GB/T 4652-2003 Test methods for rock loaders and loaders for underground mining
Some standard content:
This standard replaces GB/T4652-1984 "Test Methods for Double-arm Loaders". Compared with GB/T4652-1984, the main changes in this standard are as follows: GB/T4652--2003
adds the test content and test methods for underground mining rail-wheel bucket rock loaders, shovel loaders and crawler claw loaders, so the name of the standard is changed to "Test Methods for Underground Mining Rock Loaders and Loaders"; cancels the conventional test content and test methods of components such as the no-load running resistance of the whole machine and the pressure and settlement of the working cylinder in the original standard;
- Added the inspection content of the longitudinal and lateral stability of the loader;- Canceled the various test statistical record forms in the original standard;- Canceled the Appendix A in the original standard that has no practical significance. This standard is proposed by the China Machinery Industry Federation. This standard is under the jurisdiction of the National Technical Committee for Standardization of Mining Machinery (CSBTS/TC88). The drafting unit of this standard: Luoyang Mining Machinery Engineering Design and Research Institute. The main drafters of this standard are: Yang Xianli, Guo Ming, Huang Jialin, Huang Lida, Li Liuquan. 1
1 Scope
Underground mining rock loaders and loaders
Test methods
GB/T 4652--2003
This standard specifies the test contents and test methods of underground mining rock loaders and loaders, including the whole machine performance parameter test, load test and industrial test.
This standard applies to the factory test, type test and industrial test of rail-wheel bucket rock loaders, shovel loaders and vertical claw loaders, as well as crawler-type double-arm (crab claw) loaders and vertical claw loaders (hereinafter collectively referred to as loaders). This standard does not apply to underground mining bucket rock loaders, loaders and shovel loaders. 2 Normative references
The clauses in the following documents become the clauses of this standard through reference in this standard. For all referenced documents with dates, all subsequent amendments (excluding errata) or revisions are not applicable to this standard. However, the parties who reach an agreement based on this standard are encouraged to study whether the latest versions of these documents can be used. For all referenced documents without dates, the latest versions are applicable to this standard. GB/T6375 Test method for traction of earth-moving machinery (eqvISO7464) GB/T8419 Test method and limit for vibration of driver's seat of earth-moving machinery (neqISO7096) GB/T8499
Method for determining the center of gravity of earth-moving machinery (idtISO5005) GB/T8591 Calibration points of driver's seat of earth-moving machinery (eqvISO5353) GB/T10913 Determination of driving speed of earth-moving machinery (eqvISO6014) GB/T16710.3 Determination of noise at the driver's position under stationary test conditions of construction machinery GB/T16710.5 Determination of noise at the driver's position under dynamic test conditions of construction machinery (eqvISO6396) JB/T 3683
3 Comfort zone and reach range of construction machinery operation JB/T5503 Vertical claw loader
3 Terms and definitions
The following terms and definitions apply to this standard. 3.1
Stationary state
The loader has not started the power source, the bucket mechanism or working mechanism (such as shovel board, etc.) is in the original state, the tail of the conveyor is in the lowest position, and its center line is in the same vertical plane as the center line of the loader. 3.2
Preparatory state of operation
The loader is fully run-in according to the requirements of the instruction manual, and all mechanisms or systems are in good condition, and the power source is connected. 3.3
Operating state
Start the power source, and the loader operates under the control of the operator. 4 Test conditions and preparations before the test
4.1 Technical preparation requirements
GB/T4652-2003
Before the test, the tester should: check the completeness and correctness of the technical documents and instruments, tools, accessories, and spare parts; conduct an appearance inspection of the test prototype;
measure the wearing parts;
Check the power source to ensure that the test is carried out at the rated voltage or air pressure; check the no-load working capacity of the test prototype; check the preparation of the test site, materials, and test instruments, and make predictions. 4.2 Requirements for preparation of technical documents
The loader to be tested shall have the following technical documents: design brief;wwW.bzxz.Net
instruction manual;
product standard;
complete set of drawings:
a list of test instruments, tools, accessories and spare parts; a list of inspections of major parts and components;
original commissioning records of the loader;
a report on the test results of major parts and components. 4.3 Requirements for test sites
4.3.1The test prototype shall be tested on a test bench (site) or on site in a similar actual working condition that can meet the product performance requirements. 4.3.2For rail-wheel loaders, the track laying conditions (gauge, slope and turning radius, etc.) shall be compatible with the test prototype. 4.3.3 For crawler loaders:
The static and stationary test sites shall be hard, solid and flat ground paved with concrete or other materials; the walking and traction test sites shall comply with the relevant provisions of GB/T6375; the climbing and stability test sites shall be hard, solid ground paved with concrete or other materials, and the slope shall be 3° greater than the allowable slope of the loader.
