中間驅動技術是大型可伸縮帶式輸送機最有效的驅動技術。它主要是把輸送機deyibufengonglvfensandaodaishishusongjidegegequdongdian,congerjiangdishusongdaiyunxingdezuidazhangli,jiangdishusongdaiqiangdu,jianshaoyuanbujiandedanjiqudonggonglv,jieshengchengben,tigaoshu送機的輸送能力。中間驅動技術應用最為廣泛的是直線摩擦驅動和滾筒卸載式驅動。
1.1直線摩擦驅動
直(zhi)線(xian)摩(mo)擦(ca)中(zhong)間(jian)驅(qu)動(dong)的(de)原(yuan)理(li)是(shi)承(cheng)載(zai)輸(shu)送(song)帶(dai)壓(ya)在(zai)驅(qu)動(dong)輸(shu)送(song)帶(dai)上(shang),利(li)用(yong)兩(liang)者(zhe)間(jian)產(chan)生(sheng)的(de)相(xiang)對(dui)摩(mo)擦(ca)力(li),將(jiang)驅(qu)動(dong)帶(dai)上(shang)的(de)動(dong)力(li)傳(chuan)遞(di)給(gei)承(cheng)載(zai)輸(shu)送(song)帶(dai),從(cong)而(er)使(shi)承(cheng)載(zai)輸(shu)送(song)帶(dai)運(yun)行(xing)輸(shu)送(song)物(wu)料(liao)。直(zhi)線(xian)摩(mo)擦(ca)驅(qu)動(dong)是(shi)撓(nao)性(xing)驅(qu)動(dong)體(ti)(驅動輸送帶)對撓性牽引體(承載輸送帶)的de驅qu動dong,其qi特te點dian是shi驅qu動dong體ti也ye產chan生sheng拉la伸shen應ying變bian。若ruo將jiang輸shu送song帶dai視shi為wei均jun勻yun的de連lian續xu體ti,其qi彈dan性xing係xi數shu不bu隨sui應ying力li或huo應ying變bian的de變bian化hua而er變bian化hua,且qie忽hu略lve承cheng載zai輸shu送song帶dai與yu驅qu動dong輸shu送song帶dai間jian的de接jie觸chu壓ya力li的de差cha異yi。影ying響xiang直zhi線xian摩mo擦ca驅qu動dong牽qian引yin力li輸shu出chu的de主zhu要yao因yin素su:(1)承載輸送帶與驅動輸送帶間的接觸壓力;(2)直線摩擦驅動段的長度;(3)承載輸送帶與驅動輸送帶間的摩擦係數。
由(you)於(yu)承(cheng)載(zai)輸(shu)送(song)帶(dai)與(yu)驅(qu)動(dong)輸(shu)送(song)帶(dai)間(jian)的(de)摩(mo)擦(ca)力(li)將(jiang)中(zhong)間(jian)驅(qu)動(dong)的(de)動(dong)力(li)傳(chuan)遞(di)給(gei)承(cheng)載(zai)輸(shu)送(song)帶(dai),承(cheng)載(zai)輸(shu)送(song)帶(dai)的(de)張(zhang)力(li)在(zai)與(yu)驅(qu)動(dong)輸(shu)送(song)帶(dai)作(zuo)用(yong)段(duan)內(nei)將(jiang)會(hui)有(you)一(yi)線(xian)性(xing)降(jiang)低(di)的(de)過(guo)程(cheng),這(zhe)一(yi)張(zhang)力(li)降(jiang)低(di)值(zhi)即(ji)為(wei)中(zhong)間(jian)驅(qu)動(dong)裝(zhuang)置(zhi)輸(shu)出(chu)的(de)牽(qian)引(yin)力(li)。張(zhang)力(li)變(bian)化(hua)如(ru)圖(tu)l(a)所示。
直線摩擦驅動的特點:
(1)可降低承載輸送帶最大張力,單元驅動元部件可小型化,降低投資成本;
(2)中間驅動段結構較複雜,裝卸不便,更適用於固定式帶式輸送機;
(3)可根據需要在承載輸送帶下安裝多台中間摩擦驅動。
由you於yu驅qu動dong輸shu送song帶dai放fang在zai承cheng載zai輸shu送song帶dai的de下xia部bu,當dang兩liang輸shu送song帶dai間jian接jie觸chu壓ya力li不bu均jun勻yun時shi輸shu出chu牽qian引yin力li不bu穩wen定ding。特te別bie是shi當dang直zhi線xian摩mo擦ca驅qu動dong段duan上shang方fang無wu物wu料liao,而er其qi他ta地di方fang裝zhuang滿man物wu料liao時shi,由you於yu兩liang輸shu送song帶dai間jian的de摩mo擦ca力li最zui小xiao,易yi引yin起qi驅qu動dong輸shu送song帶dai與yu承cheng載zai輸shu送song帶dai間jian打da滑hua,增zeng加jia頭tou部bu驅qu動dong負fu擔dan,引yin起qi電dian機ji過guo載zai。
