Bridge scraper reclaimer is a large-scale equipment widely used in the industrial field, mainly used for reclaiming stacked materials such as coal, ore, cement, etc. Its efficient and stable operation is crucial for the smooth production process, and good maintenance work is the key to ensuring the normal operation of equipment, extending its service life, and reducing maintenance costs. The following will elaborate on how to maintain the bridge scraper reclaimer in detail from several important aspects.

1、 Daily inspection

1. Pre operation inspection

Before starting the bridge scraper reclaimer, the operator should first conduct a visual inspection. Check if there are any signs of deformation, damage, or looseness in the structural components of the equipment, such as whether the scraper chain is broken or twisted, whether the bridge structure is stable, and whether the connecting bolts are tightened.

Check the lubrication system to ensure that the lubricating oil at each lubrication point is sufficient and of good quality. Observe the oil level indicator, and if the oil level is too low, add lubricating oil of the corresponding specification in a timely manner. At the same time, check whether there is any leakage in the lubricating oil pipeline. If there is any leakage, it should be repaired in a timely manner to prevent equipment wear from worsening due to poor lubrication.  

The inspection of the electrical system cannot be ignored. Check if the power circuit is connected properly, if all electrical components in the electrical control cabinet are working properly, and if there are any odors or abnormal sounds. Whether the indicator lights, buttons, etc. on the operation panel are sensitive and reliable, and whether the control functions are normal. By testing the motor, observe whether its direction of rotation is correct, whether it runs smoothly, and whether there are any abnormal vibrations or noises.

2. Observation during operation

When the bridge scraper reclaimer is running, the operator should always pay attention to the operating status of the equipment. Pay attention to the operation of the scraper chain, whether it is smooth and steady, and whether there is any jamming, jumping or scratching phenomenon. If abnormal operation of the scraper chain is found, it may be caused by the chain being too loose or too tight, foreign objects blocking the track, or deformation of the scraper. The machine should be stopped in time for processing.

Pay close attention to the material retrieval situation. Observe whether the scraper can effectively scrape and transport the material, and whether the flow rate of the material is uniform and stable. If there are situations such as material blockage, inability of the scraper to retrieve materials, or significant decrease in material retrieval efficiency, it may be caused by changes in the shape of material accumulation, severe wear of the scraper, or malfunction of the retrieval mechanism. It is necessary to adjust the equipment operating parameters or conduct maintenance in a timely manner.

Pay attention to the operating sound of the equipment. During normal operation, the equipment should produce a smooth and regular sound. If abnormal noise is heard, such as sharp friction sounds, dull impact sounds, etc., the machine should be stopped immediately for inspection, and the source of the noise should be identified and repaired. Abnormal noise may be a manifestation of equipment component wear, looseness, breakage, or poor lubrication.

Meanwhile, pay attention to observing the temperature changes of the equipment. Detect the temperature of key parts such as motors, reducers, bearings, etc. by touching or using temperature measuring instruments. If the temperature is found to be too high and exceeds the normal range, the machine should be stopped immediately to check the cause. Heating may be caused by poor heat dissipation, excessive load, insufficient lubrication, or component damage, and corresponding measures need to be taken to deal with it, such as cleaning the heat dissipation channel, adjusting the load, adding lubricating oil, or replacing damaged components.

3. Review after running

After the equipment stops running, the operator should conduct another inspection of the equipment. Firstly, check the scraper chain and feeding mechanism to see if there is any material residue accumulating on the scraper, chain, or other components. If there are any material residues, they should be cleaned up in a timely manner to avoid corrosion of equipment components or affecting the next start-up operation.

Inspect and evaluate the wear and tear of the equipment. Focus on checking the wear of the scraper and chain, as well as the wear of other components in contact with the material such as chutes and guide wheels. Record the worn parts and amount, and develop corresponding maintenance or replacement plans based on the wear situation. For components with slight wear and tear, repair measures such as welding and polishing can be taken; For severely worn components, they should be replaced in a timely manner to ensure the normal operation and material efficiency of the equipment.

Check the lubrication condition of the equipment. During operation, lubricating oil may be consumed or deteriorated due to temperature rise, component friction, and other reasons. Therefore, after operation, it is necessary to check the amount of lubricating oil at each lubrication point and replenish it in a timely manner if necessary. At the same time, observe the color and texture of the lubricating oil. If the lubricating oil becomes black, thick, or has impurities, it should be replaced in a timely manner and the lubrication system should be cleaned to ensure lubrication effectiveness.

Finally, inspect the electrical system of the equipment. After turning off the power, check for signs of looseness, overheating, or damage in the electrical wiring, clean the dust and debris inside the electrical control cabinet, and ensure good heat dissipation of electrical components. Check the insulation performance of the motor, use an insulation resistance tester to measure the insulation resistance of the motor. If the insulation resistance value is found to be lower than the specified standard, the motor should be repaired or dried in a timely manner to prevent faults caused by poor insulation.

