Content

1.Introduction——————————————————2

2.Main structure and working principle——————-2

3.Control mode—————————————————3.4

4.Installation and commissioning—————————5

5.Operating procedures—————————————-6

6.Maintenance—————————————————–6

7.Possible failures and handling methods—————7

8.Spare part list—————————————————-8

1.Introduction

YK series rotary scraper type cross belt sampler is a new type sampler which collects samples directly from the moving main belt. This type of equipment can be used as a single sampler or as a primary sampler in a multi-stage sampling system.

Widely used in steel plants,power plants, coal mines and other industries for continuous transportation of bulk materials, to achieve full-section automatic random sampling, eliminate human interference. It can sample quickly, with simple structure and reliable operation.

2.Main structure and working principle  

YK type scraper type sampler is mainly composed of brake motor reducer, coupling, stainless steel (SUS304) scraper type sampler cutter, proximity switch, steel structure support frame, anti-spraying shell and so on.

The working process is as follows: the motor-driven sampling head with braking function is controlled by a timer, and the sampling cutter cuts in and sweeps the material flow horizontally from the moving conveyor belt at a certain speed according to the predetermined sampling period, intercepts a complete sample on the cross section, and the scraped sample is thrown into the chute pipe and passes through the chute. The sample enters the next level collection or transportation system.

When the sampler rotates for a cycle, it is close to the switch and sends out the control signal, brakes the motor, stops the sampler cutter and keeps it above the level of the discharge port. At the same time, the time relay starts timing until the next sampling cycle starts the motor again to take sample at a fixed interval. The sampling cycle can be controlled by the PLC Pre set and adjust.

3.Control mode

The sampler is divided into two states: local control and remote control.

In local control state is divided into local manual control mode and local automatic control mode.

3.1.Local manual control mode 

The “local/remote” selection switch is switched to the local position,

and the “automatic/manual” selection switch is switched to the manual position.

The sampler is in the local manual control mode.

In this mode, the “point/sample/linkage” three-knob is switched to the point position, and the “sampling start” button is pressed. At this time, the sampler point start-up. This mode is used for the installation and debugging of the sampler, such as the motor rotation direction of the sampler and the positioning position of the proximity switch. After debugging, switch “point/sample/linkage” three knobs to the linkage position, at this time press the “sample start” button sampler for joint operation. The motor automatically stops at the position close to the switch after one cycle of operation. This state can test whether the approaching switch position of the sampling cutter is reasonable.

3.2.Local automatic control mode

In this mode, the sampler is in the local automatic control mode, in which the sampler takes sample according to the sampling interval set by the timer, automatically sampled when reach the time interval. If the laser sensor detect the material is not in set range, the sampler does not carry out the sampling work. When the time interval of sampling is come, the material is a set range, the sampler can carry out the automatic sampling work. In this mode, the sampler can interlock with the running signal of the main belt, the main belt does not run, and the sampler does not carry out automatic sampling.

3.3.Remote control mode 

The “on-site/remote” selection switch is rotated to a remote position and the “automatic/manual” selection switch is on an automatic position, where the sampler is in a remote automatic control mode. In this mode, the remote control system can send the remote start signal through the reserved terminal interface at the terminal in the cabinet. After the remote start-up signal is connected, the sampler takes sample according to the sampling interval set by the timer. At the same time, if the laser sensor detect that the material is not a set range, the sampler does not sample.In this mode, the sampler can interlock with the running signal of the large belt, the large belt does not run, and the sampler does not carry out automatic sampling.

3.4.Structural features and advantages:

1).Compact design, suitable for low space installation.

2).Easy installation, can be directly fixed on the existing or new conveyor.

3).The sampling machine has a retaining apron to prevent the dispersion of materials.

4).The sampling speed is fast, the sample quantity is less at one time, reducing the next stage crushing and reducing load.

5).The non-contact proximity switch is used for start stop control and reliable operation.

6).Sampling cutter with balancing weight can eliminate eccentric load, effectively play a safe self-protection role, does not affect the operation of the main belt.

4. Installation and commissioning 

4.1.When installing the Central Primary sampler, according to the position and size in the system layout drawing, the installation position of the sampler is determined first. After the position is determined, according to the size of the picture, the trough idler of the belt conveyor is reduced or increased.

4.2.When lifting the whole machine, screws needed for lifting rings. Do NOT lift the whole machine with hoisting screws on the enclosure, because hoisting screw on the enclosure is only suitable for removing the enclosure!

4.3.According to the general drawing of the sampler, punch holes in the two sides of the middle frame of the belt conveyor, install and fix 6 supporting blocks, and add elastic pads when fixing, so as to ensure firm and reliable.

4.4.Lifting steel structure support frame and support seat connection is fixed, require strong and reliable, all bolt joint must be added with elastic pads.

4.5.After the frame is positioned, the assembled shaft is hoisted on the frame, and the position of the shaft is adjusted so that the center of the shaft and the running direction of the belt conveyor are the same. The motor reducer is above the belt conveyor, the scraper cutter of the sampler is perpendicular to the running direction of the belt, and the bearing seats on both sides of the sampling cutter are fastened with elastic pads. Then adjust the height of the rubber scraper so that the bottom of the rubber scraper is pasted with the conveyor belt.

4.6.Adjust the counterweight block, and make the sampling cutter balance, so that when the shaft stops, it can not rotate at any position.

4.7.When installing the retaining skirt board, adjust the rubber plate screws on the skirt board to the right position.

4.8.Install the power and control part, install the motor reducer, coupling, adjust the coaxiality between the reducer and the drive shaft, then tighten it. All bolts must be added cushions when fastening.

4.9.Install the test board at the end of the shaft, install the proximity switch, operate the  sampler by point, so that the sampling cutter scraper stops at the upper left (right) position of the conveyor belt. The sampling cutter has just taken the material position, adjust the test board, so that the test board is facing down, the center is perpendicular to the center line of the belt conveyor. Switch to auto mode, so that the sampler runs. Check whether the installation position of the test board is correct. The principle is to ensure that when the sampling cutter stops, the scraper and counterweight block are far away from the material flow of the belt, and absolutely do not allow any blocking. If at inappropriate position, and then fine-tune the test board until the sampling cutter stops at the required position.

4.10.Install sampler and coupling housing, install anti-sprinkler rubber sheet on both sides of sampling head housing,and the rubber sheet does not affect slightly clearance of the belt running.

5.Operating procedures  

5.1.Before the trial run, check the bearing, whether the reducer is short of oil, if oil shortage should be added in time.

5.2.Check the motor reducer, bearing block, steel bracket, support seat and the bolts it sees are tight.

5.3.After checking everything is normal, first send out the test signal, then start the motor.

5.4. When the sampling cutter is running, pay attention to observe whether the operation is normal, whether the starting and stopping positions are suitable, whether there is angle deviation, if find problems and stop the machine in time.

5.5. When the sampling cutter is working, it is strictly forbidden for the staff to put their heads into the containment cover for inspection, cleaning and adjustment, so as to avoid danger.

6.Maintenance 

6.1.Check the bearing block regularly, whether the bolts of the reducer are loose or not, and find out the abnormal, handle it in time.

6.2.Check rubber retaining plate, scraper wear, timely adjustment or replacement;

6.3.Regularly check whether the bearing and reducer are short of oil, add or fill lubricating oil in time.

6.4.In strict accordance with the instructions and the corresponding equipment instructions for use, maintenance and repair.

6.Possible failures and handling methods 。

7.Spare part list