1.2滾筒卸載式中間驅動技術
如圖l(b)所suo示shi,滾gun筒tong卸xie載zai式shi中zhong間jian驅qu動dong主zhu要yao通tong過guo驅qu動dong滾gun筒tong完wan成cheng對dui輸shu送song帶dai的de驅qu動dong,視shi輸shu送song帶dai為wei彈dan性xing體ti,忽hu略lve輸shu送song帶dai的de厚hou度du與yu滾gun筒tong相xiang接jie觸chu部bu分fen輸shu送song帶dai的de質zhi量liang以yi及ji彎wan曲qu應ying力li。由you歐ou拉la公gong式shi可ke知zhi,影ying響xiang牽qian引yin力li的de主zhu要yao因yin素su:(1)輸送帶在驅動滾筒分離點處的張力;(2)輸送帶在驅動滾筒上的圍包角;(3)驅動滾筒與輸送帶間的摩擦係數。
驅動滾筒的趨入段與奔離段的輸送帶張力落差即為驅動滾筒輸出的牽引力。卸載式驅動的輸送帶張力變化由圖l(b)中可看出。其特點:
(1)可降低承載帶張力,元部件可小型化,便於加工維護,降低生產成本;
(2)單元驅動功率小;
(3)多機起動時同步性較敏感;
(4)體積小,結構簡單,裝拆方便,特別適應輸送機運距的變化,適用於可伸縮帶式輸送機;
(5)卸載式驅動裝置越多,輸送帶的最大張力降低越多。
由以上2種驅動方式比較可以看出,卸載式驅動更適用於可伸縮帶式輸送機。
2、可伸縮帶式輸送機的軟起動
youyudaishishusongjigonglvfensandaogegequdongdian,duiqidongyaoqiuhengao,ruguogequdongdianbuanzhanglichuandiguilvqidong,huiyinqishusongjidahuahuoqidongbuqilai,gonglvbupinghengyinqishaodianji,yinci,zaihelifenpeigequdongdiandegonglvwai,haiyingkaolvshusongdaizhongzaishideqidongjiasudu,yijitingche、運yun行xing時shi的de輸shu送song帶dai張zhang力li瞬shun間jian值zhi降jiang低di到dao最zui小xiao,實shi現xian各ge個ge驅qu動dong單dan元yuan功gong率lv平ping衡heng,實shi現xian各ge個ge電dian機ji的de空kong載zai分fen時shi起qi動dong。因yin此ci,大da型xing可ke伸shen縮suo帶dai式shi輸shu送song機ji必bi須xu實shi現xian軟ruan起qi動dong。所suo謂wei帶dai式shi輸shu送song機ji的de軟ruan起qi動dong是shi在zai設she定ding的de起qi動dong時shi間jian內nei,通tong過guo控kong製zhi輸shu送song帶dai起qi動dong加jia速su度du值zhi,來lai確que保bao輸shu送song機ji按an所suo要yao求qiu的de速su度du曲qu線xian(見圖2)平穩起動,並達到額定運行速度,同時使電機的起動電流與輸送帶的起動動張力控製在允許範圍內。
對於大型帶式輸送機.如果不使用軟起動,而直接起動,將會給輸送機造成:(1)輸送帶打滑,不能起動,更不能滿載起動;(2)加大輸送帶起動時的動張力,造成對元部件的瞬時衝擊;(3)加大電動機的起動電流。
帶式輸送機的軟起動是可伸縮帶式輸送機的關鍵技術之一。而軟起動技術較普遍使用的有3種:
(1)差動式輪係液黏調速裝置(CST);
(2)變頻調速裝置;
液力調速裝置。
2.1差動輪係液黏調速裝置
差動輪係液黏調速裝置主要由行星齒輪減速器與可控液黏離合器組成。其工作原理:通過調節離合器中的油壓、liyongmocapianjiansuoxingchengdeyoumodedonglinianxinglaichuandidongli,bingkongzhijiansuqishuchuzhoudezhuansu,dadaoshusongjideruanqidong。diandongjizhuansutongguoxingxingjiansuqideshuruzhou、中間齒輪,傳遞給太陽輪,太陽輪使3gexingxinglunxuanzhuan,yuliheqizhongdedongmocapianxianglianjiedeneichiquanshifudongde,kezuoziyouzhuandong。dangliheqizhongwuyouyashi,xingxinglunshiziyoufudongdeneichiquanzhuandong,congershixingxingjiabuzhuandong,jiansuqishuchuzhoujiujingzhibuzhuan。dangduiliheqizhujianshijiayouyashi,liangmocapianjianyoumosuochanshengdenianxingjianqieliju,shineichiquanzhuansuzhujianxiajiang,zhizhitingzhizhuandong。