AU2015100903A4 - Remanufacturing method of scraper conveyor - Google Patents

Remanufacturing method of scraper conveyor Download PDF

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AU2015100903A4
AU2015100903A4 AU2015100903A AU2015100903A AU2015100903A4 AU 2015100903 A4 AU2015100903 A4 AU 2015100903A4 AU 2015100903 A AU2015100903 A AU 2015100903A AU 2015100903 A AU2015100903 A AU 2015100903A AU 2015100903 A4 AU2015100903 A4 AU 2015100903A4
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wear
base plate
new
middle plate
new product
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AU2015100903A
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Chunchun DONG
Xueyun Du
Fanliang Tan Tai
Yongjun Xiao
Fan Yang
Qingdong YANG
Yanliang Zhang
Feng Zhou
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Shandong Energy Heavy Equipment Manufacturing Group Co Ltd
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Shandong Energy Heavy Equipment Manufacturing Group Co Ltd
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Abstract

REMANUFACTURING METHOD OF SCRAPER CONVEYOR This present disclosure provides a remanufacturing method of a scraper conveyor, which relates to the technical field of a machine manufacturing, and the remanufacturing method includes: measure wear loss of each part of a worn scraper conveyor, and perform remanufacturing according to the wear loss; wherein the remanufacturing is repairing and/or replacing, a process of the repairing adopts a technology of plasma cladding. This present disclosure has these advantages such as saving resources, reducing the cost of investment, obviously improving the entire wear resistance, prolonging the service life, highly flexible and significantly enhancing the operability of the remanufacturing. Fig. 1

Description

REMANUFACTURING METHOD OF SCRAPER CONVEYOR TECHNICAL FIELD The present disclosure mainly relates to the technical field of a machine 5 manufacturing, and more particularly to a remanufacturing method of a scraper conveyor. BACKGROUND Any discussion of the background art throughout the specification should in 10 no way be considered as an admission that such background art is prior art nor that such background art is widely known or forms part of the common general knowledge in the field in Australia or worldwide. During a working process of a scraper conveyor, a head end, a tail end, a transitional channel and a middle channel of the scraper conveyor, not only bear the 15 pressure of cargo, but also bear the operating load of a coal mining machine, a push/pull force of a hydraulic support, the cargo load and the sliding resistance of the scraper, which causes the different components of scraper conveyor to be out of shape and to be seriously worn. Up till now, the worn out scraper conveyors inland and abroad are repaired 20 only by an ordinary surfacing welding technology and the repairing quality is quite poor, which cannot meet the requirement of the wear resistance of each part, so that the worn parts are deemed useless and gradually enter the peak period of scrap. In the practical production, all major coal mines take the ultimate wear loss of 25 the base plate of the mechanical body components as a standard to determine whether the scraper conveyor is scraped or not, but the scraped channel ledge steel, the middle plate and the base plate and so on still have great values in use, which causes enormous wasting of resources and serious pollution problems. The major coal mines only repair a few parts of which the wear losses are small, but not 1 remanufacture them. Furthermore, the space in which the base plate of the middle channel locates is narrow, so the traditional repairing technology is not able to use. So far, there is no remanufactured scraper conveyor in a real sense. 5 SUMMARY Throughout this specification, unless the context requires otherwise, the words "comprise", "comprises" and "comprising" will be understood to imply the inclusion of a stated step or element or group of steps or elements but not the exclusion of any other step or element or group of steps or elements. 10 Any one of the terms: "including" or "which includes" or "that includes" as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, "including" is synonymous with and means "comprising". It is an object of the present invention to overcome or ameliorate at least one 15 or more of the disadvantages of the prior art, or to provide a useful alternative. In view of defects and deficiencies of the existing methods, the present disclosure accordingly provides a remanufacturing method of a scraper conveyor, which can save resources, reduce the cost of investment, obviously improve the entire wear resistance, prolong the service life and significantly enhance the 20 operability of the remanufacturing, and highly flexible. In order to reach the above aim, the present disclosure accordingly provides the following technical solution: A remanufacturing method of a scraper conveyor is provided, which includes: measure wear loss of each part of a worn scraper conveyor, and perform 25 remanufacturing according to the wear loss; wherein the remanufacturing is repairing and/or replacing, a process of the repairing adopts a technology of plasma cladding. Further, before measure the wear loss of each part of the worn scraper 2 conveyor, the method further includes a cleaning process, wherein the cleaning process means to remove the oxide, carbon deposits and oil on the surface of each part. Further, a standard and a process of the repairing according to the wear loss 5 include: (1) when the wear loss of a middle plate is less than or equal to 30% of a new product, perform repairs on the middle plate by using the plasma cladding with a first wear strip and a first wear block; (2) when the wear loss of a base plate is less than or equal to 30% of a