CN110695609B - Scraper transplanting, reproducing and repairing method for scraper conveyor - Google Patents
Scraper transplanting, reproducing and repairing method for scraper conveyor Download PDFInfo
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- CN110695609B CN110695609B CN201910942257.1A CN201910942257A CN110695609B CN 110695609 B CN110695609 B CN 110695609B CN 201910942257 A CN201910942257 A CN 201910942257A CN 110695609 B CN110695609 B CN 110695609B
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- scraper
- cladding
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- blade
- weld
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
Abstract
A scraper blade transplantation reconstruction repairing method of a scraper blade conveyor aims at low cost, convenient processing and capability of effectively extending the service life of a product; the method of the invention is to clean impurities such as coal cinder oil stain and the like on the scrapped scraper plate surface due to serious abrasion of two ends; sawing off the end heads with seriously worn two ends, wherein the length of each end head does not exceed 15 percent of the total length of the scraper; forging a transplantation end head according to the original drawing size of the scraper which is removed by sawing, and forging a groove of C15 around one end of a saw cut of the scraper so as to form a single-side V-shaped groove welding seam during welding; carrying out plasma cladding transplantation on the end of the scraper by using 100-270-mesh alloy powder through a plasma cladding machine; polishing and flattening the cladding weld joint; and (4) checking whether the groove weld has cracks or air hole defects, if the defects occur, removing the weld and cladding again until the weld is qualified.
Description
Technical Field
The invention belongs to the technical field of remanufacturing, and mainly relates to a remanufacturing method of a scraper conveyor under the condition that two ends of the scraper are worn and scrapped.
Background
The scraper is one of the most common wearing parts on the scraper conveyor and is also one of the most used parts. In the operation process of the scraper conveyor, the scraper is driven by the circular chain to slide and rub with the middle groove, and the two ends of the scraper are frequently jumped up and down to be worn most seriously under the influence of coal. Generally, when the coal passing amount reaches about 500 ten thousand tons, the scraper fittings need to be replaced with new ones, because the middle groove is provided with the wear-resistant strips, the middle part of the scraper is rarely worn, but the two ends of the scraper are seriously worn with the ledge. The excessive abrasion of the two ends is a direct cause of scrapping, although the price of the scraper is not particularly high, the quantity is particularly large, the scraper is scrapped seriously only because the two ends are abraded, huge resource and energy waste is caused, and the pollution of the environment caused by producing a new scraper is not negligible. Particularly, the scraper conveyor with the middle groove width of more than 1 meter has high manufacturing cost, so that a series of harmful factors such as increased operation cost, delay of construction period, safe production and the like are caused.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a scraper transplantation, reconstruction and repair method for a scraper conveyor, which has the advantages of low cost, convenient processing and capability of effectively prolonging the service life of a product.
Aiming at the condition that two ends of a scraper are seriously abraded and scrapped after a scraper conveyor is used for a period of time, the scrapped scraper is repaired and remanufactured by adopting a transplantation technology, and the method comprises the following specific steps:
(1) Cleaning impurities such as coal cinder, oil stains and the like on the surface of the scrapped scraper plate due to serious abrasion of two ends;
(2) Sawing off the end heads with severely worn two ends, wherein the sawing off of the two ends is not more than 15% of the total length of the scraper;
(3) Forging a transplantation end head according to the original drawing size of the scrapper which is removed by sawing, and forging a C15 groove around one end of a kerf of the scrapper to form a unilateral V-shaped groove welding seam during welding;
(4) Carrying out plasma cladding transplantation on the end of the scraper by using 100-270-mesh alloy powder through a plasma cladding machine;
(5) Polishing and flattening the cladding weld joint; and (4) checking whether the groove weld has cracks or air hole defects, if the defects occur, removing the weld and cladding again until the weld is qualified.
The material of the transplanting end is similar to that of the scraper, and the length of the transplanting end at each end is preferably 10% of the total length of the original scraper. The graft end is forged using a hot die forging press. And a C15 groove on the periphery of one end of the saw cut of the scraper is processed by a C15 flat beveling machine until the chamfer angle is 30-60 degrees, and the angle/groove width is 60-10 mm, or 45-15 mm, or 30-12 mm.
Carrying out plasma cladding transplantation by adopting a plasma cladding machine, wherein the cladding voltage is 380V, the cladding current is 160-200A, the current rise time is 5-8S, the current fall time is 8-12S, the pulse frequency is 300-500 (DC), the single cladding thickness is 2-6mm, the single cladding width is 4-10mm, and the protective argon flow is 6-10L/min. The type of the used plasma cladding machine is PTA-BX-200A.
The scraper in the scraper conveyor with the model SGZ1000/1400 is made of 27SiMn, and the alloy powder used for carrying out plasma cladding transplantation on the end of the scraper is Ni45 alloy powder with 100-270 meshes, wherein the powder comprises, by mass, 0.05% of carbon, 7.57% of chromium, 3.52% of silicon, 3.55% of iron and the balance of nickel.