4.4 Power quality requirements
During the test, the power delivered to the loader: the AC voltage limit deviation is ±5%, the AC frequency limit deviation is ±1%; the compressed air shall be filtered, and its pressure deviation range is -5% to +20% of the rated value, and not less than 0.5MPa. 4.5 Test tools and accuracy requirements
4.5.1 The instruments, meters and other measuring tools used for the test shall be checked and calibrated for effectiveness before and after the test, and the performance and error shall comply with the provisions of the relevant standards. The conversion element shall be calibrated before and after the test, and its deviation shall be within the specified range. 4.5.2 The accuracy of the measuring tool shall be adapted to the requirements of the measured items, and the measuring accuracy shall meet the following requirements: size is 1 mm;
mass is 1% of the measured object;
-time is 0.1S;
operating force is 1N;
traction force is 2% of the measured object;
angle is 1°.
4.6 The test shall comply with the corresponding safety technical requirements, and necessary technical maintenance shall be carried out in accordance with the provisions of relevant technical documents. 5 Machine performance parameter test
5.1 The bucket volume shall be measured by filling the bucket with dry sand. When measuring, the bucket shall be placed at an inclination angle of 2
of 60° to the horizontal plane of its bottom plate, and the sand shall be piled up into a peak shape with a natural repose angle at each edge of the bucket mouth. 5.2 The overall dimensions of the loader shall be checked separately in the static state and the working state. GB/T4652--2003
5.2.1 The length and width shall be measured from the most protruding point (excluding the pedals) on the longitudinal and transverse planes of the loader respectively. 5.2.2 Height measurement:
- Height in static state: measure the distance between the highest point of the loader body and the track surface (for rail-wheel type) or the ground plane (for crawler type);
- Height in working state: measure the distance between the highest point of the loader body and the track surface or the ground plane when the loader is working. 5.3 Unloading height measurement:
- For direct unloading bucket rock loaders, when the bucket is in the rearmost position of unloading, measure the distance between the lowest point of the bucket teeth and the track surface;
- For shovel loaders, double-arm loaders and claw loaders with conveyors, when the transfer conveyor is in the upper and lower unloading positions, measure the distance between the lowest point of the tail of the transfer conveyor and the track surface (for rail-wheel type) or the ground plane (for crawler type). 5.4 Loading width measurement:
For rail-wheel loaders, when the bucket, crab claw or vertical claw is in the extreme left position and the extreme right position, measure the distance between the two corresponding points on the outermost side of the bucket, crab claw or vertical claw (see Figure 1); for crawler loaders, the loading width in the stationary state should be measured. Figure 1 Schematic diagram of loading width
5.5 The grabbing width, grabbing height and grabbing depth of the vertical claw loader should be measured in accordance with the relevant provisions of JB/T5503. 5.6 Determination of the movement speed of the scraper chain of the loader's transport mechanism: Put a mark on the scraper chain, measure the time it takes for the scraper chain to circulate once under no-load conditions, and calculate its movement speed.
5.7 The mass of the loader should be measured by weighing in the working preparation state. The mass of the loader can also be measured by weighing the various components of the loader.