cishixingxingluntuojiajiuzhujianjiadazhuansu,zhizhidadaoedingzhuansu。tongguokongzhiliheqizhongdeyouyaliyuyouyashijiashijian,jiukeshishusongjianzhaoshedingdesuduquxianpingwenqidong。gaizhuangzhideyoudianshiqidongshitiaosujingdugao,keyibiansuyunxing。quedianshichanpinyilaijinkou,jiageanggui,shiyongweihuyaoqiugao,duiyoudenianduyuqingjieduyaoqiuyegao;使用過程中的備品備件必須進口,事故處理也依賴外國公司。
2.2變頻調速裝置
變頻調速裝置主要由功率器件-IGBT絕緣柵極可控晶體管、可控器與電抗器組成。其工作原理:通過控製器來調節功率器中的絕緣柵極,使進入功率器件的交流電源的頻率發生變化。
電dian動dong機ji轉zhuan速su與yu交jiao流liu電dian源yuan頻pin率lv成cheng正zheng比bi關guan係xi。當dang交jiao流liu電dian源yuan的de頻pin率lv由you小xiao到dao大da變bian化hua時shi,電dian動dong機ji轉zhuan速su也ye隨sui之zhi由you小xiao到dao大da變bian化hua。隻zhi要yao控kong製zhi頻pin率lv變bian化hua範fan圍wei以yi及ji頻pin率lv變bian化hua時shi間jian,就jiu可ke使shi輸shu送song機ji按an照zhao設she定ding的de速su度du曲qu線xian平ping穩wen起qi動dong,達da到dao輸shu送song機ji的de軟ruan起qi動dong。該gai裝zhuang置zhi優you點dian是shi起qi動dong時shi調tiao速su精jing度du高gao,可ke以yi變bian速su運yun行xing,調tiao速su範fan圍wei大da。缺que點dian是shi電dian動dong機ji不bu能neng空kong載zai起qi動dong;防爆產品依賴進口、價格昂貴;控製複雜、使用維護要求高,對環境溫度與清潔度要求高;shiyongguochengzhongdebeipinbeijianbixujinkou,shiguchuliyeyilaiwaiguogongsi。suirandiankangqikeyijianshaoduiwaijiedianyuandewuran,danpinlvgaibian,haishiduidianyuanyouyidingchengdudewuran。ruguoshizaijingxiashiyong,gonglvqijiandefarewentiyeshibixujiejuedeyigejishunanguan。
2.3液力調速裝置
液力調速裝置主要由液力耦合器、電動執行器、稀油潤滑裝置與油箱等組成。其工作原理:liyongchuandongjiezhilaichuandidongli,tongguotiaojieouheqigongzuoqiangneichongyeliangdeduoshao,laikongzhiouheqishuchuzhoudezhuansu,dadaoshusongjideruanqidong。xianyoudiandongjidaidongouheqidebenglunkongyunzhuan,ranhouxiangouheqigongzuoqiangzhongzhuruchuandongjiezhiye。dangdaoliuguanchuyuzuilibianweizhishi,jinrugongzuoqiangzhongdechuandongjiezhiyequanbuyoudaoliuguanliuhuiyouxiang,cishiwolunyushuchuzhoubuzhuandong。dangdiandongzhixingqidaidongdaoliuguanhuanmanxiangwaiyidongshi,jinrudaoliuguanliuhuiyouxiangdechuandongjiezhiyezhujianjianshao,erjinrugongzuoqiangzhongdechuandongjiezhiyezhujianzengduo。zaigaosuxuanzhuandebenglunyepiandaidongxia,chuandongjiezhiyexingchenggaoyagaosuyeliu,chongxiangwolunyepian,shiwolunyushuchuzhouzhujianzhuandongqilai。suizhegongzuoqiangneichuandongjiezhiyedebuduanzengduo,wolunyushuchuzhoudezhuansuyejiuzhujianzengjia,zhizhidadaoedingzhuansu。zhiyaokongzhidaoliuguanxiangwaiyidongsudu,jiukeshishusongjianzhaoshedingsuduquxianpingwenqidong。gaizhuangzhiyoudianshiqidongshitiaosujingdujiaogao,yekebiansuyunxing,yunxingkekao,jiegoujiandan,caozuoweihufangbian,jiagedilian,guoneiyouchengshuchanpinkegonghuo。quedianshitiaosufanweixiao,zaitiaosuyunxingshidexiaolvdi。