The scraper of the scraper conveyer with the model of SGZ1250/1600 is made of 40Mn2, and the alloy powder used in plasma cladding transplantation is Fe45 alloy powder, wherein the powder comprises 0.6% of carbon, 7.5% of chromium, 2% of silicon, 22% of nickel, 3% of boron and the balance of iron.
And (4) polishing and flattening the fusion-covered weld, and then carrying out flaw detection on the fusion-covered weld by using a CUS3000 type ultrasonic flaw detector.
The method mainly aims at the scraping plates with serious abrasion at two ends, adopts the transplanting technology to repair and remanufacture the scraping plates which are usually scrapped, has low cost, convenient and quick processing, can save energy resources, is green and environment-friendly, can prolong the service life of the scraping plates with least energy resource consumption, completes the whole life cycle of the scraping plates, can maximize the use value of the base material matrix, and can directly improve the service life of the scraping plates by 2 times or more.
Detailed Description
Example 1:
taking a scraper in a scraper conveyor with the model number of SGZ1000/1400 as an example: the two ends of the scraper are seriously worn and are forcedly scrapped when not meeting the use standard, the material of the scraper is 27SiMn, and the remanufacturing process adopting the transplantation technology comprises the following steps:
(1) The scrapped scraping plates are cleaned, and impurities such as coal cinder, oil stains and the like on the surfaces of the scraping plates are thoroughly cleaned.
(2) The ends of the scraper with serious abrasion at two ends are sawn off by using a GB4228 metal band sawing machine, and the part which has less abrasion in the middle and meets the use standard is left.
(3) According to the size requirement of original drawing paper, the end part which is sawn off is forged in batches by using an FP400 model hot die forging press, and a groove of C15 is forged around one end of a kerf, so that a unilateral V-shaped groove welding seam is formed during welding, and the side groove, the upper groove and the bottom groove are all C15 and are the positions of the grooves around the transplanted end.
(4) According to the size requirement of original paper, a plasma cladding machine with the model of PTA-BX-200A is used, and Ni45 alloy powder with the specification of 200 meshes is used in cooperation to carry out plasma cladding transplantation on the end of the scraper, wherein the powder comprises 0.05% of carbon, 7.57% of chromium, 3.52% of silicon, 3.55% of iron and the balance of nickel. Cladding voltage 380V, cladding current 170A, current rise time 6S, current fall time 9S, pulse frequency 380 (DC), single cladding thickness 2mm, single cladding width 6mm, protection argon flow 8L/min.
(5) And polishing the cladding weld joint to be smooth. And (3) flaw detection treatment is carried out on the fusion-clad weld by using a CUS3000 type ultrasonic flaw detector, and whether the defects of cracks, air holes and the like exist in the groove weld is detected. And removing the defects, namely removing the welding lines, and cladding again until the flaw detection is qualified.
Because of the scraper blade quantity that treats processing is great, for adapting to the batch forging production needs, can unify the sawing size, carry out standardized batch refabrication, all use the central line as the benchmark to leave the scraper blade interlude that the total length is 810mm, the size of both ends end is all the same, can improve machining efficiency.
The scraper manufactured by the method is used underground in a coal mine, the performance of a transplanted part is stable, the condition of fracture does not occur, and the using effect completely meets the requirement of a new accessory.
Example 2:
take the scraper in the scraper conveyor with the model number of SGZ1250/1600 as an example: the two ends of the scraper are seriously worn and are forcedly scrapped when not meeting the use standard, the material of the scraper is 40Mn2, and the remanufacturing process adopting the transplantation technology comprises the following steps:
(1) The scrapped scraping plates are cleaned, and impurities such as coal cinder, oil stains and the like on the surfaces of the scraping plates are thoroughly cleaned.
(2) The ends of the scraper with serious abrasion at two ends are sawn off by using a GB4228 metal band sawing machine, and the part which has less abrasion in the middle and meets the use standard is left.
(3) And forging the end part which is sawn off by using an FP400 model hot die forging press according to the size requirement of original drawing paper, forging a groove of C15 around one end of the saw cut so as to form a single-side V-shaped groove welding seam during welding, wherein the side groove, the upper groove and the bottom groove are the positions of the grooves around the saw end.
(4) According to the size requirement of original paper, a plasma cladding machine with the model of PTA-BX-200A is used, fe45 alloy powder with the specification of 180 meshes is used in a matched mode to carry out plasma cladding transplantation on the end of the scraper, wherein the powder comprises 0.6% of carbon, 7.5% of chromium, 2% of silicon, 22% of nickel and 3% of boron, and the balance of iron. Cladding voltage 380V, cladding current 180A, current rise time 7S, current fall time 10S, pulse frequency 420 (DC), single cladding thickness 3mm, single cladding width 8mm, protection argon gas flow 9L/min.
(5) And polishing the cladding weld joint to be smooth. And (3) flaw detection treatment is carried out on the fusion-clad weld by using a CUS3000 type ultrasonic flaw detector, and whether the defects of cracks, air holes and the like exist in the groove weld is detected. And removing the defects, namely removing the welding lines, and cladding again until the flaw detection is qualified.
