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WWJ6积放式悬挂输送机
WWJ6 P&F Overhead Conveyor
安 装 手 册 Installation Manual
承德金龙输送机制造有限公司
技术工程部编制 Chengde Jinlong Conveyor Manufacture Co.,Ltd.
Technology & Engineering Department
2009年10月18日
October 18th, 2009
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目 录
C o n t e n t s 1、安装前的准备工作
Preparations prior to Installation
2、钢结构的安装
Steel Structure Installation
3、积放直轨、积放轨回转装置、道岔的安装
Installation of P&F straight track, P&F track return units, track switch
4、牵引直轨、牵引轨回转装置、驱动装置、张紧装置、润滑直轨的
安装
Installation of Power straight track, power track return units, Drive Unit,
Tension Unit & Lubrication Straight Track
5、停止器、止退器、夹紧器、发号器、油雾润滑器的安装
Installation of Stop Unit, Anti-back Unit, Clamp Unit, Signaler Unit & Spray
Lubrication Unit
6、积放小车组及吊具的安装
Installation of P&F Trolley Assembly & hook
7、牵引链的组装及安装
Installation & Assembling of Power Chain
8、气路系统的安装
Pneumatic Unit Installation
9、输送机系统单个部件的性能检查及单体调试
Performance checking of single part & single machine commissioning
10、电控系统的安装
Installation of Electric Control System
11、输送机系统机电调试及联动试车
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Conveyor System Mechanical-Electrical commissioning & Associated Trail
WWJ积放式悬挂输送机
安 装 手 册 WWJ P&F Overhead Conveyor
Installation Manual
积放式悬挂输送机是一种先进而复杂的物料输送设备，而且多和其它类型的输送设
备一起，通过可编程控制器或计算机控制，成为高度机电一体化的物料储运系统。
P&F Overhead Conveyor is a set of advanced & complicated material conveying system, which is with other conveyor equipment to form a mechanical-electrical integration system controlled by programmer controller or computer.
输送机系统功能及使用寿命决定于设计质量、制造质量和安装质量，安装质量的
优劣更为直接地影响输送机系统功能及使用寿命。因此所有安装人员必须给予足够重
视。
Conveyor system function & lifetime is decided by design quality, manufacturing quality and installation quality. The installation quality directly affects conveyor system function & lifetime, so all installation personnel should pay enough attention.
1、安装前的准备工作
Preparations prior to Installation
1）安装人员及相关人员的确定 根据工程项目的复杂程度、工程进度的急缓和安
装工作量的多少确定现场安装人员和现场指导人员的数量，同时确定双方现场联系人
名单。
Site Installation & Supervision Personnel to be confirmed: according to project complexity, schedule, workload to confirm how many site installation & supervision personnel needed, at the same time to confirm site contact person list
2）设备零部件清点 根据机电设计图纸逐一仔细清点设备零部件的规格、型号及
数量，如有出入应马上采取措施尽快解决。
Check equipment parts amount: according to design drawings to check the equipment parts amount, type. If there has any problem, work out as soon as possible.
3）设备基础检查
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Equipment’s Foundation Check
a.按P-F线立柱基础图逐一检查每个立柱基础的位置尺寸，如有出入作出相应
标记，并确定解决方案。
Based on P&F Column drawings to check the position and size of each column foundation. If there has any problem, mark at related place and then deal with as soon as possible.
b.按照厂房统一的标高基准点逐一检查每个立柱基础的标高和水平度，如有较
大问题作出相应标记，并确定解决方案。
According to uniform fiducial point in workshop to check standard level and levelness of each column. If there has relatively serious problem, mark at related place and then deal with as soon as possible.
4）相关设备安装协调 由业主组织协调整体工程进度，并制定整体工程进度计
划，与P-F线相关设备（运卷小车、打捆机、称重装置、卸卷机）的安装必须在输送机
轨道安装之前完成。
Installation harmony of related equipment: Owner should make project schedule plan, directly control & harmonize. Equipment related to P&F line(coil vehicle, compactor, weighing scale, unloader) should be installed before beginning to install conveyor track.
5）现场安装设备准备 现场安装需要配置以下安装设备:
Site installation Preparation: site installation needs following equipment
a.桥式起重机 b.叉车 c.电焊机
d.砂轮切割机 e.砂轮磨光机 f. 焊后补漆用喷枪
g.钳工工具等。
a. bridge crane b. fork truck c. electric welder d. abrasive wheel cutting machine e. disk sander f. spray gun g. other useful tools
2、钢结构的安装
Steel Structure Installation
1）立柱的制做与安装
Column manufacturing & installation
a.按照图纸技术要求现场制做立柱，立柱型钢不允许两段对接。
Column shoude be manufactured at site according to design drawing requirements, profiled steel for column does not allow to use opposite joint.
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b.清理立柱基础。
Clear column foundation.
c.用桥式起重机起吊立柱并安装、调整、紧定。安装时立柱底板与立柱基础上
平面之间允许加调整垫调整，安装后立柱铅垂度偏差应小于1/1000,全长不应大于
5mm。
Use bridge crane to hang up column for installation, adjusting, tightening. When installing, allow to use adjusting plate between column bottom plate and column foundation upper surface. After installation, column verticality tolerance should be less than 1/1000, altogether less than 5mm.
d.立柱基础二次浇注。
Column foundation should be poured again.
2）辅助梁的安装
Supplementary beam installation
a.辅助梁标高根据厂房统一的标高基准点确定。
Supplementary beam level height should be decided by workshop standard level.
b.按照图纸技术要求现场截取辅助梁的定尺长度(根据立柱实际位置以现场实测
尺寸为准)，并起吊安装到立柱顶端。纵向辅助梁和横向辅助梁的连接多采用插接形
式，在回空链跨越轨道处纵向辅助梁和横向辅助梁的连接采用搭接形式。同一跨度内
的辅助梁型钢一般不允许两段对接，特殊情况下两段辅助梁对接时必须用加强版等强
度对接。
According to drawing requirements to decide supplementary beam length(based on column actual position and site measurement). Then hang up beams to column top and install. Connection between lengthways and transverse beams uses inserting joint, and overlapping joint is used at where empty return chain crosses track. Profiled steel of supplementary beam within the same span does not allow to use opposite joint between two sections, except special state using strengthening plates.
c.辅助梁安装的尺寸精度要求：
Precision requirements for Supplementary beam installation:
辅助梁直线度偏差应小于1/1000,全长不应大于8 mm。
Supplementary beam straightness tolerance should be less than 1/1000, altogether less than 8mm.