5.8 Crawler loader ground contact pressure measurement: After measuring the mass of the loader, use formula (1) to calculate the average ground contact pressure of the crawler loader:
P = 0. 098G/(2 × BL)
Where:
P—average ground contact pressure, in megapascals (MPa); G—loader mass, in kilograms (kg); B—track width, in centimeters (cm); L—track contact length, in centimeters (cm). (1)
5.9 The center of gravity position of the loader should be measured in accordance with the relevant requirements of GB/T8499 when it is stationary. At the same time, the longitudinal and lateral stability of the loader under empty and working conditions should also be verified. 5.9.1 The longitudinal stability of the loader should be checked on an inclined site in both uphill loading and downhill loading directions (see Figure 2). Slope of the test site:
-For rail-wheel loaders, it should be greater than the allowable slope of 1°; -For crawler loaders, it should be greater than the allowable slope of 3°. Uphill loading
Figure 2 Schematic diagram of loader longitudinal stability inspection Downhill loading
5.9.2 The lateral stability of the loader should be evaluated under the following working conditions when it is stationary and working: -For direct unloading bucket loaders, it should be carried out when the working mechanism is loaded in the extreme left and extreme right positions; for shovel loaders, double-arm loaders and claw loaders with conveyors, it should be carried out when the working mechanism is rotated to the left or right to the extreme position and the conveyor is also rotated to the extreme position in the direction of the working mechanism (see Figure 3). 1-Working mechanism;
2-Transfer and transportation mechanism.
Figure 3 Schematic diagram of lateral stability inspection of loader with conveyor 5.10 The travel speed of the loader shall be measured on the horizontal track (for rail-wheel type) or the ground plane (for belt type) in accordance with the relevant provisions of GB/T10913.
5.11 The traction test of crawler loader shall be carried out in the working state in accordance with the relevant provisions of GB/T6375. 5.12 The braking performance shall be inspected on a site with a slope that meets the requirements of 5.9.1. When the loader is driving downhill in normal driving state, the braking distance does not exceed the specified value from the time the travel motor or pneumatic motor is turned off, and the braking is considered to be effective. 5.13 Loader maneuverability inspection
5.13.1 Ground clearance measurement
The ground clearance is determined by measuring the distance from the track surface (for rail-wheel type) or the ground plane (for crawler type) to the lowest point of the machine body. 5.13.2 Turning radius measurement
The crawler loader turns in situ at the maximum steering angle on the walking and traction test site. The measured distances from the turning center axis to the center line of the outer crawler track and the distance from the turning center axis to the outermost point of the loader body are the minimum turning radius of the crawler track and the minimum turning radius of the loader (see Figure 4). During measurement, the turning angles of the working mechanism and the transport mechanism should ensure that the body width B is minimum. 1——Working mechanism;
2—Transfer and transport mechanism.
Figure 4 Schematic diagram of the minimum turning radius measurement of the loader GB/T4652—2003
5.14 Determination of the driver's operating range: Based on the driver's seat calibration point specified in GB/T8591 (the driver's standing point for those without a seat), draw the side view, front view and top view coordinate diagrams of the relative positions of each control device according to a certain proportion, and compare them with the relevant contents of JB/T3683 to assess whether they meet the comfortable operating area and reach range. 5.15 The vibration at the driver's operating position shall be measured in accordance with the provisions of GB/T8419 under working conditions. 5.16 The noise at the driver's operating position shall be measured in accordance with the methods specified in GB/T16710.3 and GB/T16710.5 when the machine is running without load.
5.17 The operating force of the operating device shall be measured by a dynamometer or a pressure gauge under working conditions to determine the maximum operating force of the full operating stroke. 5.18 For loaders with built-in light sources, use an illuminance meter to measure the illumination in the loading area, unloading area and operating position respectively. 5.19 For the explosion-proof performance of flameproof loaders, tests shall be carried out in accordance with the provisions of relevant standards. 6 Load test
6.1 The loader shall be subjected to a load test on the test bench or test field of the manufacturer. 6.2 The hardness (Professor's coefficient f), blockiness and loose density of the material to be loaded by the test sample shall be similar to the properties of the ore and rock specified to be loaded by the loader. During the test, the material stacking should imitate the actual operation site, the material stacking width should not be less than the loading width of the prototype, and the stacking height should be 1.5m~2m.
6.3 For the prototype subjected to load test under the specified use conditions, the total amount of ore and rock continuously loaded each time: for bucket loader, it should be not less than 15m; for shovel loader, it should be not less than 60m2;
for double-arm loader and vertical claw loader, it should be not less than 200m. 6.4 Determination of technical productivity: On the horizontal track (for rail-wheel type) or on the ground (for crawler type), the loader working mechanism and the conveyor are arranged along the center line of the machine to continuously load loose ore and rock, and the total amount of ore and rock loaded per unit time is measured and converted and determined. 7 Industrial Test
7.1 The test contents include the reliability of the loader, the productivity and energy consumption, the stability of the performance of the main components, the comfort of the driver, the convenience of technical maintenance, the sensitivity of the working mechanism, and whether the disassembly, transportation and assembly of the whole machine are suitable for the requirements of the mine shaft and tunnel working environment.