new 10 product, perform repairs on the base plate by using the plasma cladding with a second wear strip and a second wear block; (3) when the wear loss of a middle plate is less than or equal to 30% of a new product, and meanwhile the middle plate has no more than three worn parts of which the wear loss is more than 30% of a new product and less than or equal to 15 50% of a new product, firstly perform repairs on the middle plate by using surfacing welding and then using the plasma cladding with a first wear strip and a first wear block; (4) when the wear loss of a base plate is less than or equal to 30% of a new product, and meanwhile the base plate has no more than three worn parts of which 20 the wear loss is more than 30% of a new product and less than or equal to 50% of a new product, firstly perform repairs on the base plate by using surfacing welding and then using the plasma cladding using a second wear strip and second wear block; (5) when the wear loss of the width of a monolateral of channel ledge steel is 25 less than or equal to 23% of a new product, and the wear loss of the inside height of the chain track is less than or equal to 8% of a new product, perform repairs on the channel ledge steel by using the plasma cladding with a third wear strip and a third 3 wear block. Further, a standard and a process of the repairing according to the wear loss include: (1) when the wear loss of a middle plate and/or the wear loss of a base plate is 5 more than 30% of a new product, replace the worn middle plate and/or worn base plate with a new product; (2) when the wear loss of an end section of a middle plate and/or a base plate is more than 30%, the wear loss of other parts is less than or equal to 30% of a new product, and the total length of the worn end section is less than 40% of a new 10 product, replace the worn end section of the middle plate and/or base plate with a new product and repair the other parts; (3) when the wear loss of the monolateral-width of a chain track of channel ledge steel is more than 23% of a new product, and/or the wear loss of the inside height of the chain track is more than 8% of a new product, replace the worn 15 channel ledge steel with a new product. A process of the replacing with a new product according to the wear loss further includes: perform strengthening treatment on the new product, which includes: (1) perform the plasma cladding on the surfaces of a new middle plate and a 20 new base plate by using first wear strip and a first wear block; (2) perform the plasma cladding on the surface of a new end section of a middle plate by using a first wear block; (3) perform the plasma cladding on the surface of a new end section of a base plate by using a second wear block; 25 (4) perform the plasma cladding on the surface of new channel ledge steel by using a third wear block. 4 Further, the first wear strips respectively locate in planes of the repaired middle plate, the new middle plate and the new base plate, and the single-track cladding width of the first wear strip is 10~15mm; the first wear blocks respectively locate at the surface of the repaired middle plate, the new middle plate and a new end 5 section of the middle plate and a connection opening of the new base plate. The second wear strip locates in the plane of the repaired base plate and the single-track cladding width of the second wear strip is 5~7mm; the second wear blocks respectively locate at a connection opening of the repaired base plate and the surface of a new end section of the base plate. 10 The first wear blocks and the second wear blocks respectively locate just under the chains, and the amount and the space between them match with the chains.; The third wear strip locates inside the chain track of the channel ledge steel and the distances between the third wear strip and the two ends of the monolateral edge inside the chain track both are 15~20mm; the third wear block locates at a 15 connection opening of the channel ledge steel, the length of the third wear block is 80~1 00mm, and the distances between the third wear block and the two ends of the monolateral edge inside the chain track both are 15~20mm. Both of the specifications of the first wear block and the second wear block are 60~100mm x 60~100mm; all of the single-track cladding thicknesses of the first 20 wear strip, the second wear strip and the third wear strip are 2.5~3.5mm; all of the single-track cladding thicknesses of the first wear block, the second wear block and the third wear block are 2.5~3.5mm. The first wear strips, the second wear strips and the third wear strips respectively constitute patterns with different textures, and the length and width of 25 the pattern respectively equals to the length and width of the part where the pattern locates; the pattern is set as any one of a diamond, a fish-bone shape and a straight-bar-overlapped fish scale shape; the first wear strip, the second wear strip and the third wear strip adopts a discontinuous and symmetric process to perform 5 the cladding, which can effectively prevent the cladding deformation and contributes to improving the wear resistance and aesthetic extent of the repaired part. The first wear block and the third wear block are made of multiple first wear strips which are overlapped to be clad, and the second wear block is made of 5 multiple second wear strips which are overlapped to be clad. The overlap rate of the first wear strips and the overlap rate of the second wear strips are 30%-50%, which contributes to wear resistance of the connection opening. Further, after performing remanufacturing according to the wear loss, the method further includes: perform testing and anti-corrosion treatment; wherein 10 the testing includes a hardness test and a wear-resistance property test. In this present disclosure, the processes of performing the plasma