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辅助梁纵向水平度偏差应小于1.5/1000,全长不应大于12 mm。
Supplementary beam lengthways levelness tolerance should be less than 1.5/1000, altogether less than 12mm.
辅助梁中心线与轨道中心线的偏移量不应大于5mm。
Deviation between supplementary beam center line and track center line should be less than 5mm.
4）驱动张紧平台的安装
Drive & Tension Platforms Installation
a.在驱动张紧平台的纵向辅助梁安装之后架设横向辅助梁，横向辅助梁只能先
点焊在纵向辅助梁上，待驱动张紧装置安装调整合适后进一步焊牢固定。
Install transverse supplementary beam of drive & tension platforms after the lengthways supplementary beam has been installed, the transverse beam should be spot-welded on the lengthways beam at first, and be welded tightly after drive & tension unit have been adjusted properly.
b.驱动张紧装置安装调整合适后进一步架设检修平台、栏杆和扶梯。
Install maintenance platform, railing, ladder after drive & tension unit have been adjusted properly.
c.驱动张紧平台的水平度偏差应小于3/1000,全长不应大于15 mm。
Drive & Tension platforms levelness tolerance should be less than 3/1000 and altogether less than 15mm.
5）平衡轨的安装
Balance Track Installation
a.平衡轨的安装必须在轨道、积放小车组、C 形钩安装之后进行。
Install balance track after track, P&F trolley assembly, C-hook have been installed.
b.平衡轨安装时应保证二平衡轨的平行度和水平度均不大于 5mm。
When Installing balance track, should insure that parallelism and levelness between two balance tracks should be less than 5mm.
c.平衡轨安装时保证平衡轨底面到C形钩平衡轮上面的运动间隙不大于15mm。
When Installing balance track, should insure that moving gap between balance track bottom surface and balance wheel top surface of C-hook should be less than 15mm.
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6）钢结构安装检查与补焊
Check and repair welding after steel structure has been installed
a.钢结构安装后全面检查焊接质量，焊缝高度 6～8mm。
Check welding quality after steel structure has been installed, welding seam height is 6-8mm.
b.钢结构安装后视现场情况酌加斜支撑。
According to site actual state to add inclined support steel after steel structure has been installed.
3、积放直轨、积放轨回转装置、道岔的安装
Installation of P&F straight track, P&F track return unit, track switch
1）根据输送线线体部件安装编号图依次安装积放直轨（图1）、积放轨回转装置
（图2）和道岔（图3）。
According to conveyor part installation number drawing to orderly install P&F straight track(diagram 1), P&F track return unit(diagram 2), track switch(diagram 3).
2）积放直轨、积放轨回转装置和道岔之间用螺栓连接固定，相关尺寸调整合适后
焊接牢固。积放直轨、积放轨回转装置和道岔上方用角钢或槽钢与辅助梁焊接固定。
P&F straight track, P&F track return unit, track switch are connected by screws at first and welded tightly after related sizes have been adjusted properly. The top of P&F straight track, P&F track return unit, track switch are tightly welded with supplementary beam using angle steels or channel steels.
3）积放直轨的安装要求
Installation Requirements of P&F straight track Installation
a.积放直轨的纵向水平度偏差不应大于1/1000，全长不应大于10mm。
P&F straight track lengthways levelness tolerance should be less than 1/1000, altogether less than 10mm.
b.积放直轨的直线度偏差在6m长度上不应大于3mm，全长不应大于8mm。
P&F straight track straightness tolerance should be less than 3mm within 6m length, altogether less than 8mm.
c.积放直轨接口不应偏斜和扭转，轨道纵向中心面的铅垂度偏差不应大于截面
高度的1/100。
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P&F straight track connecting end shoule not be slanted & twisted, verticality of track lengthways central plane should be less than 1/100 of section height.
d. 积放直轨接口间隙不应大于1.5mm，轨道工作面的接口高低差不应大于
1mm，且应沿输送机前进方向前低后高，轨道接口左右偏移偏差不应大于1.5mm。
Gap shoule be less than 1.5mm between two P&F straight track connecting ends. Work surfaces tolerance of two connected tracks should be less than 1mm and the front track is a little lower than behind track along the conveyor running direction.
图1 积放直轨 Diagram 1 P&F Track
图2 积放轨滚子回转装置
Diagram 2 P&F Track Roller Turn Assembly
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图3 道岔 Diagram3 Track Switch
4）积放轨滚子回转装置、道岔的安装要求
Installation Requirements of P&F track roller return unit & Track Switch
a.积放轨滚子回转装置、道岔的轨道下平面的平面度偏差在 1000 mm 以内为
±2mm。
Bottem surface levelness tolerance of P&F track roller return unit & track switch should be ±2mm within 1000mm.
b.积放轨滚子回转装置、道岔与积放直轨接口不应偏斜和扭转。
P&F track roller return unit & track switch conncection with P&F straight track should not be slanted & twisted.
c.积放轨滚子回转装置、道岔与积放直轨接口间隙不应大于1.5mm，轨道工作
面的接口高低差不应大于1mm，且应沿输送机前进方向前低后高，轨道接口左右偏移
偏差不应大于1.5mm。
Connection Gap shoule be less than 1.5mm from P&F track roller return unit & track switch to P&F track. Work surfaces tolerance of two connected tracks should be less than 1mm and the front track is a little lower than behind track along the conveyor running direction.
5）输送线积放线体部件（积放直轨、积放轨回转装置、道岔）全部安装合拢后应
进行全线检查与整修，补焊不良焊缝，去除毛刺和焊渣。
Should check and repair components in P&F area of conveyor(P&F straight track, P&F track roller return unit & track switch) after they are installed. Re-weld bad welding, remove burrs & welding spatters.
同时用一台组装好的积放小车组(含前中后小车和载荷梁)全线检查其通过性，如
有问题必须及时进行彻底整修。
Use one set of trolley assembly(including front, intermediate, rear trolley & load bar) to check the trafficability of conveyor. Carry out thorough reconditioning if there has any problem.
