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Structure Principles of Bucket-wheel

Stacker-reclaimers used in Thermal


Power Plant, and Common Faults and
Troubleshooting

August 20, 2017


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Operating Principles
• When a bucket-wheel stacker-
reclaimer is used for coal
reclaiming, the coals stacked in
the coal yard are excavated to
the cantilever machine, and
then are transported to the belt
conveyor of the coal handling
system via coal dropping device
and the raw coal bunker via the
belt in sequence.
• At coal stacking, coals are
placed in the cantilever via coal
dropping device for storage in
the coal yard after being
transported by the belt
conveyor of the coal handling
system. 2
Structure

The main body consists of


bucket-wheel mechanism, front
boom, boom belt conveyor,
upper structure, pitching
mechanism, revolving platform,
traveling mechanism, gate seat,
slewing mechanism, lubrication
system, dust-proof sprinkler
system, cab, tripper car, cable
drum, central cabling device,
tripper car cable handing
device, hurricane prevention
and mooring system, front arm
frame locking device, ground
accessories, counterweight
system and electrical part.
3
Main Technical Performances and Specifications

1 Characteristics of Materials
Category: coal Bulk density: ~0.85t / m3
Grain size: ≤ 100mm Water content: ≤ 12%
2 Production Capacity
Reclaiming: Rated 600 t, Max. 660 t.
Stacking: Rated 1200 t, Max. 1320 t
3 Height of Material Pile:
Above rail: +12 m
Below rail: -1.5 m

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4 Bucket-wheel Mechanism
Bucket-wheel diameter: φ 5000mm
Qty. of buckets: 8
Bucket-wheel speed: 7r/min
Reducer model: P2KA14
Motor power: N=45kW

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5 Boom Belt Conveyor
Belt type: common trough type
Belt width: B=1200mm
Belt speed: V=2.5m/s
Idler diameter: Φ=159mm
Motor model: YE3-280S-4
Power: N=75kW
Rotation speed: n=1480r/min

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6 Pitching Mechanism

Pitching type: hydraulic pitching

Pitching angle: -13.13~+9.59°

System pressure: ≤16MPa

7
7 Traveling Mechanism
Rail gauge x wheel base: 7m x 6m
Traveling peed: operating speed:
5m/min (speed control by frequency
variation)
Shunting peed: 15m/min (speed
control by frequency variation)

Wheel: diameter - Φ600mm


Qty. - 20 (including 12 driving
wheels)

Maximum wheel pressure: 250kN

Driving power: 6 x 7.5KW


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8 Slewing Mechanism
Slewing angle: -110°~ +110°
Slewing radius: 35m(slewing center to bucket-wheel
center line)
Slewing speed as per 1/cosΦ speed control by frequency
variation: n=0.058~0.116 r/min
Motor: variable frequency motor YZP160L-4
Power: N=15kW
Rotation speed: n=1480r/min

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9 Tripper Car
Type: turn-back single tripper car with half hanging structure (dip angle
16°, provided with ground belt conveyor, height from the theoretical
center line and the ground: 1000mm)

Belt width: 1200mm, sharing a rubber belt with the ground belt conveyor.

Belt speed: 2.5m/s

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10 Power Supply System
Power supply mode: torque-type cable drum
Power supply voltage: 6000V, 50Hz;

11 Communication System
Communication mode: torque-type cable drum
Power supply voltage: 230V, 50Hz;

12 Sprinkler System
Water supply mode: The machine is equipped with a water tank with a capacity of ~6m3.
Water pump: model: IS50-32-250A
Flow rate: 11m3/h;
Head: 70m
Motor: Y132S-2
Power: N=7.5kW
Rotation speed: n=2900r/min

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13 Rail Clamping Device

Type: electro-hydraulic

Power: 2X1.5KW

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Precautions before Operation

1. The operator must be familiar with the product instructions, be well


trained, and have certain knowledge of the structure and operation
(including its mechanical and electric structure and operation) of the
bucket-wheel stacker-reclaimer.
2. Fill the stacker-reclaimer with required oil and water.
3. Check if each lubrication part is injected with adequate oil and grease.
4. Check if various braking devices are reliable.
5. Turn on the machine power switch and check if machine parts such as
instrument, lighting lamp and electrical switch are normal.
6. Release the rail clamping device and lift the anchor, and sound an
alarm.