The end material is 40Mn2, can forge the production in batches, in order to carry out standardized batch refabrication, the saw cutting size is unified, uses the central line to remain the scraper blade interlude size for 1010mm as the benchmark.
The scraper blade after refabrication is used in the pit in the colliery and is compared the discovery, and the partial stable performance of transplanting does not appear cracked condition, and the result of use has reached the requirement of new accessory.
Claims (7)
1. A scraper blade transplantation reconstruction method of a scraper conveyor is characterized by comprising the following steps:
(1) Cleaning coal cinder and oil stain impurities on the surface of the scrapped scraper plate due to serious abrasion of two ends;
(2) Sawing off the end heads with severely worn two ends, wherein the sawing off of the two ends is not more than 15% of the total length of the scraper;
(3) Forging a transplantation end head according to the original drawing size of the scrapper which is removed by sawing, and forging a C15 groove around one end of a kerf of the scrapper to form a unilateral V-shaped groove welding seam during welding; processing a bevel of C15 around one end of a saw cut of the scraper to a chamfer angle of 30-60 degrees by a C15 flat beveling machine, wherein the angle/the bevel width is 60-10 mm, or 45-15 mm, or 30-12 mm; the length of the transplanting end is 10% of the total length of the scraping plate;
(4) Carrying out plasma cladding transplantation on the end of the scraper by using 100-270-mesh alloy powder through a plasma cladding machine; cladding voltage is 380V, cladding current is 160-200A, current rising time is 5-8S, current falling time is 8-12S, single cladding thickness is 2-6mm, single cladding width is 4-10mm, and argon flow is protected to be 6-10L/min;
(5) Polishing and flattening the cladding weld joint; and (4) checking whether the groove weld has cracks or air hole defects, if the defects occur, removing the weld and cladding again until the weld is qualified.
2. The blade conveyor blade transplant rehabilitation method of claim 1, wherein the transplant end is made of a material similar to that of the blade.
3. The scraper conveyor scraper transplantation rehabilitation method of claim 1 or 2, characterized in that the transplantation end is forged by using a hot die forging press.
4. The blade conveyer blade transplantation reconstruction method of claim 1 or 2, wherein the model of the plasma cladding machine is PTA-BX-200A.
5. The blade conveyor blade transplantation restoration method according to claim 1 or 2, wherein after the cladding weld is ground to be flat, flaw detection is performed on the cladding weld by using a CUS3000 type ultrasonic flaw detector.
6. The scraper conveyor scraper transplantation restoration method of claim 1 or 2, wherein the scraper is made of 40Mn2 for a scraper conveyor with the model number of SGZ1250/1600, and the alloy powder used in plasma cladding transplantation is Fe45 alloy powder.
7. The blade conveyor blade transplantation and reconstruction method of claim 1 or 2, wherein the blade is 27SiMn for a blade conveyor of model SGZ1000/1400, and the alloy powder used for plasma cladding transplantation of the blade tip is Ni45 alloy powder.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910942257.1A CN110695609B (en) | 2019-09-30 | 2019-09-30 | Scraper transplanting, reproducing and repairing method for scraper conveyor |
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| CN201910942257.1A CN110695609B (en) | 2019-09-30 | 2019-09-30 | Scraper transplanting, reproducing and repairing method for scraper conveyor |
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| CN110695609A CN110695609A (en) | 2020-01-17 |
| CN110695609B true CN110695609B (en) | 2023-01-03 |
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| CN111451711A (en) * | 2020-04-10 | 2020-07-28 | 西安灯芯草信息科技有限公司 | Coal machine part repairing and reinforcing method |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4988033A (en) * | 1989-07-28 | 1991-01-29 | Advanced Longwall Equipment, Inc. | Repair of flight bars |
| FR2720671A1 (en) * | 1994-06-07 | 1995-12-08 | Fmc Corp | Method of manufacturing a squeegee bar, and squeegee bar. |
| CN203784236U (en) * | 2014-04-08 | 2014-08-20 | 广州东凌粮油股份有限公司 | Transmission structure of oil residue scraper plate |
| CN107225360A (en) * | 2017-06-06 | 2017-10-03 | 华电郑州机械设计研究院有限公司 | Plate in intermediate channel after the middle pan of scraper conveyor method of worn and reparation |
-
2019
- 2019-09-30 CN CN201910942257.1A patent/CN110695609B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4988033A (en) * | 1989-07-28 | 1991-01-29 | Advanced Longwall Equipment, Inc. | Repair of flight bars |
| FR2720671A1 (en) * | 1994-06-07 | 1995-12-08 | Fmc Corp | Method of manufacturing a squeegee bar, and squeegee bar. |
| CN203784236U (en) * | 2014-04-08 | 2014-08-20 | 广州东凌粮油股份有限公司 | Transmission structure of oil residue scraper plate |
| CN107225360A (en) * | 2017-06-06 | 2017-10-03 | 华电郑州机械设计研究院有限公司 | Plate in intermediate channel after the middle pan of scraper conveyor method of worn and reparation |
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