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4、牵引直轨、牵引轨回转装置、驱动装置、张紧装置、润滑直轨的安装
Installation of power straight track, power track return unit, Drive Unit, Tension Unit & Lubrication Straight Track
1）根据输送线线路节点图依次安装牵引直轨、牵引轨回转装置（图4）、驱动装置
（图5）、张紧装置（图6）。牵引直轨、牵引轨回转装置、驱动装置、张紧装置上方
用角钢与辅助梁焊接固定。
According to conveyor part installation number drawing to orderly install power straight track, power track return unit(diagram 4), drive unit(diagram 5), tension Unit(diagram 6). The top of power straight track, power track return unit, drive unit, tension unit are tightly welded with supplementary beam using angle steels.
a . 牵引轨滚子回转装置
a. Power Track Roller Turn Assembly
b. 光轮回转装置
b. Traction Wheel Turn Assembly
图4 牵引轨回转装置
Diagram 4 Power track return unit
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图5 驱动装置
Diagram 5 Drive Unit
图6 张紧装置
Diagram 6 Tension Unit
2）牵引直轨的安装要求
Installation Requirements of Power Straight Track
a.牵引直轨的纵向水平度偏差不应大于1/1000，全长不应大于10mm。
Power straight track lengthways levelness tolerance should be less than 1/1000, altogether less than 10mm.
b.牵引直轨的直线度偏差在6m长度上不应大于3mm，全长不应大于8mm。
Power straight track straightness tolerance should be less than 3mm within 6m length, altogether less than 8mm.
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c.牵引直轨接口不应偏斜和扭转，轨道纵向中心面的铅垂度偏差不应大于截面
高度的1/100。
Power straight track connecting end shoule not be slanted & twisted, verticality of track lengthways central plane should be less than 1/100 of section height.
d.牵引直轨接口间隙不应大于1.5mm，轨道工作面的接口高低差不应大于
1mm，且应沿输送机前进方向前低后高，轨道接口左右偏移偏差不应大于1.5mm。
Gap shoule be less than 1.5mm between two power straight track connecting ends. Work surfaces tolerance of two connected tracks should be less than 1mm and the front track is a little lower than behind track along the conveyor running direction.
3）牵引轨回转装置（含光轮回转装置和滚子回转装置）的安装要求
Installation requirements of power track return units(including traction wheel return unit & roller return unit)
a.牵引轨回转装置的轨道下平面的平面度偏差在 1000 mm 以内为±2mm。
Bottem surface levelness tolerance of power track return units should be ±2mm within 1000mm.
b.牵引轨回转装置与牵引直轨接口不应偏斜和扭转。
Power track return units connection with power straight track should not be slanted & twisted.
c.牵引轨回转装置与牵引直轨接口间隙不应大于1.5mm，轨道工作面的接口高
低差不应大于1mm，且应沿输送机前进方向前低后高，轨道接口左右偏移偏差不应大
于1.5mm。
Connection Gap shoule be less than 1.5mm from power track return units to power straight track. Work surfaces tolerance of two connected tracks should be less than 1mm and the front track is a little lower than behind track along the conveyor running direction.
d.牵引轨回转装置的吊装点至少不小于3点。
Suspending points of power track should not be less than 3 points.
4）驱动装置、张紧装置的安装要求
Installation requirements of Drive Unit & Tension Unit
a. 驱动装置、张紧装置的轨道下平面的平面度偏差在 1000 mm 以内为±2mm。
Bottom surface levelness tolerance of drive unit & tension unit should be ±2mm within 1000mm.
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b. 驱动装置、张紧装置与牵引直轨接口不应偏斜和扭转
Drive unit & tension unit connections with power straight track should not be slanted & twisted.
c. 驱动装置、张紧装置与牵引直轨接口间隙不应大于1.5mm，轨道工作面的接
口高低差不应大于1mm，且应沿输送机前进方向前低后高，轨道接口左右偏移偏差不
应大于1.5mm。
Connection Gaps shoule be less than 1.5mm from drive unit & tension unit to power straight track. Work surfaces tolerance of two connected tracks should be less than 1mm and the front track is a little lower than behind track along the conveyor running direction.
5）润滑直轨的安装 润滑直轨安装在张紧装置的轨道接口处。润滑直轨的安装必须
在牵引链安装之后。
Installation of Lubrication Straight Track: it is installed at track connection of tension unit. And it must be installed after power chain installation is completed.
6）输送线回空线路部件（牵引直轨、牵引轨回转装置、驱动装置、张紧装置）全
部安装合拢后（暂时不装润滑直轨，留有1m的开口空档）应进行全线检查与整修，补
焊不良焊缝，去除毛刺和焊渣。
Should check and repair components in empty return area of conveyor(power straight track, power track return units, drive unit & tension unit) after they are installed. Re-weld bad welding, remove burrs & welding spatters.
同时用一段推杆间距长度组装好的牵引链 (含8个节距的链条、一个推杆、3套链
支撑小车)全线检查其通过性，如有问题必须及时进行彻底整修。
Use one segment of properly assembled power chain(including 8 pitches chain, a push dog & 3 sets of chain-backup trolleys) to check the trafficability of conveyor. Carry out thorough reconditioning if there has any problem.
5、停止器、止退器、夹紧器、发号器、油雾润滑器的安装
Installation of Stop Unit, Anti-back Unit, Clamp Unit, Signaler Unit & Spray Lubrication Unit
1）停止器、发号器、夹紧器安装前的准备工作
Preparations prior to installation of Stop Unit, Signaler Unit, Clamp Unit
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停止器、发号器、夹紧器安装前必须先组装好一套车组吊具(含前中后小车、载
荷梁、发号杆和C形钩)，并将车组吊具装入积放轨道，推到准备安装停止器、发号
器、夹紧器的操作工位。
Before to install Stop Unit, Signaler Unit, Clamp Unit, must assemble a intact set of trolley assembly with C-hook(including fornt, intermediate, rear trolley, load bar, signaler bar, C-hook), then install them in P&F track and push them to the work-station which will be installed stop unit, signaler unit, clamp unit.