cladding with the first wear strip, the second wear strip and the third wear strip include: the cladding speed is 190~220mm/min, the voltage is 34~35.5V, the initial current is 220~240A, the working current is 230~250A, the ending current is 210~240A, the 15 swing distance of the welding gun is 8~10mm, the swing frequency of the welding gun is 65~75 times per minute, the swing speed of the welding gun is 66~67mm/s, and the left-right fine adjustment distance of the welding gun is 9~11 mm. Further, the processes of performing the plasma cladding with the first wear block, the second wear block and the third wear block include: the cladding speed 20 is 140~160mm/min, the voltage is 33.5~34.5V, the initial current is 220~240A, the working current is 220~250A, the ending current is 210~240A. This present disclosure has these advantages as below: 1. In this present disclosure, performing repairs on the worn parts by using the plasma cladding process, with the help of the first wear strip, the second wear strip, 25 the first wear block and the second wear block, can effectively reduce the wear loss of the middle plate and base plate which is caused by the chains, and with the help of the third wear strip and the third wear block, also can effectively reduce the wear 6 loss of the channel ledge steel which is caused by the scraper, so as to improve the entire wear resistance of the conveyor. 2. In this present disclosure, perform multiple times of the plasma cladding process under the condition that the intension of the substrates of the middle plate 5 and the base plate are not decreased, so as to save the resources and reduce the cost of investment. 3. In this present disclosure, repairing the worn part and performing strengthening treatment on the new product used to replace are conductive to prolong the service life of each part. 10 4. In this present disclosure, performing remanufacturing by using the plasma laser cladding process is suitable for the remanufacturing within the plane, also is suitable for the remanufacturing in a narrow space, which is highly flexible and can significantly enhance the operability of the remanufacturing. BRIEF DESCRIPTION OF THE DRAWINGS 15 Fig. 1 is a schematic structural view of a middle channel/transitional channel of the present disclosure. In Fig.1, 1-channel ledge steel, 2-middle plate, 21-connection opening of the middle plate, 22-end section of the middle plate, 3-base plate, 31-connection opening of the base plate, 32-end section of the base plate, 4-chain track, 20 5-monolateral edge inside the chain track, 6- connection opening of the channel ledge steel. Wherein the connection opening 21 of the middle plate locates at the joint position of the adjoining middle plates 2, the end sections 22 of the middle plate separately locate at two ends of the middle plate 2, the connection opening 31 of 25 the base plate locates at the joint position of the adjoining base plates 3, the end sections 32 of the base plate separately locate at two ends of the base plate 3. The chain track 4 locates at the inside of the channel ledge steel 1, the 7 monolateral edges 5 inside the chain track separately locate at the upper part and the lower part of the chain track 4, and connection opening 6 of the channel ledge steel locates at the joint position of the adjoining channel ledge steel 1. 5 DETAILED DESCRIPTION In order to make the skilled in this art understand the present disclosure better, the present disclosure will now be described more clearly and fully hereinafter. According to the exemplary embodiments of this disclosure, all other similar embodiments obtained by those skilled in this art without any creative work belong 10 to the protection scope of the present disclosure. Embodiment One: A remanufacturing method of a scraper conveyor is provided, which includes the following steps: 1. Perform surface treatment on each part of a conveyor to remove the oxide, 15 carbon deposits, and oil. 2. Measure the wear losses of the first middle plate 2 and the first base plate 3 of the middle channel and the wear losses of the second middle plate 2 and the second base plate 3 of the transitional channel, and measure the wear loss of the channel ledge steel 1 of the middle channel, the measured data are as follows: 20 The wear loss of the first middle plate 2 is equal to 20% of a new product, the wear loss of the end section 32 of the first base plate is equal to 33% of a new product, the wear loss of other parts is equal to 21% of a new product, and the total wear-length of the end section 32 is equal to 36% of a new product. The wear loss of the end section 22 of the second middle plate is equal to 35% 25 of a new product, the wear loss of other parts is equal to 23% of a new product, and the total wear-length of the end section 22 is equal to 25% of a new product, the wear loss of the second base plate 3 is equal to 18% of a new product. 8 The wear loss of the monolateral width of the chain track 4 of the channel ledge steel 1 is equal to 20% of a new product, and the wear loss of the inside height of the chain track 4 is equal to 7% of a new product. 3. According to the wear losses, perform the repairs on the first middle plate 2, 5 the second base plate 3 and the channel ledge steel 1 using the plasma cladding process, replace the end section 22 of the second middle plate and the end section 32 of the first base plate with the new ones, and repair other parts. 