the roadheader, and then installed.
After ensuring that the roadheaders, bridge loaders, and belt conveyors are each properly tested, a joint test run is performed. If there is any abnormality, the machine must be shut down immediately. Check the cause and troubleshoot before starting the test again. After the joint trial operation is carried out, it must be strictly checked and accepted by relevant departments before it can be used.