2）停止器、止退器及夹紧器的安装
installation of stop unit, signaler unit, clamp unit
a. 非操作工位停止器、止退器的安装按输送线线路布置图执行，线路布置图中
标示的停止器的定位尺寸是指停止器的停止板工作面尺寸。
Stop unit & anti-back unit of non-operation should be installed according to conveyor line layout drawing. The positioning size of stop unit showed in line layout drawing is the size of work surface of stop plate.
b.止退器安装前应将积放轨道凸缘槽钢的凸缘割去磨平。
Should cut the lip of channel steel and burnish before installing anti-back unit.
c. 各操作工位停止器、止退器、夹紧器的安装必须严格保证 C 形钩中心线与工
位中心线重合。
Installation of Stop unit, anti-back unit, clamp unit of each work-station should strictly insure that C-hook centre line is coincide with work station center line.
d. 各停止器、止退器安装时先点焊在轨道上，各部尺寸调整合适后方可焊牢。
停止器及止退器的安装尺寸要求见图 7。
Each stop unit, anti-back should be spot-welded on track at first when installing and be welded tightly after all related sizes have been properly adjusted. The installation sizes of stop unit & anti-back unit see diagram 7.
3）发号器的安装
Installation of signaler unit
a. 占位发号器的安装应在停止器安装之后进行，并由积放小车组中小车上的发
号杆确定占位发号器的安装位置（此时的积放小车组可以不带 C 形钩）。
Occupation signaler unit should be installed after stop unit have been installed, and its position will be decided by the signaler bar of intermediate trolley on P&F trolley assembly(P&F trolley assembly at this time may not have C-hook with it ).
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b. 满位发号器的安装应在系统整体试车时进行，安装位置现场确定。
Installation of full-position signaler unit should be done when system trail, its position shoude be decided at site.
4）油雾润滑器的安装 油雾润滑器组装在润滑直轨上，润滑直轨安装在张紧装
置的轨道接口处。
Installation of Spray Lubrication Unit: it will be installed on lubrication straight track, and the lubrication straight track will be installed at the track connecting place of tension unit.
图7 停止器及止退器的安装
Diagram 7 Installation of Stop Unit & Anti-back Unit 以下为图7中翻译：
停止板：stop plate 现场割豁口：site cutting gap
线路图停止器标记：symbol for stop unit
前小车中心线：center line of front trolley
6、积放小车组及吊具的安装
Installation of P&F trolley assembly & hook
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1）积放小车组的安装 积放小车组包括前小车、中小车、后小车、发号杆和两种
载荷梁。在积放小车组装入积放轨道前首先把前小车、中小车、后小车、发号杆和载
荷梁用螺栓组装在一起（图8），然后从检修区的检修道岔开口处将积放小车组装入
积放轨道。
Installation of P&F trolley assembly: P&F trolley assembly consists of front trolley, intermediate trolley, rear trolley, signaler bar and two kind of load bar. At first, use screws to assemble front trolley, intermediate trolley, rear trolley, signaler bar, load bar together(diagram 8), then put trolley assembly into P&F track from opening gap in maintenance track switch of maintenance area.
图8 四车积放小车组
Diagram 8 Four-P&F-Trolley Assembly
2）吊具的安装 吊具包括C形钩、U形吊板、支撑块、承载销轴等组件，组装后的
吊具起吊到积放小车组下方连接固定。
Hook installation: hook consists of C-hook, U-shaped plate, support block, load pin, etc. Assembled hook will be taken to connect with P&F trolley assembly.
3）积放小车组及吊具的安装批次及数量
Installation time & amount of P&F trolley assembly & hook
a.输送线积放线体部件全部安装合拢后先组装好一台积放小车组（不含吊具）
全线检查积放轨道的通过性。
After parts in P&F area have been properly installed, then assemle a set of P&F trolley assembly(no c-hook) to check the trafficability of P&F track.
b.各操作工位停止器、发号器、夹紧器安装时必须用一套组装好的车组吊具作
为安装基准，严格保证 C 形钩中心线与工位中心线重合。
When installing stop unit, signaler unit, clamp unit of each work station,
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must take a set of properly installed P&F trolley assembly with c-hook as installation base. Strictly insure that center line of c-hook coincides with center line of work station.
c.空载试运行前，根据现场情况可以安装第一批车组吊具10－20套。
Before empty load trial, may install 10-20 sets of P&F trolley assembly with hook according to site actual state.
d.热负荷试车前，根据现场情况可以安装第二批全套的车组吊具。
Before heat trail, may install the rest P&F trolley assembly with hook according to site actual state.
7、牵引链的组装及安装
Installation & Assembling of Power Chain
1）牵引链的组装 牵引链由外链片、内链片、销轴、推杆外链片、链支撑小车组
成（图9），牵引链的组装见图10。
Assembling of Power Chain: power chain consists of side link, conter link, pin, push dog, chain backup trolley(diagram 9), its assembling see diagram 10.
图9 牵引链
Diagram 9 Power Chain
图10 链条的组装
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Diagram 10 Chain Assembling
牵引链链条组装时必须把链条松开一定的长度，以便把一对外链片放在两相邻的
内链片中间，装入销轴后旋转90°，即可把内链片、外链片连接在一起，而不需要任何
工具。
When Assembling power chain, it must be loosed a little to put a pair of side link in the center of center link, turn the pin 90°, center link and side link is connected. No need to use any tool.
牵引链的组装长度视现场的安装条件决定，通常牵引链(含推杆和链支撑小车)的
组装长度为2--3个推杆间距。
Assembling length of Power chain is decided by site actual state. Usually assembling length of power chain is as long as 2-3 push dog space.
2）牵引链的安装 输送线回空线路安装合拢后留有1m的开口空档，牵引链从此开
口空档处用销轴将每一节链条一段一段地连接好，并送入牵引轨道。
Installlation of power chian: there reserves a 1m gap after empty return line has been installed, power chain will be sent into P&F track from this gap.
安装链条时张紧装置的回转光轮应调整到内侧的极限位置，张紧装置的伸缩轨处
于合拢状态。以保证最终链条完全合拢后张紧装置仍留有足够的伸缩行程。
When installing chain, return traction wheel of tension unit should be set at its inner limit position, expansion track is under full shrinking state. The above can insure that tension unit has enough expansion travel after chain has been fully installed.
