Comprehensive statistical analysis of Henan Red Star belt conveyor

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Comprehensive statistical analysis of belt conveyor faults

Belt conveyor The safe, stable and reliable operation of the coal mine ensures the balanced production of the coal mine. Once any part of the fault occurs, it will affect the normal production of the local or even the whole mine. For example, the belt tearing fault of the main shaft belt conveyor will affect the whole mine production, and the failure of the belt conveyor in the local panel area will affect the normal production of the panel. For modern coal mines, abnormal planned downtime will cause huge direct and indirect losses.

Through the statistical analysis of belt conveyor equipment faults, we study the fault law, analyze the fault causes, take targeted measures, from the design and transformation, operation and maintenance, improve the operation and management level of belt conveyor, further reduce the failure rate of belt conveyor, and improve the reliability of coal transportation system. Next, we make a detailed statistical analysis of the belt conveyor fault.

 Belt conveyor

Based on the statistical analysis of typical cases of belt conveyor in Shendong mining area from 2002 to 2012, it is found that the faults mainly occurred in the main roadway belt conveyor and the main shaft belt conveyor, accounting for 47.1% and 38.5% respectively, while the proportion of the upper warehouse belt conveyor is small, which has a great relationship with its laying length, driving power, tension, etc The number of hoists is more than that of main hoists, and its failure rate is relatively more.

(1) On the whole, the failure rate of belt conveyor is wavy, rising from 2002 to 2004, decreasing from 2004 to 2008, rising from 2008 to 2011, and decreasing obviously from 2011 to 2012, with a range of more than 50%. According to the actual situation, the coal output of Shendong mining area increased rapidly from 2002 to 2008, and the number of failures increased The failure rate of belt conveyor has decreased in chemical and mechanical management, only four times in 2008. However, from 2009 to 2011, with the integration of Shendong mining area, the coal output reached nearly 200 million tons, and the failure rate of belt conveyor increased. With the special rectification and improvement of belt conveyor in Shendong mining area around the end of 2011, the failure rate decreased significantly.

(2) The results show that the average single failure time of belt tearing, belt breaking and vulcanization joint failure is 31.3 h, 27.1 h and 13 h respectively, followed by the driving fault (including motor, reducer, etc.), and the average single fault affecting production time is 13 H; It refers to drum fault (including drum shaft fracture, cylinder skin fracture, bearing and rubber coating fault), whose average single impact on production time is as long as 12.5h; heavy load shutdown fault, removal of fault requires on-site coal cleaning and treatment of related equipment failure, with an average single impact on production time of 7 h; while the impact of tension fault is 11.2 h; control system fault is divided into hardware failure and software program failure The production time is 6.8h for each time, and 9h for other faults.

(3) Most of the faults are mainly caused by maintenance, such as strengthening the management of equipment spot inspection and failing to deal with the hidden trouble in time, accounting for 78.8%; however, there are also equipment failures due to system design, such as unreasonable equipment selection, unreasonable coal hopper structure, mismatched system program, etc On the other hand, it is mainly manifested as roller faults, such as roller shaft, bearing and cylinder skin, which will fail quickly under the condition of high-intensity operation of heavy-duty and high-power belt conveyor.

High power belt conveyor mainly adopts variable frequency motor soft start, accounting for 45.5% of all statistical data, followed by CST Controllable hydraulic soft start mode, accounting for 36.6%. Other short distance belt conveyors generally adopt hydraulic coupling buffer direct start mode; from the perspective of fault frequency, CST Controllable Soft start mode has high failure rate, which accounts for the failure rate in 2009-2012 Up to 65.5%, followed by inverter failure, accounting for 24.5%. The first four kinds of faults of belt conveyor are conveyor belt, roller, drive and control program, and the failure rate accounts for 88.5% of the total failure rate.

Design of basic parameters of belt conveyor And daily operation and maintenance are very important for the reliability of the transportation system. It is necessary to strengthen the maintenance of the transportation system, vigorously promote the spot inspection and repair system, and strengthen the fine maintenance; scientific design and selection of type is of great significance to improve the operation reliability of the belt conveyor. Relying on the development of modern science and technology, the optimization design, correct selection and transformation can improve the reliability of the transportation system.

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