4. Perform the hardness test and the wear-resistance property test on each part of the remanufactured conveyor, and perform anti-corrosion treatment on them. 10 Herein, the specific steps of performing the repairs on the first middle plate 2 and the second base plate 3 using the plasma cladding process include: (1) The plane of the first middle plate 2 is clad with first wear strips, and the plane of the second base plate 3 is clad with second wear strips. A process of performing the plasma cladding with the first wear strip and the 15 second wear strip includes: the cladding speed is 190mm/min, the voltage is 34V, the initial current is 220A, the working current is 230A, the ending current is 210A, the swing distance of the welding gun is 8mm, the swing frequency of the welding gun is 65 times per minute, the swing speed of the welding gun is 66mm/s, and the fine adjustment distance on the left-right direction of the welding gun is 9mm. 20 The single-track cladding width of the first wear strip is 10mm, the single-track cladding width of the second wear strip is 5mm, and the single-track cladding thickness of the first wear strip and the single-track cladding thickness of the second wear strip both are 2.5mm. (2) The connection opening 21 of the first middle plate is clad with a first wear 25 block, and the connection opening 31 of the second base plate is clad with a second wear block, and the specifications of the first wear block and the specifications of the second wear block both are 60x100mm. 9 A process of performing the plasma cladding with the first wear block and the second wear block includes: the cladding speed is 140mm/min, the voltage is 33.5V, the initial current is 220A, the working current is 220A, and the ending current is 210A. 5 The first wear block is made of multiple first wear strips which are overlapped to be clad, and the overlap rate is 35%, which contributes to improving the wear resistance of the connection opening 21 of the middle plate. The single-track cladding width of the first wear strip is 11 mm, and the single-track cladding thickness of the first wear strip is 2.8mm. 10 The second wear block is made of multiple second wear strips which are overlapped to be clad, the overlap rate is 40%, which contributes to improving the wear resistance of the connection opening 31 of the base plate; the single-track cladding width of the second wear strip is 5.5mm, and the single-track cladding thickness of the second wear strip is 2.7mm. 15 The specific steps of performing the repairs on the channel ledge steel 1 using the plasma cladding process include: (1) The inside of the chain track 4 of the channel ledge steel is clad with a third wear strip. A process of the inside of the chain track 4 of the channel ledge steel being 20 clad with the third wear strip by using the plasma cladding process includes: the cladding speed is 200mm/min, the voltage is 34V, the initial current is 220A, the working current is 240A, the ending current is 240A, the swing distance of the welding gun is 9mm, the swing frequency of the welding gun is 70 times per minute, the swing speed of the welding gun is 66mm/s, and the left-right fine adjustment 25 distance of the welding gun is 10mm. The distances between the third wear strip and the two ends of the monolateral edge 5 inside the chain track both are 15mm, the single-track cladding width of the 10 third wear strip is 13mm, and the single-track cladding thickness of the third wear strip is 3.0mm. (2) The connection opening 6 of the channel ledge steel is clad with a third wear block. 5 A process of perform cladding on the connection opening 6 of the channel ledge steel with the third wear block includes: the cladding speed is 150mm/min, the voltage is 34V, the initial current is 220A, the working current is 220A, and the ending current is 240A. The length of the third wear block is 80mm, and the distances between the third 10 wear block and the two ends of the monolateral edge 5 inside the chain track both are 15mm. The third wear block is made of multiple first wear strips which are overlapped to be clad, and the overlap rate of the first wear strips is 30%, which contributes to improving the wear resistance of the connection opening 6 of the channel ledge 15 steel. The single-track cladding width of the first wear strip is 12mm, and the single-track cladding thickness of the first wear strip is 3.5mm. The specific steps of replacing the end section 22 of the second middle plate and the end section 32 of the first base plate with the new ones, and repair other parts include: 20 (1) Remove the end section 22 of the second middle plate and the end section 32 of the first base plate respectively by using a carbon gouging method, grind the edges of the second middle plate 2 and the first base plate 3 using a angle grinder, and respectively weld a new end section to the position of the original worn end section by track welding, and pre-heat it to 80'C before conduct welding, and the 25 selected wire for welding is GHS-60. (2) The surface of the new end section 22 of the second middle plate, that is connection opening 21 of the second middle plate, is clad with a first wear block; 11 the surface of the new end section 32 of the first base plate, that is the connection opening 31 of the first base plate, is clad with a second wear block. The specifications of the first wear block and the specifications of the second wear block both are 70x100mm. 5 A process of performing plasma cladding with the first wear block and the second wear block includes: the cladding speed is 160mm/min, the voltage is 34.5V, the initial current is 240A, the working current is 250A, and the ending current is 240A. The first wear block is made of multiple first wear strips which are overlapped to 10 be clad, the second wear block is made of multiple second wear strips which are overlapped to be clad, both the overlap rates of the first wear block and the second wear block are 40%, which contribute to improving the wear resistance of the connection opening 21 of the middle plate and the connection opening 31 of the base plate. 