链条完全合拢后再安装带有油雾润滑器组装的润滑直轨。
After chain has been properly installed, then install lunbrication straight track(has spray lubrication unit).
8、气路系统的安装
Pneumatic Unit Installation
1）气源管径3/4",接口标高4500mm,距气源接口500mm处设置截止阀。
Air supply pipe diameter is 3/4", connection level height is 4500mm, stop valve is set at 500mm from air supply.
2）气路管道用管夹固定在辅助梁上方.管夹间距3~4m。
Pneumatic pipes is tightened on supplementary beam usingn pipe clips. Space between every two clips is 3-4m.
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3）气路管道安装完毕,接通气路单元（图11）前用压缩空气吹除管内异物,保证管
内畅通清洁。气路单元的油雾器内加注20号润滑油。
After pneumatic pipes have been installed, before connecting pneumatic unit(diagram 11), use compressed air to blow pipes to insure that pipe is unblocked and clean. Fill #20 lubrication oil into sprat lubricator.
图11 停止器气路单元
Diagram 11 Pneumatic Unit of Stop Unit
4）气路接通后,手动操作气缸动作若干次,直至气缸动作平稳无抖动无卡阻为止。
After pneumatic unit has been connected, manually make cylinder move several times until it moves smoothly.
5）气路系统安装结束严格检查各接头及气路单元有无漏气现象及管道有无振动现
象。
After pneumatic unit has been connected, strictly check each connection & pneumatic part whether have air-leak and vibration.
9、输送机系统单个部件的性能检查及单体调试
Performance checking of single part & single machine commissioning
1）回转装置的性能检查 输送机系统的回转装置包括积放轨滚子回转装置、光轮回
转装置和牵引轨滚子回转装置，各种回转装置安装后应手动检查滚子和光轮的转动灵
活性，如有异常及时整修。
Capacity check of return units: return units of conveyor system consist of P&F track roller return unit, traction wheel return unit, power track roller return unit. Should manually check roller and traction wheel whether they turn smoothly. Repair if there has problem.
2）驱动装置的单体调试
single commissioning of drive unit
a.在减速器的齿轮箱内按油标指示油位加注70~120号工业齿轮油。在套筒滚子链
及支撑轨上滴注少量的HJ-50机械油。
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Fill #70-#120 industry gear oil in gear box of reducer. Drip a small quantity of HJ-50 machine oil on sleeve roller & backup track.
b.检查驱动链轮、从动链轮及支撑轨的水平度。
Check levelness of drive sprocket, driven sprocket & backup track.
c.调整驱动装置的切换机构，使两台驱动装置均处于备用状态。
Set switching mechanism of drive unit to make two drive units both under standby state.
调整驱动装置的过载保护弹簧长度，压缩后弹簧长度为350mm。
Set overload protection spring length of drive unit, pressed spring length is 350mm.
调整驱动装置的过载保护开关，使之与浮动架的接触面可靠啮合。
Set overload protection switch of drive unit to make it stably meshed with touching surface of floatable frame.
d.驱动装置调整完成后, 接通电源进行空负荷试验,时间不少于2小时,减速器应运
转正常。
After drive units have been set, turn on power to carry out empty load trial. The time should not be less than 2 hours and the reducer should work normally.
e.调整驱动装置的切换机构，使一台驱动装置的驱动爪进入啮合状态，驱动爪
端面与直线滚子组滚子表面之间的运动间隙3.2mm。
Set switching mechanism of drive unit to make drive dog of one drive unit in meshing state, moving gap between top surface of drive dog and roller surface of straight roller assembly is 3.2mm.
f.沿线路走向全线检查整条牵引链(此时全线无车组吊具)。
Check whole power chain along conveyor running direction(no trolley assembly with hook in conveyor line at this time)
g.接通电源，点动试车后连续运行24小时。并随时检查驱动链的驱动爪与牵引
链的啮合状况及运动平稳性，观察有无卡阻及异常声响。
Turn on power to run conveyor for 24 hours. Check meshing state of drive dog and power chain and the stability of their movement. Observe whether there have jam and abnormal noise.
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图12 驱动链的调整
Diagram 12 Adjustment for Drive Chain
3）张紧装置的单体调试
single commissioning of tension unit
a. 张紧装置的单体调试与驱动装置的单体调试同时进行。
single commissioning of tension unit carries out when doing single commissioning of drive unit
b. 检查张紧装置伸缩轨的实际伸出长度，伸缩轨的实际伸出长度应不大于张紧
行程900mm的1/2。
Check actual expanding length of tension unit expansion track. The actually expanded length should be less than 1/2 tension unit travel.
c. 检查张紧装置浮动架的浮动状况，观察有无卡阻及异常声响。
Check floating state of floatable frame to see whether there has jam or abnormal noise.
d. 检查张紧装置气缸和气路单元的管路连接状况，观察有无漏气现象。
Check whether tension unit cylinder and pipe connection have air leak.
e. 检查张紧装置检测开关位置是否正确。
Check whether detecting switch of tension unit is correct.
4）停止器、分支道岔、夹紧器的单体调试
single commissioning of stop unit, diverge track switch, clamp unit
a. 停止器、分支道岔、夹紧器的单体调试应全线逐一进行。
Single commissioning of stop unit, diverge track switch, clamp unit should be carried out one by one with whole conveyor.
b. 接通电源和气源，手动调试，检查停止器、分支道岔、夹紧器的动作状况，
观察有无卡阻及异常声响。
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Turn on power & air supply, manual set, check movement state of stop unit, diverge track switch, clamp unit and whether there have jam & abnormal noise.
c. 检查停止器、分支道岔、夹紧器气缸和气路单元的管路连接状况，观察有无
漏气现象。
Check pipe connection state of stop unit, diverge track switch, clamp unit and observe whether there have air leak.
d. 检查停止器、分支道岔、夹紧器检测开关位置是否正确。
Check whether position of detecting switch of stop unit, diverge track switch, clamp unit is correct.