2、 Regular maintenance

1. Lubrication and maintenance

Develop a detailed lubrication plan and perform comprehensive lubrication maintenance on the bridge scraper reclaimer according to the lubrication cycle and lubrication parts specified by the equipment manufacturer. For different components, appropriate lubricating oil or grease should be selected. For high-speed running bearings, lubricating grease with moderate viscosity is generally selected to ensure good lubrication and heat dissipation performance; For gear transmission components such as reducers, specialized gear oil should be selected, and the appropriate viscosity grade should be chosen based on its load and operating speed.

When performing lubrication operations, pay attention to cleanliness. Use a clean oil gun or oil injector to inject lubricating oil into the lubrication point, avoiding impurities from mixing into the lubricating oil and affecting the lubrication effect. At the same time, attention should be paid to the amount of lubricating oil added, as too much or too little may have adverse effects on the equipment. Adding too much lubricating oil may cause problems such as poor heat dissipation and oil seal leakage; Adding too little will not meet the lubrication needs of the equipment, leading to increased component wear.

Regularly inspect and maintain the lubrication system. Clean the lubrication filter to ensure the cleanliness of the lubricating oil. Check if the working pressure of the oil pump is normal, and adjust or repair it promptly if there are any abnormalities. For long-term operating equipment, regular sampling and testing of lubricating oil should be conducted to analyze its chemical composition and performance indicators. If lubricating oil deterioration is found, it should be replaced in a timely manner.

2. Component fastening

Regularly tighten and inspect the connecting bolts of each component of the equipment. Due to the vibration and impact generated during the operation of the bridge scraper reclaimer, it is easy to cause bolt loosening. Therefore, bolts should be tightened at regular intervals to prevent displacement, deformation, or damage to equipment components caused by loose bolts.

When tightening bolts, pay attention to using appropriate tools and tightening torque. Operate according to the tightening torque standard provided by the equipment manufacturer to avoid over tightening or over loosening. Tightness may cause bolt breakage or thread damage; If it is too loose, the reliability of the connection cannot be guaranteed. For important connection parts, such as the connection between the bridge and the pillar, the connection between the scraper chain and the driving device, etc., special attention should be paid to inspection and fastening.

At the same time, it is necessary to check whether there are any open welds, cracks, or other conditions in the welding parts of the equipment. For welding defects discovered, they should be repaired in a timely manner, using appropriate welding processes and materials to ensure welding quality. Regularly carry out rust removal and anti-corrosion treatment on the structural components of the equipment, apply anti-corrosion paint, and prevent the strength of the structural components from decreasing due to corrosion, which may affect the overall stability of the equipment.

3. Electrical system maintenance

Regularly clean the electrical system, removing dust and debris from the electrical control cabinet, motor surfaces, and electrical circuits. Excessive accumulation of dust may lead to poor heat dissipation and short circuits in electrical components. When using tools such as hair dryers or vacuum cleaners for cleaning, be careful to avoid damaging electrical components.

Check the connection of electrical circuits to ensure that they are firmly connected and free from looseness, oxidation, or damage. For aged or damaged wires and cables, they should be replaced in a timely manner. At the same time, it is important to check the insulation performance of the circuit and regularly measure the insulation resistance of the circuit using an insulation resistance tester to ensure that the insulation resistance value meets the specified requirements. If a decrease in insulation resistance is found, the cause should be promptly identified and addressed to prevent leakage accidents.

Inspect and maintain the electrical components inside the electrical control cabinet. Check whether the contacts of contactors, relays, circuit breakers and other components are worn or eroded. If there are any problems, replace the contacts or the entire component in a timely manner. Check if the capacitor is bulging or leaking, and replace it promptly if there are any abnormalities. Regularly set and check the parameters of electronic devices such as frequency converters and PLCs to ensure their normal operation and control accuracy meets the requirements. At the same time, it is important to backup important electrical parameters and programs to prevent data loss.

Perform regular maintenance on the motor. In addition to checking the insulation performance of the motor, it is also necessary to regularly clean the cooling fan and ventilation duct of the motor to ensure good heat dissipation. Check the bearings of the motor, regularly add lubricating grease or replace the bearings. At the same time, attention should be paid to observing the operating current and temperature of the motor. If any abnormal operation of the motor is found, it should be stopped for inspection and troubleshooting in a timely manner.

3、 Replacement of vulnerable parts

1. Scraper chain

The scraper chain is the core working component of the bridge scraper reclaimer and one of the most easily worn parts. The degree of wear mainly depends on factors such as the properties of the material, the amount of material taken, and the running time. Generally speaking, when the wear of the scraper chain reaches a certain level, it needs to be replaced in a timely manner.

Before replacing the scraper chain, sufficient preparation work should be done. Firstly, it is necessary to select suitable scraper chain spare parts based on the model and specifications of the equipment. Ensure that the quality of spare parts meets the requirements and that the size matches the original scraper chain. Then, develop a detailed replacement plan and safety measures, and arrange professional maintenance personnel to carry out the operation.