15 The single-track cladding width of the first wear strip is 13.5mm, and the single-track cladding thickness of the first wear strip is 3mm; the single-track cladding width of the second wear strip is 6mm, and the single-track cladding thickness of the second wear strip is 3mm. (3) The plane of the first base plate 3 is clad with second wear strips, and the 20 plane of the second middle plate 2 is clad with first wear strips. A process of performing the plasma cladding with the first wear strip and the second wear strip includes: the cladding speed is 220mm/min, the voltage is 35.5V, the initial current is 240A, the working current is 250A, the ending current is 240A, the swing distance of the welding gun is 10mm, the swing frequency of the 25 welding gun is 75 times per minute, the swing speed of the welding gun is 67mm/s, and the left-right fine adjustment distance of the welding gun is 11 mm. The single-track cladding width of the first wear strip is 14mm, and the 12 single-track cladding thickness of the first wear strip is 2.6mm. The single-track cladding width of the second wear strip is 6mm, and the single-track cladding thickness of the second wear strip is 3.1 mm. In this embodiment, the first wear strips form a diamond pattern, the length and 5 the width of the diamond pattern are respectively and correspondingly equal to the length and the width of the first middle plate 2 or the second middle plate 2; the pattern formed by the second wear strips or the third wear strips is a fishbone shape, and the length and the width of the fishbone-shape pattern are respectively and correspondingly equal to the length and the width of the first base plate 3, the 10 second base plate 3 or the channel ledge steel 1. In this embodiment, directly performing repairs on the first middle plate 2, the second base plate 3 and the channel ledge steel 1 by using the plasma cladding process can promote the chains of the scraper conveyor to slide on the surfaces of the first wear strip, the second wear strip, the first wear block and the second wear 15 block, so as to reduce the wear to the middle plate 2 and the base plate 3, and meanwhile reduce the wear to the channel ledge steel 1 with the help of the third wear strip and the third wear block, and improve the entire wear resistance of the conveyor. In this embodiment, replace the end section 22 of the second middle plate and 20 the end section 32 of the first base plate with the new ones, and repair other parts, which can save the resources and reduce the cost of investment. In this embodiment, there is no need to remove the first base plate 3 and the second base plate 3 when the first base plate 2 and the second base plate 3 are repaired by using the plasma cladding process, the repair process is accomplished 25 directly in the narrow space of the middle channel and the transitional channel, which can get high flexibility and significantly improve the operability of remanufacturing. 13 Embodiment Two: A remanufacturing method of a scraper conveyor is provided, which includes the following steps: 1. Perform surface treatment on each component of a conveyor to remove the 5 oxide, carbon deposits, and oil. 2. Measure the wear losses of the first middle plate 2 and the first base plate 3 of the middle channel and the wear losses of the second middle plate 2 and the second base plate 3 of the transitional channel, and measure the wear loss of the channel ledge steel 1 of the middle channel, the measured data are as follows: 10 The wear loss of the first middle plate 2 is equal to 35% of a new product, and the wear loss of the first base plate 3 is equal to 20% of a new product; meanwhile the first base plate 3 has three worn parts of which the wear loss is equal to 39% of a new product. The wear loss of the second middle plate 2 is equal to 22% of a new product, 15 and meanwhile the second middle plate 2 has two worn parts of which the wear loss is equal to 45% of a new product, and the wear loss of the second base plate 3 is equal to 33% of a new product. The wear loss of the width of the monolateral chain track 4 of the channel ledge steel 1 is equal to 27% of a new product, and the wear loss of the inside height of 20 the chain track 4 is equal to 6% of a new product; replace the worn channel ledge steel 1 with the new product. 3. Based on the wear losses, replace the first middle plate 2, the second base plate 3 and the channel ledge steel 1 with the corresponding new products, and perform strengthening treatment on the new products; for the first base plate 3 25 and the second middle plate 2, firstly perform the repairs on their worn parts by using surfacing-welding technology to make their wear losses are less than or equal to 30% of a new product, and then perform the repairs by using the plasma cladding 14 process. 4. Perform the hardness test and the wear-resistance property test on each part of the remanufactured conveyor, and perform anti-corrosion treatment on them. Therein, the specific steps of replacing the first middle plate 2 and the second 5 base plate 3 with the corresponding new products and performing strengthening treatment on the new products include: (1) In order to prevent deformation, firstly place stiffeners on the channel ledge of the both ends of the middle channel and fix them by using track welding, and then turn the middle channel over, remove the first middle plate 2 using a semi-auto 10 cutting machine, and grind the cut edge of the middle channel using the angle grinder. The second base plate 3 of the transitional channel is removed by the above method. (2) The surfaces of the new first middle plate 2 and the new second base plate 3 are respectively clad with first wear strips. 