[core tip] The history of belt machine application in the world is nearly 200 years, and the design and manufacturing technology of belt machine has also been developed rapidly since China joined WTO. However, the problem of "big horse-drawn car" of belt machine at home and abroad has never been solved, resulting in a serious waste of power and energy.

Belt machine application development in the world has a history of more than 100 years, China's accession to the WTO, the design and manufacturing technology of belt machine has also been fast development. However, the problem of "big horse-drawn car" of belt machine at home and abroad has never been solved, resulting in a serious waste of electric energy.

With the increasing energy crisis, the country and even the world to strengthen energy saving and emission reduction, to achieve the goal of sustainable development of low-carbon economy is a more difficult task, to achieve the belt machine power saving, reliable, safe and efficient transport operation, is not only the needs of enterprise efficiency, but also the requirements of the macro development of society, but also the belt machine design and production enterprises are obliged to responsibility!

There are more reasons for the belt machine not to save energy, but the main reason is that the rollers are not good! Traditional roller manufacturing accuracy fluctuation curve, as well as the labyrinth seal cavity filled with grease, resulting in a relatively large rotational resistance; especially poor sealing effect, the bearing is dripping water or dust pollution time is unpredictable, the roller bearing pollution, and the normal rolling friction between the tape into abnormal sliding friction, resistance becomes greater, in order to ensure the reliable operation of the belt machine, the configuration of the belt machine had to be In order to ensure the reliable operation of the belt machine, the configuration of the belt machine has to be designed and calculated as two times or more of the actual driving power of the belt machine, forming the phenomenon of "big horse-drawn car", resulting in a large amount of wasted electricity.

From 1996 to 2003, Beijing Yurunhua Technology Development Co., Ltd. made five major technical revolutions of the rollers, and successfully developed the real rollers with high manufacturing accuracy, low rotational resistance (more than 1 times lower than the national standard), good sealing performance, no pollution damage to the bearings, and anti-corrosion and wear resistance of the tube body. Obtained national invention patent: "Belt Conveying Machinery Rollers" (Invention Patent No.: 02115632.8); "A kind of roller" (Invention Patent No.: 200910064235.6), the patent has been declared as international patent in USA, Canada, Russia, Australia and Brazil.

Through the continuous 16 years of research and development practice on the rollers and even the belt machine, Yurunhua has also developed the method of power-saving belt machine: "A power providing device of mechanical equipment and the method of reducing the configuration power of mechanical equipment" (Invention patent application number: 201110200274.1). Under the premise of ensuring safe, reliable, power-saving and efficient operation of the belt machine, it realizes the power-saving effect of reducing the configuration power by 50%, and takes the lead in overcoming the world difficulty of power-saving of the belt machine.

Equipped with Yu Runhua's rollers that can reduce the configuration power of the belt machine by about 50%. However, the traditional belt machine design and use of thinking stereotypes have been taken for granted, reduce the power of double there are great concerns, but fear to affect the normal operation of the belt machine conveying. Therefore, we have developed the method of splitting the configuration power, which not only ensures the safe and reliable operation of the belt machine, but also realizes the power saving effect of reducing the configuration power by 50%.

First, the method of splitting the configuration power of the belt machine:

The configuration power of the traditional belt machine is more than 2 times of the actual driving power needed, and most of the power is wasted when the resistance of the belt machine does not increase; but if it is reduced to the actual power, when the unpredictable resistance increases, it will cause the motor to be overloaded and damaged, which will have a serious impact on the production. The method of splitting the configuration power completely solves this mutual contradiction.

The calculated configuration power is split into two parts: drive power providing device (hereinafter referred to as motor) 1 and reserve power providing device (hereinafter referred to as motor) 2. Motor 1 is designed to be 1.2-1.5 times the actual power required by the belt machine and can be used as a drive for normal operation of the belt machine alone; motor 2 is connected to motor 1 with a bonding device 5; a current monitoring device 8 is provided in the middle, whose function is that When the current of motor 1 reaches the set limit value, it can automatically start motor 2, and vice versa, automatically disconnect motor 2; alarm device 9 is connected with motor 2, drive power current meter 7 and reserve power current meter 10 are used to monitor motor 1 and motor 2 respectively; 3 is the belt machine; 4 is the connector (coupling, reducer). The working principle is: 1. When the belt machine needs to be started, open the closed switch to turn on the power, motor 1 and motor 2 work together to start the belt machine (through the coupling, reducer 4, drive the belt machine 3 operation). When the belt machine reaches the normal speed, the current of motor 1 returns to within the set limit value, the current monitoring device 8 automatically disconnects the power of motor 2, and motor 1 alone drives the belt machine to run, realizing the effect of power saving; when the belt machine has an unpredictable increase in resistance, the current of motor 1 will rise, and when it reaches the set limit value, the current monitoring device 8 automatically re-connects the power of motor 2 to start Motor 2 and motor 1 drive the belt machine together to ensure reliable operation. But at the same time, an alarm signal is issued to warn the operator that the resistance of the belt machine has increased and a potential fault has appeared, so that timely inspection and maintenance can be carried out to avoid major accidents.