During the replacement process, it is necessary to follow the correct steps for disassembly and installation. First, remove the old scraper chain from the equipment and mark the connection sequence and direction of the chain for easy reference during installation. Be careful during the dismantling process to avoid damaging other components of the equipment. Then, inspect and pre assemble the new scraper chain to ensure that each link of the chain is firmly connected and the scraper is installed correctly. Finally, install the new scraper chain onto the equipment, connect it in the order and direction marked, and adjust the tension of the chain to meet the operational requirements of the equipment.

2. Scraper blade

The scraper comes into direct contact with the material during the material retrieval process, bearing significant frictional and impact forces, making it prone to wear and tear. When the wear of the scraper is severe enough to affect the efficiency of material retrieval or may cause damage to other components of the equipment, replacement is necessary.

When replacing the scraper, choose spare parts with the same material and specifications as the original scraper. First, remove the old scraper from the scraper chain. Usually, the scraper is fixed by bolt connection or welding. When removing, be careful not to damage the scraper chain. Then, install the new scraper onto the scraper chain, ensuring a secure installation, correct position and angle of the scraper, and effective scraping of materials.

3. Bearings

Bearings are important rotating components in bridge scraper reclaimers, and their operating status directly affects the overall performance and service life of the equipment. Due to long-term load, high-speed operation, and friction, bearings are prone to wear, fatigue, damage, and other issues. Regularly check the operation status of bearings. If abnormal noise, increased vibration, temperature rise, and other phenomena are found in the bearings, timely inspection and maintenance should be carried out.

When it is determined that the bearing needs to be replaced, the equipment should be stopped first and the relevant components should be removed to expose the bearing. Then, use professional tools to remove the old bearings from the shaft, taking care not to damage the shaft neck. Before installing a new bearing, the journal and bearing seat should be cleaned and inspected to ensure a smooth and undamaged surface. When installing a new bearing onto the shaft, the correct installation method should be used, such as hot or cold installation, to ensure that the bearing is installed in place and fits well with the shaft and bearing seat. After installation, add an appropriate amount of lubricating oil and conduct a trial run to check if the bearing is operating normally.

4、 Training and Recording

1. Operator training

Professional training for the operators of the bridge scraper reclaimer is an important part of doing a good job in maintenance work. Operators should be familiar with the structural principles, operating procedures, safety precautions, and maintenance requirements of the equipment. Through training, enable operators to operate equipment correctly, promptly detect abnormal situations during equipment operation, and take corresponding measures to handle them.

The training content should include the key points of daily equipment inspection, operational skills, fault diagnosis and troubleshooting methods, maintenance procedures and standards, etc. A combination of theoretical teaching and practical operation can be used for training, allowing operators to deepen their understanding and recognition of the equipment through practical operation on the basis of mastering theoretical knowledge. At the same time, regular assessments should be conducted on operators to ensure their proficiency in operating equipment and performing maintenance work.

Strengthen safety awareness training for operators, enabling them to understand the potential safety risks that may exist during equipment operation and how to take effective safety precautions. For example, it is strictly prohibited for personnel to approach the operating parts during equipment operation, and the equipment must be stopped and the power must be cut off before maintenance and repair. Only operators with good safety awareness and operational skills can ensure the safe operation and smooth maintenance of equipment.

2. Maintenance records

Establish a comprehensive maintenance record system to provide detailed records of the maintenance work of the bridge scraper reclaimer. The record content should include information such as maintenance date, maintenance items, maintenance personnel, equipment operation status, discovered problems and their handling, replaced parts, etc. Maintenance records can be saved in the form of paper forms or electronic documents for easy reference and analysis.

Through maintenance records, it is possible to timely understand the maintenance status and operating trend of equipment, providing a basis for developing reasonable maintenance plans and maintenance decisions. For example, based on the wear and replacement records of equipment components, their service life can be predicted and spare parts preparation work can be done in advance; By analyzing the frequency and causes of equipment failures, targeted improvement measures can be taken to reduce the equipment failure rate.

Maintenance records can also serve as important information for equipment management, used for establishing equipment archives and asset management. Maintenance records can provide reference for related work during equipment transfer, scrapping, or technological transformation. At the same time, maintenance records are also an important basis for supervising and assessing maintenance work, which helps ensure the quality and effectiveness of maintenance work.

To do a good job in the maintenance of the bridge scraper reclaimer, it is necessary to start from multiple aspects such as daily inspections, regular maintenance, replacement of vulnerable parts, training and recording, and carry out the work comprehensively and meticulously. Only in this way can we ensure the normal operation of equipment, improve its service life, reduce maintenance costs, and provide strong support for the production and operation of enterprises. In actual maintenance work, a scientific and reasonable maintenance plan should be developed based on the actual situation and operating characteristics of the equipment, and strictly implemented according to the requirements of the plan. At the same time, it is necessary to constantly summarize experience, improve maintenance methods and techniques, and enhance the level and quality of maintenance work.