10、电控系统的安装
Installation of Electric Control System
1）安装概述:
Installation Summary:
a、输送线电气控制主体选用西门子公司生产的可编程控制器控制，即主机 CPU
6ES7-315-2DP，并采用 ET200M 分布式 I/O 形式，电气系统硬件构成包括主控柜、
现场 I/O 柜、工位操作盒、发号器、执行元件电磁阀线圈等其他设备，以及为连接它
们的而敷设的线槽线管和电缆导线等元件。
Electric control main body of conveyor line chooses Simens
programmable controller, i.e. CPU 6ES7-315-2DP, ET200M distributive
I/O. Hardwards of electric system consist of main control cabinet, site I/O
cabinet, work station operation box, signaler device, solenoid of execute
elements and those connecting components like cables, cable trays,
pipes, conduits and so on.
b、安装前应详细查阅电气平面布置总图、外部线管布置图、系统配置图及有关的
其它电路图。
Should carefully read electric plane layout drawing, outside wire pipes
layout, system arrangement drawing and other related drawings.
2) 主控柜的安装
Installation of Main control cabinet
a、首先进行主控柜的安装，主控柜安装在电控室内。主控柜由两个单柜组合而
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成，其尺寸为宽 1600mmX 高 1800mmX 厚 500mm 外加 200mm 高底座。通过安装
螺钉安装在电控室预留的安装底板上。电控室内有甲方提供的动力电源,通过动力电缆
连接到动力控制柜的断路器上。
Main control cabinet is installed in electric control room at first. It
consists of two single cabinets and its size is
1600mm(W)X1800mm(H)X500mm(D) with a 200mm base. It is installed
on mounting plate using screws. Control room has power supply
provided by Buyer, it will be connected to breaker of power control
cabinet through power cables.
b. 上位机监控部分连同桌椅也安放在电控室内。
Monitoring part of Level-II automation and its table are also in control
room.
3) 外部Ｉ／Ｏ电控柜的安装
Outside I/O control cabinet installation
由 PLC 控制系统网络配置图可知,系统外部由几个 I/O 电控柜组成，它们的位置可
通过电气平面布置图分成的区域中所给的位置而定。所有 I/O 电控柜的外形尺寸为宽
800mmX 高 1600mmX 厚 500mm 外加 200mm 高底座。通过膨胀螺钉固定在混凝土
地面上。I/O 电控柜应安装在指定位置立柱附近。
Known from PLC control system network drawing, system oueside is
consisted of several I/O electric control cabinets, their positions are
decided as shown in electric layout . All I/O electric control cabinets size
is 800mm(W)X1600mm(H)X500mm(D) with a 200mm base. They are
fixed on concrete groud by expansion bolts. I/O electric control cabinets
should be installed near appointed columns.
4) 外部线槽线管的安装
Installation of outside cable pipe lines
安装前先查阅外部线槽布置图，线槽分动力线槽、控制线槽两部分。安装时应分
别按外部线槽布置图所提供的走向，沿轨道走向设立角钢支架进行敷设安装固定。所
有线槽线管连接处均要用导线短接连接一体，并进行接地处理。
Carefully read the outside cable groove layout drawing. Cable groove
has two kinds: power cabel groove & control cable groove. Lay cable
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grooves along track running direction based on outside cable groove
layout drawing. All connections of cable grooves & pipes shoulde be
connected as a whole and have grouding.
a、动力线用 50mmX50mm 线槽,源头从动力控制柜开始到各分区远程控制柜及传
动站。动力线槽内有传动电机电缆和各 I/O 电柜交流 230V 供电电源。
Power cable uses 50mmX50mm cable groove. It will be distributed from
power control cabinet to each remote control cabinet and driving station.
It has AC 230V power supply cables for drive motors and each I/O
cabinet.
b、控制线用 150mmX75mm 线槽及 50mmX50mm 两种线槽, 源头从主控柜开始
到各分区 I/O 电柜。控制线槽内有现场 I/O 直流 24V 输入输出信号电缆和西门子总线
电缆。
Control cable uses cable grooves of 150mmX75mm & 50mmX50mm. It
will be distributed from main control cabinet to each I/O cabinet. It has
DC 24V I/O signal cable and Simens bus cable.
5) 外部电缆的安装
Installation of outside cable
由控制柜到设备各部位的控制电缆必须布置在电缆桥架内；
Control from control cabinet to equipment must be layed inside cable
trays.
所有外部电缆必须予以编号,每根电缆的编号是唯一的；
All outside cable must be numbered and each cable number is unique.
必须采取措施确保在电缆间传输的电压不会引起任何相互干扰；
Must insure that voltages transmited in different cables can not cause
any interference.
电缆的长度足以能够便于更换元器件；
Cable length should be enough long for changing elements.
控制柜进出线采用电缆桥架，在控制柜的顶部或底部进出线；
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Cable goes in or out of control cabinet using cable tray, on top or at
bottom of control cabinet.
在电缆桥架内不可以进行任何导线连接；信号线和强电线（动力线）必须分
隔开布置；
Inside cable tray, cable can not be connected through any wire; signal
cable and power cable must be separated.
为了便于更换和修理，至少要提供 10%的备用导线，并标明导线的去向。
Should provide 10% spare wire for changing and repairing, and mark
wire going direction.
电缆必须具有足够的长度而且能够使元件间进行快速准确的信号交换；
Cable must have enough length and can let elements exchange signals
quickly & accurately.
需要走外部的导线或柔性电缆必须走保护软管，不能外露；
Wires need to go at outside or soft cable must have protection conduit
and can not be exposed.
所有的元器件必须以便于维护的方式进行连接；
All elements must be connected
在应用于操作且需要移动的场合，外露的电缆必须是具有适宜的柔韧性而且
具有适当的保护；
At outside place, exposed cable must have proper flexility and protection.
导线的颜色标准 Wires Color Standard
主 电 路
main circuit
控 制 电 路
Control circuit
地 线
grounding
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交流 A 相：黄色
AC A phase: yellow
B 相：绿色
B phase: green
C 相：红色
C phase: red
中线：黑色
Neutral: black
交流控制：相线：红色
零线：黑色
AC control: phase: red
zero line: black
直流控制：（+/-） 棕色、蓝色
DC control:
（+/-）brown,
blue
黄绿色
yellowgree
n
电缆使用标准：导线的横截面积必须符合国家标准，耐温不小于 50℃，必须
满足设备和电气元件长期正常稳定安全地运转。
Cable standard: cross sectional area must comply with national
standards, temperature resistance shoulde not be less than 50℃ and
can satisfy the requirements of equipment long-term & safe operation.