The following is an example of a belt conveyor that was awarded by Beijing Yurunhua in December 2010 to Gansu Qilianshan Group Yongdeng Cement Company. The belt conveyor has a length of 162.278 meters, a width of 0.8 meters, a belt speed of 1.6 meters, a capacity of 250 tons per hour, and an angle of: 0, conveying cement. The Tianjin Cement Design Institute designed the power configuration of 30 kW according to the performance and experience of traditional rollers and national standards, and after supporting the rollers of Beijing Yurunhua Company, it was calculated to be replaced with 18.5 kW to meet the normal operation of the belt machine, and then it was replaced with 22 kW with the consent of Yongdeng Cement Company.

The belt machine was put into normal use from March 22, 2011, and the current test was conducted on June 27, the no-load current was 16.9-17.6A; the full-load current was 18.1-19.2A, the actual driving power was less than 10 kW, which means that the configuration power of 15 kW can meet the normal operation of the belt machine, which is 50% lower than the traditional experience and standard design. If we follow the method of splitting the configuration power, that is, we can take two combinations: 1. set motor 1 to 11 kW and motor 2 to 7.5 kW; 2. set motor 1 to 15 kW and motor 2 to 5.5 kW. According to the above working principle, it can receive the significant power saving effect of the belt machine when the unpredictable resistance does not increase operation, but also can ensure the reliable operation after the unpredictable resistance increases, especially the alarm signal issued at the same time to warn the operator of potential early failure, timely inspection and elimination to avoid major accidents.

Comparison of power saving effect after replacing all original belt machines with Yurunhua's rollers:

At the beginning of 2011, a raw material belt machine of 190m in length and 1.2m in width, 3401-1, in Sanqi Cement Plant of Jidong Cement Group was renovated by replacing all the rollers, and a data comparison test was conducted with the same but not the 3401-2 belt machine renovated by replacing the rollers. The result is that the actual operating power decreases by about 10KW, and the power consumption of tons of limestone decreases by about 0.01KWh/t, (calculated about 1.5 years, and the power saving will be the cost of the rollers flushed to zero). If the method of splitting configuration power is used, the power saving effect will be more significant.

In 2009, the belt machine with length of 1200m and width of 0.8m in Ulan Cement in Inner Mongolia was transformed with driving power of 220KW, and the current was 390-430(A) before the replacement of rollers and 360-380(A) after the replacement, which reduced the current by 40-50(A) on average;

In a belt machine with length 200m, width 1.4m, angle 14?, capacity 300t/h, belt speed 1.32m/s in Shanxi Lubao Group Coking Plant, the driving power is 75KW, the current of A, B and C before the replacement of rollers is 53, 56 and 48 (A) respectively, after the replacement, the current of A, B and C is 44, 49 and 40 (A) respectively, with an average reduction of current 8 (A);

In the belt machine of Henan Mengdian Cement, the driving power is 45KW, the current is 40(A) before the replacement of the rollers, and 28(A) after the replacement, with an average current reduction of 12(A). Zhang Xinli, the minister of equipment of Mengdian Cement, also said that Beijing Yurunhua's rollers are noiseless, like "dumb rollers".

To sum up, the key to power saving of belt machine is based on the basis of small and always unchanging rotating resistance of the rollers and reducing the resistance coefficient of belt machine operation. Otherwise, the configuration power splitting has no substantial power saving significance. Therefore, it is necessary to make an introduction of the core technology of the real rollers of Yurunhua.

The real long-life true rollers must have three core features at the same time: 1、New sealing structure, a little grease is added in the labyrinth cavity, which has very little effect on the rotating resistance, that is, to ensure that the shower and dust do not pollute the roller bearings, and the bearings operate under good lubrication for a long time, and the normal service life reaches 150,000 hours; 2、The bearing position at both ends of the roller is different from the shaft degree ≤ 0.05mm (roller manufacturing) High precision is also one of the key conditions to ensure the bearing life), no viscosity resistance of grease in the sealing cavity, the average rotational resistance ≤1N (more than 1 times lower than the national standard), external