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GB/T 35060 consists of the following four parts under the general title General specification of shearer:
——Part 1: Complete machine;
——Part 2: Cutting transmission unit;
——Part 3: Haulage driving unit;
——Part 4: Electric control system.
This part is Part 2 of GB/T 35060.
This part is developed in accordance with the rules given in GB/T 1.1-2009.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. The issuing body of this document shall not be held responsible for identifying any or all such patent rights.
This part was proposed by and is under the jurisdiction of China Coal Industry Association.
General specification of shearer - Part 2: Cutting transmission unit
1 Scope
This part of GB/T 35060 specifies the requirements, test methods, inspection rules, as well as marking, packaging, transportation and storage of the cutting transmission unit of shearer for the underground coal mining working face.
This part is applicable to the cutting transmission unit of shearer used by longwall mining (hereinafter referred to as “shearer”).
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 3480.5 Calculation of load capacity of spur and helical gears - Part 5: Strength and quality of materials
GB/T 7233.1-2009 Steel castings - Ultrasonic examination - Part 1: Steel castings for general purposes
GB/T 9450 Steels - Determination and verification of the depth of carburized and hardened cases
GB/T 10111 Generation of random numbers and procedures applied to sampling inspection for product quality
GB/T 11352-2009 Carbon steel castings for general engineering purpose
GB/T 11354 Determination of nitrided case depth and metallographic microstructure examination for steel and iron parts
GB/T 11365 Accuracy of bevel and hypoid gears
GB/T 13306 Plates
GB/T 13384 General specifications for packing of mechanical and electrical product
GB/T 13924 Inspection code for accuracy of involute cylindrical gears
GB/T 35060.1 General specification of shearer - Part 1: Complete machine
JB/T 5000.10 Heavy mechanical general techniques and standards - Part 10: Assembly
JB/T 5943 Construction machinery - General specifications for welding parts
JB/T 8831 Methods for oil selection of industrial enclosed gears
JB/T 9172 Gear nitriding and nitrocarburizing process and its quality control
MT/T 784 DO type floating seals for winning machinery
3 Requirements
3.1 General requirements
3.1.1 The cutting transmission unit shall be manufactured according to the drawings and technical documents approved by prescribed procedures.
3.1.2 Raw materials used for manufacturing the cutting transmission unit shall meet the drawing requirements.
3.1.3 The model, specification and performance of standard parts and procured parts shall meet the design requirements.
3.1.4 Parts processed according to the design drawings shall pass the inspection.
3.2 Assembling requirements
3.2.1 The assembling shall meet the requirements of JB/T 5000.10.
3.2.2 The shell shall meet the following requirements:
a) the quality grade of steel castings meets the requirements of Grade II quality criteria specified in GB/T 7233.1-2009, Clause 5;
b) the surface quality of steel castings meets the requirements of GB/T 11352-2009, 4.5;
c) the quality of welding parts meets the requirements of JB/T 5943;
d) there is no viscous sand, welding slag, scrap iron, oil stain and other foreign matters in the shell;
e) the pressure-bearing shell and waterway pipeline are free from leakage after subjecting to the pressure test at a pressure that is 1.5 times of the rated pressure for 5min;
f) the shell used as oil tank shall not leak before assembly;
g) rust-proof treatment shall be carried out for the shell.
3.2.3 The gear shall meet the following requirements:
a) the gear materials and heat treatment quality shall be inspected according to GB/T 3480.5, GB/T 9450, GB/T 11354 and JB/T 9172;
b) the accuracy of involute cylindrical gears shall be inspected according to GB/T 13924;
c) the accuracy of bevel gears shall be inspected according to GB/T 11365;
d) the gear surface hardness, effective hardened layer depth, metallographic structure and machining accuracy shall meet the requirements of product technical documents.