通過上述對3zhongruanqidongzhuangzhidejishujingjifenxibijiaokeyikanchu,yelitiaosuzhuangzhiyunxingkekao,caozuoweihujianbian,jiagedilian,younengquanbumanzudaishishusongjiruanqidongyaoqiu,chanpinguoneikeyijiejue。yinerxuanzeyelitiaosuzhuangzhizuoweidaishishusongjideruanqidongzhuangzhibujinshijishukexingde,erqieyeshijingjihelide。
煤科院上海分院研製成功的液力調速裝置榮獲煤炭部科技進步一等獎、國家“七五”重大科研成果獎。目前國內煤炭用帶式輸送機軟起動裝置絕大多數為液力調速裝置,僅上海分院製造的液力調速裝置就有100多(duo)套(tao)。差(cha)動(dong)輪(lun)係(xi)液(ye)黏(nian)調(tiao)速(su)裝(zhuang)置(zhi)引(yin)進(jin)以(yi)後(hou),真(zhen)正(zheng)在(zai)國(guo)內(nei)煤(mei)礦(kuang)帶(dai)式(shi)輸(shu)送(song)機(ji)上(shang)實(shi)際(ji)使(shi)用(yong)的(de)僅(jin)為(wei)幾(ji)套(tao)。變(bian)頻(pin)調(tiao)速(su)裝(zhuang)置(zhi)在(zai)國(guo)內(nei)煤(mei)礦(kuang)帶(dai)式(shi)輸(shu)送(song)機(ji)上(shang)使(shi)用(yong),僅(jin)1套是引進的,而且是非防爆的,後因控製複雜、工人不易掌握等原因,對控製部分進行了改造。這2種軟起動裝置在國內不能普遍使用,主要原因是價格太貴,操作維護複雜,工人不易掌握,備品備件依賴進口。
3、驅動係統的控製
以往帶式輸送機多以接觸器,繼電器為主要電氣控製手段,體積大、維修困難,且控製容量有限,采用以美國GE90 - 30係列可編程序控製器為核心的電氣控製係統一可編程序控製器控製係統的控製裝置,控製、保護功能齊全,具有慢速起動功能,易於擴充,電路結構簡單,維修方便,可靠性高。該係統具有以下功能:
(1)連續檢測電機轉速或輸送帶線速度,各電機順序分別空載起動,對電網的衝擊較小;
(2)具有超速及打滑保護功能。
利li用yong可ke編bian程cheng序xu控kong製zhi器qi的de高gao速su計ji數shu器qi模mo塊kuai,可ke以yi任ren意yi預yu置zhi超chao速su上shang限xian值zhi及ji打da滑hua的de下xia限xian值zhi,當dang高gao速su計ji數shu器qi的de計ji數shu值zhi超chao過guo或huo低di於yu預yu置zhi時shi,可ke編bian程cheng序xu控kong製zhi器qi內nei部bu繼ji電dian器qi即ji動dong作zuo,實shi現xian超chao速su或huo打da滑hua保bao護hu;
(3)本係統可實現慢速起動(起動時間可調)以及各電機功率自動平衡,精度達到95%以上;
(4)可編程序控製器容易掌握,操作簡便,具有很強的抗幹擾和驅動能力,工作可靠,維修方便。
該係統保護齊全,設有沿線停車、跑偏、煙霧、打滑、軸溫、油溫、煤位、機械閘限位、超溫自動灑水等保護。
目前國內外對撕帶、斷duan帶dai保bao護hu裝zhuang置zhi的de研yan究jiu進jin展zhan不bu大da,抗kang撕si裂lie輸shu送song帶dai由you於yu價jia格ge昂ang貴gui,目mu前qian還hai不bu被bei大da多duo數shu用yong戶hu所suo接jie收shou。本ben係xi統tong對dui輸shu送song帶dai的de斷duan帶dai保bao護hu進jin行xing了le一yi定ding的de研yan究jiu,在zai滿man足zu可ke靠kao性xing、經濟性的前提下,在輸送帶發生斷帶現象時能及時停下主電機,避免事態的進一步擴大,這是目前最有效的解決辦法。
4、結語
(1)長距離、大運量可伸縮帶式輸送機中間驅動技術的最佳選擇是用卸載式驅動技術和調速型液力耦合器軟起動技術;
(2)中間驅動技術可降低輸送帶張力,減少單元元部件功率,有利於通用化,便於維護;
(3)調速型液力耦合器是最經濟實用軟起動技術。
相關輸送機產品:
1、皮帶輸送機
2、鬥式提升機
3、刮板輸送機