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Faults and Troubleshooting
Fault Type Causes Troubleshooting

The materials
dropped are out- Slope of the lateral baffle of guide chutes:
of-center 1. Adjust the position of transmission drum;
The belt tension is 2. Adjust the position of turnabout drum;
Belt misalignment non-uniform.
3. Adjust the aligning idler;
Materials adhere
to the surface of 4. Check if the belt is severely deformed/damaged;
transmission/turna 5. Clean and clear the surface of each drum.
bout drum
The cleaning 1. Replace the damaged parts and components of the
device loses cleaning device.
efficacy. 2. Replace the cleaning device.
Materials adhere to The materials are 1. Control the humidity of incoming materials from
the belt too wet. the stock yard.
Excessive 2. Adjust the watering belt and water amount of the
materials dropped water injection nozzle, and figure out the reasons;
for the belt eliminate the fault of excessive materials dropped.
The belt is fallen or The brake of
sliding in forward hydraulic push rod Replace the brake.
direction while is damaged or Adjust the brake.
moving backward adjusted too loose. 14
Fault Type Causes Troubleshooting

The traveling
Find out the reasons, and then repair or replace the motor.
motor is damaged

Find out the reasons, and replace relevant damaged parts


The reducer fails.
and components.
The rail clamping
Find out the reasons, and release the rail clamping device
The crane fails device or the brake
or the brake.
to travel. is not released
The bearing of
traveling wheels is Find out the reasons, and replace the bearing.
burned.

The electrical Figure out the reasons as per relevant requirements of the
control fails. electrical instructions, and then eliminate.

Failure in
reversing of The limit travel
the crane Replace with a new travel switch.
switch is damaged
during Find out the disconnecting part, and connect the control
traveling (at The control wiring
circuit.
the end point is disconnected
of stock yard)
The rail
The driving motor
clamping Repair or replace it.
is damaged. 15
device fails.
Fault Type Causes Troubleshooting

1. Check if the brake wheel and its ring are burned out.
Repair or replace is if any.
Failure in the motor 2. Check if the motor bearing is burned out. Figure out the
reasons and replace it if any.
3. Check if the motor winding is burned out.
Slewing
1. If the pressure spring loses efficiency or breaks, replace it,
fails.
Torque limiting coupling and adjust the spring pressure.
fails. 2. If the working face of the friction plate is damaged, repair
or replace it.

The electrical control


Connect the circuit.
circuit is disconnected.

1. If the pressure spring breaks, and then replace it.


2. If grease exists on the control wheel (ring) surface, and
The brake fails.
then clean it.
3. Check if the brake wheel and brake ring are damaged.

The braking Torque limiting coupling


Refer to the handling measures of failure in slewing.
fails. fails.
The slewing limit switch Replace the limit travel switch, and adjust the traveling
fails. distance.
Failure in electrical Check one by one as per the electrical instructions and
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control circuit eliminate.
Fault Type Causes Troubleshooting

The boom fails to conduct The level gage fails. Repair or replace it.
luffing and material
stacking as per the preset
height and stroke. The electrical
circuit is Check the line and connect it.
disconnected.

It does not shutdown when The limit switch is Replace with a new travel switch, and adjust the
the boom is in place. damaged. operating position.

The oil pipeline is


The supporting action of oil Clean and clear the oil pipeline of the oil cylinder
blocked or the valve
cylinders is out of step. actuated slowly, and adjust the balance valve.
oil hole is too small

The sealing gasket


or joint is damaged,
Oil leakage Replace or repair the element timely
or the interface
surface is misfitted.

Check if contaminants exist on the interface surface


The boom drops
The system leaks oil. of the hydraulic lock and one-way valve. And check
automatically, out of control.
if the pressure-regulating spring cannot be reset. 17
Safety Precautions
1. Before startup, check if the rail clamping device and the anchor become loose, and
sound an alarm.
2. When the wind pressure is greater than 250Pa, stop the machine and cut off power
supply and clamp the track. For long-term shutdown, the power supply shall be cut
and the track shall be clamped.
3. In case of emergencies, press the emergency stop switch to cut off the power supply.
4. When reclaiming, avoid material collapse that may bury the bucket wheel. If the
bucket wheel is buried by materials, stop the bucket wheel and slowly drive the
trolley to leave the material pile. Do not start the hydraulic pitching mechanism and
lift the boom.
5. The motor of bucket wheel and belt shall both be started at the no-load state.
6. During rapid shunting, put the front boom to the horizontal and central position of
the rail.
7. Make sure that the ground lead between rail and other electric equipment of
machinery has good electrical conductivity, to avoid electric shock.
8. Before leaving the machine, operators shall move the boom to the horizontal and
central position of the rail and then cut off the main power supply.
9. It is forbidden to allow the equipment to reclaim materials in running status without
slewing.
10. During maintenance and disassembling of the hydraulic system, the boom should
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be fixed on the ground or bracket.
End
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