15 The cladding width of the first wear strip is 12.5mm, and the cladding thickness of the first wear strip is 3.3mm. A process of performing the plasma cladding with the first wear strip includes: the cladding speed is 21 0mm/min, the voltage is 34.5V, the initial current is 230A, the working current is 230A, the ending current is 230A, the swing distance of the 20 welding gun is 8mm, the swing frequency of the welding gun is 68 times per minute, the swing speed of the welding gun is 66.5mm/s, and the fine adjustment distance on the left-right direction of the welding gun is 10mm. (3) The connection opening 21 of the new first middle plate and the connection opening 31 of the new second base plate are respectively clad with first wear 25 blocks, and the specifications of the first wear block is 7Ox80mm. The first wear block is made of multiple first wear strips which are overlapped to be clad, and the overlap rate of the first wear strips is 38%, which contributes to 15 improving the wear resistance of the connection opening. The single-track cladding width of the first wear strip is 10.5mm, and the single-track cladding thickness of the first wear strip is 2.9mm. A process of performing the plasma cladding with the first wear block and the 5 second wear block includes: the cladding speed is 147mm/min, the voltage is 34V, the initial current is 235A, the working current is 225A, and the ending current is 240A. (4) Weld the new first middle plate 2 processed with the strengthening treatment to the position of the original first middle plate 2 by using track welding, 10 and weld the new second base plate 3 processed with the strengthening treatment to the position of the original second base plate 3 by using track welding. Pre-heat them to 100 C and then conduct welding with the wire of GHS-60. The specific steps of replacing the channel ledge steel 1 with the new product and performing the strengthening treatment on the new product include: 15 (1) Remove the worn channel ledge steel 1 using the semi-auto cutting machine, grind the cut edge of the conveyor using the angle grinder, and weld the new channel ledge steel 1 to the position of the original worn channel ledge steel 1 by using track welding. Pre-heat them to 11 0 0 C and then conduct welding with the wire of GHS-60. 20 (2) The connection opening 6 of the new channel ledge steel is clad with third wear blocks by using the plasma cladding. The length of the third wear block is 90mm, and the distances between the third wear block and the two ends of the monolateral edge 5 inside the chain track both are 17mm. 25 The third wear block is made of multiple first wear strips which are overlapped to be clad, and the overlap rate of the first wear strips is 45%, which contributes to improving the wear resistance of the connection opening 6 of the channel ledge 16 steel. The cladding width of the first wear strip is 14.5mm, and the cladding thickness of the first wear strip is 3.2mm. A process of perform the plasma cladding with the third wear block includes: the cladding speed is 155mm/min, the voltage is 34V, the initial current is 230A, the 5 working current is 220A, and the ending current is 220A. The specific steps of repairing the first base plate 3 and the second middle plate 2 include: (1) Perform the repairs on the worn parts of the first base plate 3 and the second middle plate 2 by using surfacing welding to make the wear losses of the 10 worn parts are equal to 25% of a new product. (2) The surface of the second middle plate 2 is clad with first wear strips, and the first base plate 3 is clad with second wear strips. The single-track cladding width of the first wear strip is 13.5mm, and the single-track cladding thickness of the first wear strip is 3.0mm. The single-track 15 cladding width of the second wear strip is 6.5mm, and the single-track cladding thickness of the second wear strip is 3.0mm. A process of performing the plasma cladding with the first wear strip and the second wear strip includes: the cladding speed is 220mm/min, the voltage is 35.5V, the initial current is 240A, the working current is 240A, the ending current is 20 230A, the swing distance of the welding gun is 8mm, the swing frequency of the welding gun is 67 times per minute, the swing speed of the welding gun is 66mm/s, and the left-right fine adjustment distance of the welding gun is 9mm. (3) The connection opening 21 of the second middle plate is clad with a first wear block, and the connection opening 31 of the first base plate is clad with a first 25 wear block. Both of the specifications of the first wear block and the specifications of the second wear block are 80x100mm. 17 The first wear block is made of multiple first wear strips which are overlapped to be clad, the second wear block is made of multiple second wear strips which are overlapped to be clad, and the overlap rate of the first wear strips and the overlap rate of the second wear strips both are 37%, which contribute to improving the wear 5 resistance of the connection opening 21 of the middle plate and the connection opening 31 of the base plate. The single-track cladding width of the first wear strip is 15mm, and the single-track cladding thickness of the first wear strip is 3.5mm. The single-track cladding width of the second wear strip is 7mm, and the single-track cladding 10 thickness of the second wear strip is 3.5mm. A process of performing the plasma cladding with the first wear block and the second wear block includes: the cladding speed is 160mm/min, the voltage is 34.5V, the initial current is 240A, the working current is 250A, and the ending current is 220A. 15 In this embodiment, the pattern formed by the first wear strips is a straight-bar-overlapped fish scale shape, so is the pattern formed by the second wear strips. The length and the width of the straight-bar-overlapped fish scale shape pattern are respectively and correspondingly equal to the length and the width of the new first middle plate 2, the new second base plate 3, the second 20 middle plate 2 or the first base plate 3. In this embodiment, replace the first middle plate 2, the second base plate 3 and the channel