7.2 Test requirements
7.2.1 The weak links should be fully exposed and eliminated during the factory and load tests, and the industrial underground loading test can be carried out after further assessment of the various performances of the loader.
7.2.2 The underground loading test should be carried out on the site of use, and the hardness (Praeter coefficient f), block size and loose density of the loaded ore rock should not be less than 5
GB/T 4652—2003
Requirements for loader design.
7.2.3 If a fault occurs during the test and the test is stopped, the fault should be eliminated, the cause should be found and measures should be taken, and the test should continue until all the specified test contents are completed. 7.2.4 Whether the test prototype complies with the requirements of safety regulations, industrial hygiene and labor protection, the suitability of the lighting and sound signal devices, the reliability of the locking device, the safety of the protective covers of the rotating, moving and conductive parts, and the grounding device should be tested through the operation of each assembly component and the entire machine.
7.3 Test rock loading
The total rock loading Q completed by the industrial test should not be less than the estimated value of formula (2), of which the underground rock loading should not be less than 80% of the total. During the test, except for normal wear, repair, maintenance and adjustment, the main parts of the loader shall not be replaced, otherwise the test should be recalculated.
QH ≥ K: × Ar × 104
Where:
QH——the specified value of the total amount of ore and rock loaded, in cubic meters (m3); (2)
K;——operating condition coefficient, for loaders working in cycles, K0.3; for loaders working in continuous mining, K,=1.2; for loaders working in continuous excavation, K;=0.7;
Ar—technical productivity of loader, in cubic meters per minute (m2/min). 7.4 Technical and economic indicators and evaluation of whole machine performance 7.4.1 In order to determine the technical status after the test, the loader should be disassembled and inspected within the scope specified in the test outline. The causes of fracture and defects of machine parts should be determined through part inspection and analysis of working conditions, and, if necessary, through experimental inspection of materials and inspection of manufacturing quality. The processability of machine manufacturing and repair should be evaluated based on the complexity of the part structure, universal indicators, and the difficulty of assembly, disassembly and adjustment during use and maintenance. 7.4.2 In order to determine the technical and economic indicators of the loader, the loading volume, failures, repairs, maintenance and other conditions should be observed daily and hourly during the industrial test. The observation time should not be less than 100 hours, and the observation results should be statistically recorded. 7.4.3 At the end of the observation, the performance indicators such as the availability K1, operation rate K2, mean time between failures T, actual use productivity Qm and energy consumption ratio A of the loader should be calculated according to formula (3) to formula (7). K, = [To/(T.+T)X100%
Where:
K, - availability (reliability coefficient), unit is percentage (%)); T. - loading operation time of the test sample, unit is hour (h); T, - downtime due to failure, unit is hour (h). K2 = ET./(T.+T +T2)J×100%
Wherein:
K——operation rate (time utilization coefficient), in percentage (%); T.——Maintenance and auxiliary operation time related to the prototype, in hours (h). T To /ne
Where:
Mean time between failures (mean time between failures), in hours (h); T.
ng———Number of failures.
Where:
Qm =- W./T
Qm—-——Actual productivity, in cubic meters per hour (m/h); W—Total amount of ore and rock loaded, in cubic meters (m\); T—Time used to load the total amount of ore and rock, in hours (h). 6
·（3）
（4）
Wherein:
GB/T4652---2003
A Energy consumption ratio (electricity consumption ratio or compressed air consumption ratio), electricity consumption ratio unit is kilowatt-hour per cubic meter (kWh/m); compressed air consumption ratio unit is cubic meter per cubic meter (m2/m2); E—the amount of electricity and compressed air consumed for the total amount of ore and rock loaded, in units of kilowatt-hour (kWh) and cubic meter (m2) respectively. 8 Test results
After the whole machine performance parameter test, load test and industrial test are all completed, all test results should be sorted, analyzed and concluded, and the corresponding test report should be compiled according to the relevant requirements of factory test, type test and industrial test to form a formal test document.
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