外部管线以桥架（镀锌或喷塑）为主，热镀锌钢管、金属软管为辅；
Outside line pipe mainly uses cable trays(galvanized or plastic spray),
secondly uses heat galvanized steel pipes and metal conduits.
外部管线和内部管线的布置必须符合国家有关规定，必须耐用可靠、整齐美
观、方便维修及方便清扫等；
Laying Outside & inside line pipes must comply with related national
rules, they must be serviceable, beautiful, be easily for cleaning and be
convenient for maintenance.
强弱电走线必须严格分开，且弱电必须采取有效的屏蔽。
Strong and feeble current cable must be strictly separated, and the
feeble current cable must have effective protection.
连接线采用多股铜绝缘软线，在经常移动的位置适当预留有足够长度，以免
急剧弯曲和产生过度张力；
Connecting cable is copper insulation soft. Cable should be long enough
at place that cable is moved often, avoiding damage.
6) 外部各工位操作盒的安装
Installation of each outside work station operation box
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a、操作盒分：工位操作盒、分流道岔操作盒、张紧站操作盒，操作盒均设有急停
按钮。
operation box: work station operation boxs, diverge track switch
operation boxs, tension unit operation boxs. All of them have E-stop
button.
b、工位操作盒应按电气布置图所给工位操作盒所在位置，应分别安装在工位处就
近的支撑立柱上。
Work station operation boxs should be separately installed on the
nearest support column according to the position showed in electric
layout drawing.
c、分支道岔操作盒应按电气布置图所给操作盒所在位置，应分别安装在相应道岔
附近的支撑立柱上。
Diverge track switch operation boxes should be separately installed on
the nearest support column of track switch according to the position
showed in electric layout drawing.
d、张紧站操作盒它们的位置应分别安在各自张紧站安装支架旁便于操作的地方。
Tension unit operation boxes shoulde be separately installed at the
place that is beside tension units installation brackets and is convenient
for operation.
7) 外部光电开关的安装
Installation of outside photoelectric switch
光电开关是由带有安装支架的光电开关构成，发射与接收、反射成对出现，视现
场情况安装在工位处被检测物体的两侧。光电开关的安装工位数量见电气平面部置
图。
photoelectric switch has a installation bracket, it is coupled with emission
& reflection or emission & receiving。According to site actual state, it will
be installed at two sides of object that will be detected.
8) 外部发号器及电磁阀的安装
Installation of outside signaler unit & solenoid valve
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a、发号器分占位发号器及瞬间发号器，它们是由装有发号器的支架构成，发号器
的数量及代号可参看电气平面部置图。所有发号器均装在承重轨道的一侧。
signaler unit has two kinds: occupation signaler unit and instant signaler
unit. They consist of signaler & bracket. Their amount and number are
showed in electric plane layout drawing. All signaler units should be
installed on the side of loadbearing track.
b、占位发号器的安装在距停止器的停止板前进方向的后面～540mm 的位置（现
场调定）。发号支架用螺丝紧固后再点焊在承重轨道上。
occupation signaler unit should be installed 540mm position from stop
plate back of stop unit(decide at site). Spot weld the bracket on
loadbearing track after it has been tightened by screws.
c、瞬间发号器又分为满位发号器和道岔清除发号器，满位发号器安装尺寸应按下
列公式计算:
instant signaler unit has two kinds: full-position signaler unit & track
switch clear signaler unit. Installation size of full-position signaler unit
should be calculated based on following equation:
（停止器位置的积存小车数-1）X1850mm+540mm-200mm（现场调
定）。
(stored hook amount at stop unit-1) X1850mm+540mm-200mm(decide
at site)
道岔清除发号器应安装在能够确认小车车尾已过道岔干涉区的轨道位置上。
track switch clear signaler unit should be installed at where can confirm
that tail of P&F trolley assembly has passed track switch interference
area.
d、停止器为单电控电磁阀，分支道岔和夹紧器为双电控电磁阀。
Stop unit is single control solenoid valve,diverge track switch & clamp
unit are double control solenoid valve.
所有电磁阀及发号器的连接均通过各自的 I/O 控制柜接线端子由带有编号的电
缆进行连接。I/O 控制柜接线端子出线形式可分为上部或底部出线两种。
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All solenoid valves and signaler units should be connected by numbered
cable through their I/O control cabinet terminals. I/O control cabinet
terminal cables can go from top or bottom.
9) 外部认址器的安装
Installation of outside address-reading device
外部认址器分为: A.读写头控制器 B.DP 网关和电源 C.载码体。系统认址数量根据
电气平面部置图所标数量。
outside address-reading device is consisted: A. read-write head
controller B. DP network gateway and power supply C. Encoded body
System address-reading amount is showed in electric plane layout
drawing.
a、读写头控制器固定在工位处承重轨道一侧，它通过电缆接口与 DP 网关相连。
Read-write head is set at one side of loadbearing track at work station, it
is connected with DP network gateway through cable connection.
b、DP 网关和电源装在一个控制盒内，盒子固定在工位处承重轨道的括架支撑
上。
DP network gateway and power supply are inside a control box which
has been set on yoke support of loadbearing track at work station.
c、载码体用于存放小车钩号及轧机跟踪信息，安装在每辆小车横梁的支架上。
Encoded body is stored with hook number & related information, is
installed on bracket of trolley assembly beam.
10）电压额定值和保护措施
Voltage rated value & Protection measure
a. 主电源：电源为三相 A、B、C、N、PE 五线制，415V±10% 3 相 50HZ，
或三相四线制。
Main power supply: three-phase, A 、 B 、 C 、 N 、 PE five wires,
415V±10% three-phase 50HZ or three-phase four wires.
b. 在停电情况下的保护：
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Protection under power-off state
控制系统在电源停电时，为了避免设备损坏或人身伤害，不允许设备运动执
行元件有任何运动；
To avoid equipment damages or physical injuries, not allow equipment
have any movement when control system has no power.
设备出现故障时，如传动站超载、张紧站因链条变化出现位移时、压缩空气
压力低时,设备应能立即停止运行，不允许设备运动部件有任何动作，故障排
除后，应由人工在本地控制柜启动系统。
If equipment have fault(like drive station overload, tension station
position change caused by chain variation, low air pressure), they should
be stopped at once without any movement. Manually start system at
local control cabinet after fault has been solved.