ledge steel 1 with new products, and perform strengthening treatment on the new products, which contributes to improving the wear resistance and prolong service life. Perform multiple times of the plasma cladding process 25 under the condition that the intension of the substrates of the middle plate 2 and the base plate 3 are not decreased, so as to save the resources. In this embodiment, for the first base plate 3 and the second middle plate 2, firstly perform the repairs on their worn parts by using the surfacing-welding 18 technology, and then perform the repairs by using the plasma cladding process, which contributes to reduce the cost of investment. Contrast Experiment One: Get a worn middle plate A and a worn base plate B, and weigh them separately 5 to get the pre-experiment weight. A and B are respectively ground with 45-steel for three times, for each time, the grinding test force F=200N, the grinding time is set as 2.5 hours, and then weigh A and B after grinding to get the post-experiment weight. Calculate the weight loss after each grinding and take the average of the weight losses obtained from the three tests. 10 The wear loss of the worn middle plate A is 27% of a new product the wear loss of the worn base plate B is 22% of a new product which has three worn parts, the wear losses of the three worn parts are 43% of a new product. Repair the worn middle plate A and the worn base plate B respectively by using the remanufacturing method of this disclosure to obtain a repaired middle plate C and a repaired base 15 plate D, and perform the above grinding test on them. Get a new middle plate E and a new base plate F, and perform the above grinding test on them. Perform strengthening treatment on the new middle plate E and the new base plate F by using the remanufacturing method of this disclosure to obtain a 20 strengthened middle plate G and a strengthened base plate H, and then perform the above grinding test on them, thus obtain the experimental data as show in Table one: Table one Weight A B C D E F G H loss (g) 0.1334 0.1204 0.0481 0.0436 0.1329 0.1201 0.0401 0.0418 19 The above experiment is performed in a lab of Dazu Remanufacturing Co., LTD., Shandong Energy Reshipment Group. As shown in Table one, the weight loss of the worn middle plate A is roughly same with the weight loss of the new middle plate E, and their wear resistance 5 properties are equivalent. The weight loss of the worn base plate B is roughly same with the weight loss of the new base plate F, and their wear resistance properties are equivalent. The weight loss of the worn middle plate A is 2.77 times of the weight loss of the repaired middle plate C, and the weight loss of the worn base plate B is 2.76 10 times of the weight loss of the repaired base plate D. The weight loss of the new middle plate E is 3.31 times of the weight loss of the strengthened base plate H, and the weight loss of the new base plate F is 2.87 times of the weight loss of the strengthened base plate H. Therefore, in the term of the wear resistance, under the condition that the 15 intension of the substrates of the middle plate and the base plate are not decreased, the wear resistance of the repaired part repaired by using the remanufacturing method of this disclosure is obviously better than the wear resistance of the original worn part, and the wear resistance of the replaced and strengthened part using the remanufacturing method of this disclosure is superior to 20 the wear resistance of a new product. Contrast Experiment Two: All the substrate materials of the repaired middle plate C, the new middle plate E and the strengthened middle plate G are set as 16Mn, and the repaired middle plate C and the strengthened middle plate G have the same part to be repaired or 25 strengthened, and it adopts the alloy powder with same formula composition in the processes of the repairing and the strengthening. Randomly select two different repaired parts of the repaired middle plate C 20 which are respectively marked as Part 1 and Part 2. Randomly detect the hardness of three points of each part by using a portable hardness meter, and record their average. Use the same test method to detect and record the average hardness of Part 1 and Part 2 of the new middle plate E and the strengthened 5 middle plate G, so as to obtain the experimental data shown in Table two: Table two: repaired middle new middle strengthened middle plate C plate E plate G average hardness Part 1 Part 2 Part 1 Part 2 Part 1 Part 2 (HRC) 50 52 38 40 51 53 The above experiment is performed in a lab of Dazu Remanufacturing Co., LTD., Shandong Energy Reshipment Group. As shown in Table two, in the term of the average hardness of Part 1 and Part 10 2, the repaired middle plate C corresponds to the strengthened middle plate G, both of which are greater than the hardness of the new middle plate E. Thus, in the aspect of the hardness, the hardness of the repaired part and the replaced and strengthened part by using the remanufacturing method of this disclosure is obviously superior to the hardness of a new product. 15 Additionally, it should be understood that even though this specification is described as exemplary embodiments, each embodiment include not only one method solution, which is considered to make this specification clear. The specification should be deem as a whole by those ordinary skilled in this art, the method solution of every embodiment can be can be properly devised to form other 20 embodiments understood by those skilled in this art. 21

Claims (5)

1. A remanufacturing method of a scraper conveyor, comprising: measuring wear loss of each part of a worn scraper conveyor, and performing remanufacturing according to the wear loss; wherein the remanufacturing comprises repairing and/or replacing, and a process of the repairing adopts a technology of plasma cladding.
