(1) During the initial start-up and operation of thescraper conveyor, special attention should be paid to checking the tightness of the scraper chain. As the conveyor runs, the distance between the chutes will gradually decrease. If the chain is too loose, issues like chain jamming, chain skipping, chain breaking, and the chain derailing may occur. The inspection method is to reverse the conveyor and count the number of loose chain links. If there are more than two completely loose chain links, the chain needs to be tightened again.
The proper tension of the scraper chain is fundamental to the smooth operation of the conveyor. When the chain is loose, the irregular movement during operation can cause it to dislocate from the normal track. In a mining or industrial material handling environment, this can quickly disrupt the entire production flow. By reversing the conveyor for inspection, operators can get a clear view of the slack state of the chain. Each loose link represents a potential risk factor, and when multiple links show excessive slack, it’s a sign that immediate adjustment is required. This not only helps prevent sudden breakdowns but also ensures the long-term durability of the chain.
(2) The working face should be kept straight. If the working face is not straight, the tension on the two chains will be unequal, resulting in uneven chain wear, the bottom chain derailing, getting stuck, or even breaking.
A straight working face is crucial for balanced stress distribution on the chains. In a conveyor system, the two chains work in tandem to move materials along the chutes. When the working face curves or is misaligned, one chain will bear more load than the other. Over time, this uneven load leads to differential wear. The more heavily stressed chain may experience rapid abrasion, weakening its structure and increasing the likelihood of derailment or breakage. This can cause costly downtime for maintenance and repairs, as well as potential safety hazards if the conveyor is handling heavy or hazardous materials.
(3) The bending of the conveyor should be appropriate, and there should be no “sharp bends.” The curved section should consist of no less than eight chutes. When pushing, pay attention to the coordination between the front and rear hydraulic jacks to avoid sharp bends. Otherwise, the chutes may become misaligned, causing chain breakage or derailment accidents. It is especially important to note that the conveyor should not be pushed when it is stopped.
The bending radius of the conveyor is a key factor in its structural integrity. A proper bend allows the chain and chutes to adapt gradually to the change in direction, minimizing stress concentrations. If a sharp bend is forced, the mechanical stress on the chutes and the chain becomes excessive. The chutes can shift out of alignment, creating gaps or misfits that can trap or break the chain. Hydraulic jacks play a vital role in controlled movement during conveyor adjustment, and incorrect operation of these jacks can lead to sudden, harmful bends. Additionally, pushing a stationary conveyor risks damaging the entire structure due to the lack of lubrication and smooth movement that running provides.
(4) The conveyor should be laid flat. Due to the limitations of the chute structure, it can only accommodate a vertical variation of 3″ – 5″. Therefore, if there are local bumps or dips on the working face floor, they should be leveled. Laying the conveyor flat is beneficial for the operation of the scraper chain, reducing chute wear and power consumption.
A flat conveyor bed ensures uniform contact between the chain and the chutes, optimizing the transfer of power to move materials. When the conveyor is uneven, the chain has to work harder to overcome the additional friction caused by the height differences. This not only accelerates the wear of the chutes but also demands more power from the drive system. Over time, this can lead to increased energy costs and premature component failure. Leveling any irregularities on the working face floor is a proactive measure to maintain efficient conveyor operation.
(5) During blasting operations, the transmission parts, pipelines, unit cables, switches, etc. of the conveyor must be well protected. When the conveyor is transporting iron materials or long items, safety measures should be formulated to avoid personal accidents.
Blasting operations generate intense shockwaves, debris, and dust that can severely damage the delicate components of the conveyor. Protecting the transmission parts, cables, and switches is essential for maintaining the conveyor’s functionality. When handling long or heavy iron materials, there are additional risks such as the items getting caught in the chain or falling off the conveyor, endangering workers. Safety measures like proper restraint systems, warning signs, and restricted access areas can prevent these potential hazards.
(6) There should be no excessive bends at the overlapping parts of the transition chute tail, the machine tail, and the intermediate chute. If there are bends, they should be padded with wooden boards.
These overlapping areas are stress concentration points. Excessive bending can cause premature fatigue and cracking of the chute materials. Wood padding provides a simple yet effective way to distribute the stress more evenly, reducing the risk of structural damage. It also helps to maintain a smoother transition for the scraper chain, preventing jolts and potential chain misalignment.
(7) Pay special attention to the vibration of the coupling. Check the vibration of the hydraulic coupling when the conveyor starts. To maintain good heat dissipation conditions, the protective cover plate and the hydraulic coupling should be cleaned regularly.
The vibration of the coupling can be an early indicator of mechanical problems, such as misalignment, imbalance, or component wear. Excessive vibration not only affects the performance of the coupling but can also transmit harmful forces throughout the conveyor system. A clean protective cover plate and hydraulic coupling are essential for efficient heat dissipation. Heat buildup can degrade the performance of the coupling fluid and accelerate component aging, leading to more serious malfunctions if left unaddressed.
In addition to these operational guidelines, regular maintenance schedules are indispensable for the long-term health of the scraper conveyor. Maintenance should be a comprehensive program that includes daily, weekly, and monthly checks. Daily checks can involve a quick visual inspection of key components like the chain, chutes, and couplings for any obvious signs of damage or wear. Weekly inspections might go deeper, including lubrication checks and minor adjustments. Monthly overhauls could involve more in-depth component inspections, replacement of worn parts, and system-wide performance testing.
Moreover, the quality of the materials used in the conveyor’s construction significantly impacts its lifespan. High-strength, wear-resistant metals for the chain and chutes can withstand the harsh operating conditions better. The type of lubricants chosen also matters; they should have good anti-wear and anti-corrosion properties to reduce friction and protect components. Operator training is another crucial aspect. Workers need to be educated about the proper operation techniques, safety precautions, and the importance of regular maintenance. This knowledge empowers them to detect early signs of problems and take corrective action promptly, minimizing downtime and maximizing productivity.