3.2.4 The axial clearance of axle groups shall meet the requirements of product drawing documents.
3.2.5 The adopted DO type floating seals shall meet the requirements of MT/T 784.
3.2.6 All parts shall be cleaned and washed before assembly.
3.2.7 The selection of lubricating oil shall meet the requirements of JB/T 8831.
3.2.8 Fasteners shall be tightened according to specified torque.
3.3 Appearance requirements
The outer surface of the cutting transmission unit shall be smooth and free of sharp edges, flashes, burrs, cracks and other defects, and shall be sprayed (coated) with anti-rust primer according to the drawing requirements. The paint surface shall be uniform in thickness and firm in combination without peeling and falling off.
3.4 Performance requirements
3.4.1 Operation of clutch mechanism
The clutch mechanism shall be flexible in operation, full in stroke and reliable in action.
3.4.2 No-load running
The no-load running shall meet the following requirements:
a) operating stably without abnormal vibration, noise and temperature rise;
b) no leakage at each joint surface and seal;
c) no fastener looseness on each connection surface;
d) the turning direction of the output shaft meets the design requirements;
e) the output shaft speed meets the requirements of design (technical documents for supply).
3.4.3 Temperature rise
After continuous and stable running according to the test method specified in 4.2.4, there shall be no leakage at each joint seal, the maximum oil temperature in oil tank shall not exceed 100℃, and the maximum temperature rise shall not exceed 75K.
3.4.4 Overload
After loading at 125% of the rated power of the cutting (main) motor for 10min, the operation shall be stable, without violent vibration, abnormal noise and temperature rise.
3.5 Mass
The mass shall meet the design requirements, with an error not exceeding ±5%.
4 Test methods
4.1 Appearance inspection
Visual inspection.
4.2 Performance test
4.2.1 Test conditions
Install the cutting transmission unit on a test stand to close to the horizontal position. Inject oil into the oil tank according to the specified oil quality and level, and supply power and cooling water according to the design requirements (the water inlet temperature is not lower than 10℃). The turning direction of the output shaft shall comply with the technical documents.
Note: The “twin trawling test method” is allowed to be adopted, i.e. the output shafts of the left and right cutting transmission units of the twin-drum shearer are connected by couplings, the input shaft of the cutting transmission unit serving as the tested piece is connected with the cutting (main) motor or the test strand drive motor and the other cutting transmission unit serving as a companion test piece is in a speed- accelerating running state, and its input shaft end is connected with a test stand loading device. For the single-drum shearer, two cutting transmission units of the same model may be connected in the same way. The twin trawling test method may also be used to compensate for the loss of power in the mechanical closed test strand.
4.2.2 Test for operation of clutch mechanism
Operate the clutch mechanism for separation and reunion for 5 times.
4.2.3 No-load running test
After the cutting transmission unit operates without load continuously for 120min, observe the operation situation and leakage at each seal, and measure and record the temperature rise.
4.2.4 Temperature rise test
Operate the cutting transmission unit with load continuously at 50% of the rated power of cutting (main) motor for 60min, 75% of the rated power of cutting (main) motor for 60min, and 100% of the rated power of cutting (main) motor for 30min. In the process of operation, observe the operation situation and leakage at each seal, measure and record the oil temperature in oil tank and the ambient temperature.
4.2.5 Overload test
After the temperature rise test, load at 125% of the rated power of cutting (main) motor continuously for 10min.
4.3 Mass
Measure by conventional weighing method.
5 Inspection rules
5.1 Inspection classification
The inspection is classified into end-of-manufacturing inspection and type inspection.
5.2 End-of-manufacturing inspection
5.2.1 The cutting transmission units shall be subjected to end-of-manufacturing inspection one by one.
5.2.2 For the end-of-manufacturing inspection items, see Table 1.
5.2.3 If all the end-of-manufacturing inspection items are acceptable, the cutting transmission unit is regarded as passing the end-of-manufacturing inspection. If there is rejected item, the transmission unit is allowed to be repaired or readjusted for re-inspection. If the re-inspection result is acceptable, the inspection item is judged as acceptable.
Foreword i
1 Scope
2 Normative references
3 Requirements
4 Test methods
5 Inspection rules
6 Marking, packaging, transportation and storage