设置在 P&F 线线体中的工位操作箱、道岔操作箱上的紧急停止按钮被操作
时，设备应能立即停止运行，不允许设备运动部件有任何动作，操作箱上的
紧急停止按钮释放后，P&F 线能够自动运行。
When E-stop button of work station operation box in P&F line, track
switch operation box have been pushed, conveyor should stop at once
without any movement. P&F line will auto-run after E-stop button has
been released.
c. 互锁保护:
Interlock Protection:
在前后动作逻辑关系的各应用单元间必须具有可靠的互锁关系，前后不能产
生误操作，以免产生危险；
Operation units that have logical relation must have reliable interlock to avoid dangers caused by incorrect operation.
无论自动或手动方式各应用单元内部的前后动作顺序也应有互锁；
Whether under manual or auto mode, movement sequence of each
operation unit should also have interlock.
点对点联锁,必要时进行数据传输联锁；
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Point-to-point interlock, data transmission will be interlocked if necessary.
输送线上所有电机与主控联锁，任一电机出现故障，能向本地控制柜提供报
警信号；
All motors in conveyor is interlocked with main control system, any of
them has fault, alarm signal will be sent to local control cabinet.
有气动控制的设备，必须有气压保护装置；
Those equipment with pneumatic control must have pressure protection
device
输送线与各设备之间的相关联锁；
Mutual interlock among conveyor line and each equipment
故障保护联锁；
Fault protection interlock
手动时安全联锁；
Safety interlock under manual mode.
运动部件的极限保护等。
Moving parts limit protection, etc.
11) 绝缘强度和绝缘阻抗
insulation strength and insulation resistance
设备安装接线完毕，交流外部端子对地绝缘电阻不小于 10MΩ。
Resistance between outer AC terminal and ground should not less than
10 MΩ after equipment has been installed and wired.
12) 抗干扰能力
Anti-interference Capacity
电气设备均有足够的抗电磁辐射能力；
All electric equipment have enough anti-electromagnetic radiation
capacity.
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电控系统及元件必须能够适应工厂电网上的电压波动和脉冲干扰。
Electric control system & elements must adapt voltage pulsation & pulse
interference from plant power net.
11、输送机系统机电调试及联动试车
Conveyor System Mechanical-Electrical commissioning & Associated Trail
1) 输送机系统机电调试准备：
Preparations for Conveyor System Mechanical-Electrical commissioning
a. 全线检查钢结构的安装质量，如有欠缺予以加固。
Check all steel structures installation quality, strengthen at where needs.
b. 全线检查气路系统的安装质量，如有欠缺予以整修。
Check pneumatic unit installation quality, repair at where needs.
c. 全线检查电控系统的安装质量，对I\O点的正确性进行校验，使之完全符合图
纸要求。
Check installation quality of electric control system, verify accuracy of I/O points to make them under drawings requirements.
d. 仔细检查驱动装置超载检测开关、张紧装置双向限位检测开关、压缩空气压
力检测开关和急停按钮的动作可靠性。
Check movement reliability of drive unit overload detecting switch, tension unit dual-direction limit detecting switch, compressed air pressure detecting switch, E-stop switch.
e. 用一组积放小车全线检查积放直轨、弯轨、道岔的接口尺寸，如有卡阻予以
整修。
Use a set of P&F trolley assembly to check connection gap size of P&F straight, curve, track switch. If there has jam, repair at where needs.
f. 积放轨道的承载轨踏面全部予以彻底清理干净，加注适量的润滑脂。
Working surface of free track must be cleaned completely, add proper amount of lubricating grease.
2）按下式确定装入输送机轨道的车组吊具数量:
Confirm trolley assembly amount with hook based on following equation:
线路长度/平均车距＋工位数X2=调试用最少车组数
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Line length/average space between trolley assemblies+work stationX2=least trolley assembly amount for commissioning
3）输送机系统机电调试：
Conveyor System Mechanical-Electrical commissioning:
输入PLC控制程序，启动输送机系统，牵引链和车组吊具进入程序运行状
态。输送机系统调试过程中，必须多人多处认真观察：
Input PLC control program, start conveyor system, power chain and trolley assembly with hook is in program-contrlled running state. In the course of commissioning, must have enough people to observe carefully at different places.
a. 牵引链和车组吊具运行状况，如有卡阻紧急停车。
If power chain and trolley assembly with hook jam at somewhere, stop immediately.
b. 停止器、分支道岔、夹紧器、张紧装置的动作情况，如有问题及时处理。
If stop unit, diverge track switch, clamp unit, tension unit have any problem, deal with it immediately.
c. 驱动装置的运行状况、噪音及温升情况，如有异常及时处理。
If drive unit has any problem, deal with it immediately.
4）调试过程中出现的问题及时处理后，输送机系统应程序运行24小时无故障。
After problems occurred in commissioning have been solved, conveyor system should run 24 hours with no fault.
5）输送机系统和相关工艺设备的联动热负荷试车：
Associated trail of conveyor system and related process equipment:
a. 配合相关工艺设备的电气人员建立 P－F 线与集卷站的运卷小车、打捆
机、称重装置、卸卷机的电气联机信号。
Help electric personnel of related process equipment eatablish online signal from P&F line to coil vehicle, compactor, wrighing scale, unloader of coil reform station.
b. 启动输送机系统，牵引链和车组吊具进入联机后的程序运行状态。联动热
负荷试车过程中，必须认真观察相关工艺设备的动作和输送机相关部件的
动作是否协调一致，如有问题及时处理。
Start conveyor system, power chain and trolley assembly with hook are in program running state. In the course of associated trial, must carefully obverse whether the movement of process equipoment and conveyor related parts are harmonious and consistent. Deal with problem if threr
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has any.
6）联动热负荷试车过程中出现的问题及时处理后，输送机系统应程序运行24小
时无故障。最终使控制程序达到P－F线的设计要求。
After problems occurred in associated trial have been solved, conveyor system should run 24 hours with no fault. Finally insure that contrl program will achieve design requirements of P&F line.
承德金龙输送机制造有限公司
Chengde Jinlong Conveyor Manufacture Co.,Ltd.