2. The remanufacturing method of a scraper conveyor according to Claim 1, before measure the wear loss of each part of the worn scraper conveyor, the method further comprising a cleaning process, wherein the cleaning process means to remove the oxide, carbon deposits and oil on the surface of each part; after performing remanufacturing according to the wear loss, the method further comprising: performing testing and anti-corrosion treatment; wherein the testing comprises a hardness test and a wear-resistance property test.
3. The remanufacturing method of a scraper conveyor according to Claim 2, wherein a standard and a process of the repairing according to the wear loss comprise: (1) when the wear loss of a middle plate is less than or equal to 30% of a new product, perform repairs on the middle plate by using the plasma cladding with a first wear strip and a first wear block; (2) when the wear loss of a base plate is less than or equal to 30% of a new product, perform repairs on the base plate by using the plasma cladding with a second wear strip and a second wear block; (3) when the wear loss of a middle plate is less than or equal to 30% of a new product, and meanwhile the middle plate has no more than three worn parts of which the 22 wear loss is more than 30% of a new product and less than or equal to 50% of a new product, firstly perform repairs on the middle plate by using surfacing welding and then using the plasma cladding with a first wear strip and a first wear block; (4) when the wear loss of a base plate is less than or equal to 30% of a new product, and meanwhile the base plate has no more than three worn parts of which the wear loss is more than 30% of a new product and less than or equal to 50% of a new product, firstly perform repairs on the base plate by using surfacing welding and then using the plasma cladding using a second wear strip and second wear block; (5) when the wear loss of the width of a monolateral chain track of channel ledge steel is less than or equal to 23% of a new product, and the wear loss of the inside height of the chain track is less than or equal to 8% of a new product, perform repairs on the channel ledge steel by using the plasma cladding with a third wear strip and a third wear block.
4. The remanufacturing method of a scraper conveyor according to Claim 3, wherein a standard and a process of the repairing according to the wear loss comprise: (1) when the wear loss of a middle plate and/or the wear loss of a base plate is more than 30% of a new product, replace the worn middle plate and/or worn base plate with a new product; (2) when the wear loss of an end section of a middle plate and/or a base plate is more than 30% of a new product, the wear loss of other parts is less than or equal to 30% of a new product, replace the worn end section of the middle plate and/or base plate with a new product and repair the other parts; (3) when the wear loss of the width of a monolateral chain track of channel ledge steel is more than 23% of a new product, and/or the wear loss of the inside height of the chain track is more than 8% of a new product, replace the worn channel ledge steel with a new product; 23 a process of the replacing with a new product according to the wear loss further comprises: perform strengthening treatment on the new product, which comprises: (1) perform the plasma cladding on the surfaces of a new middle plate and a new base plate by using first wear strip and a first wear block; (2) perform the plasma cladding on the surface of a new end section of a middle plate by using a first wear block; (3) perform the plasma cladding on the surface of a new end section of a base plate by using a second wear block; (4) perform the plasma cladding on the surface of new channel ledge steel by using a third wear block.
5. The remanufacturing method of a scraper conveyor according to Claim 4, wherein: the first wear strips respectively locate in planes of the repaired middle plate, the new middle plate and the new base plate; the first wear blocks respectively locate at the surface of the repaired middle plate, the new middle plate, a new end section of the middle plate and a connection opening of the new base plate; the second wear strip locates in the plane of the repaired base plate; the second wear blocks respectively locate at a connection opening of the repaired base plate and the surface of a new end section of the base plate; the first wear blocks and the second wear blocks respectively locate just under the chains, and the amount and the space between them match with the chains; the third wear strip locates inside the chain track of the channel ledge steel and the third wear block locates at a connection opening of the channel ledge steel; the first wear strips, the second wear strips and the third wear strips respectively constitute patterns with different textures, the pattern is set as any one of a diamond, a 24 fish-bone shape and a straight-bar-overlapped fish scale shape; the first wear block and the third wear block are made of multiple first wear strips which are overlapped to be clad, and the second wear block is made of multiple second wear strips which are overlapped to be clad. 25
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CN110424006A (en) * 2019-08-12 2019-11-08 青岛德创表面技术工程有限公司 A kind of technique preparing coating for metal surfaces using ion melting and coating technique

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CN102140615A (en) * 2011-01-12 2011-08-03 青岛海纳等离子科技有限公司 Surface strengthening method of mining round link chain
CN102764953A (en) * 2012-06-15 2012-11-07 泰安博纳金属耐磨技术有限公司 Manufacture method for scrapping plate of coal mine scrapping plate conveyor
CN104607780A (en) * 2014-12-18 2015-05-13 大同煤矿集团有限责任公司 Abrasion resisting treatment process for chute of scraper conveyer

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CN110424006A (en) * 2019-08-12 2019-11-08 青岛德创表面技术工程有限公司 A kind of technique preparing coating for metal surfaces using ion melting and coating technique

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