Slewing bearings are critical components in large equipment like cranes, excavators, and wind turbines, enabling rotation and supporting significant loads. A robust replacement strategy is essential to minimize downtime, ensure safety, and optimize operational costs. This strategy involves a combination of proactive maintenance, condition monitoring, and a well-planned replacement or repair process.

Slewing Bearing Replacement Strategy for Large Equipment

I. Proactive Maintenance and Inspection (Preventive & Predictive)

The goal is to extend bearing life and predict failure before it happens.

Regular Lubrication:

Frequency: Follow manufacturer guidelines. This typically ranges from every 50-100 hours of operation for slow-moving equipment to every 8 hours for continuously rotating equipment.

Method: Add grease slowly while rotating the bearing to ensure even distribution and purge old, contaminated grease. Sufficient grease is applied when it overflows from the seal.

Type of Grease: Use heavy-duty, extreme-pressure (EP) grease as recommended by the manufacturer.

Gear Lubrication: If the slewing bearing has integrated gears, lubricate them separately as their requirements differ from the raceways. Apply small amounts of grease at the point of mesh.

Bolt Torque Checks:

Initial Check: After 100 hours of initial operation, re-check bolt torque.

Subsequent Checks: Every 300-500 hours, and more frequently in harsh conditions (vibration, shock).

Procedure: Wipe bolts clean, apply thread-locking adhesive if replacing, and tighten to the manufacturer’s specified pre-tension (often 70% of the bolt material’s yield limit). Use Q&T (quenched and tempered) washers; spring washers are prohibited.

Importance: Loose bolts can lead to uneven load distribution, localized stress, and premature failure.

Visual Inspections:

Frequency: At least weekly, or before each operation.

What to look for:

Cracks or damage on the slewing ring.

Signs of biting, gnawing, or surface peeling on gear teeth.

Integrity of seals: replace damaged seals promptly and reset any that have fallen off. Seals prevent contamination of the raceways.

Unusual noise or impact during rotation.

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Jaw crushers are robust machines essential for primary crushing in various industries, but like any heavy equipment, they can experience issues. Regular maintenance and prompt troubleshooting are key to minimizing downtime and ensuring efficient operation.

Common Jaw Crusher Issues and Their Solutions

1. Main Engine Suddenly Stops or Fails to Start

Possible Causes:

Crushing chamber/discharge port blockage: Material buildup can halt the machine.

V-belt issues: Loose, broken, or slipping V-belts.

Eccentric shaft bushing problems: Loose bushing can cause the eccentric shaft to get stuck.

Low voltage/insufficient motor power: Electrical issues can prevent the motor from driving the sheave.

Damaged bearings: Worn or damaged bearings can cause the machine to seize.

Fixes:

Clear blockages: Stop the crusher and remove any material blocking the discharge port or crushing chamber.

Check and adjust V-belts: Tighten loose V-belts or replace broken ones.

Reinstall/replace bushing: If the eccentric shaft bushing is loose, reinstall or replace it.

Adjust voltage: Ensure the working voltage meets the motor’s requirements.

Replace bearings: If bearings are damaged, replace them.

2. Reduced Crushing Capacity / Output Does Not Meet Standards

Possible Causes:

Incorrect feed size: Material fed into the crusher is too large, causing clogging.

Worn jaw plates: Worn or unevenly worn jaw plates reduce crushing efficiency.

Improper settings: Incorrect eccentric speed, stroke length, or discharge opening settings.

Clogged discharge chute: Material buildup in the discharge chute can cause back-pressure.

Incorrect relative position of jaw plates: The tooth grooves of the movable and fixed jaw plates are misaligned.

Voltage too low: Insufficient power to the motor.

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Overheating in a cone crusher is a common issue that can lead to significant downtime and costly repairs. It usually indicates an underlying problem that needs to be addressed promptly.

Cone Crusher Overheating Causes and Solutions

I. Lubrication System Issues (Most Common Cause)

Poor Quality or Insufficient Lubricating Oil:

Cause: Using incorrect oil viscosity, old/degraded oil, or having low oil levels. Contaminated oil (with water, fine mud, or impurities) significantly reduces its lubrication effectiveness and can cause abnormal wear.

Solution:

Regularly check the oil level and top up as needed.

Replace lubricating oil according to manufacturer specifications and maintenance schedules.

Ensure the correct type and viscosity of oil are used for the operating conditions (consider synthetic oil for extreme temperatures).

Analyze fluid samples regularly to detect contaminants and degradation.

Clean the oil tank and replace the oil if contaminated.

Clogged Oil Lines or Cooler:

Cause: Blockages in return pipes, oil grooves, or the cooler itself, leading to poor oil circulation and heat dissipation.

Solution:

Check for blockages in all lubrication lines and the cooler.

Clean the cooler and all tubing/oil grooves thoroughly.

Ensure the cooling water supply is sufficient and at adequate pressure.

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A lining trolley plug steel template, also often referred to as a tunnel lining steel formwork or shutter, is a specialized piece of equipment crucial for constructing the inner lining of tunnels and other underground structures. Its primary applications revolve around ensuring the precise shape, dimensions, and quality of concrete linings.

Lining Trolley Plug Steel Template Application

Tunnel Construction (Primary Application): This is the most significant area of application.

In-situ Concrete Lining: For tunnels where the concrete lining is cast directly in place, large steel formwork systems mounted on trolleys are used. These trolleys move incrementally as the tunnel progresses, allowing for continuous concrete pouring and curing.

Precast Segment Manufacturing: For tunnels built with precast concrete segments (common in TBM tunneling), custom steel molds (templates) are used in factory settings to produce each segment with high precision. These segments are then transported to the tunnel site and assembled.

Various Tunnel Shapes: These templates are custom-designed for different tunnel geometries, including circular, horseshoe-shaped, egg-shaped, or other irregular cross-sections.

Culverts and Other Underground Sections: Beyond tunnels, these steel templates are also used for concrete linings in:

Culverts: Structures that allow water to flow under roads, railways, or embankments.

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Choosing the appropriate motor power for a tunnel lining trolley is crucial for efficient and safe operation. It involves considering various factors related to the trolley’s function, the tunnel’s characteristics, and the concrete lining process.

Tunnel Lining Trolley Motor Power Selection

1. Functions of the Tunnel Lining Trolley and Associated Loads:

A tunnel lining trolley typically performs several tasks, each requiring specific power:

Traveling/Movement: This is the primary function. The motor needs to overcome:

Rolling resistance: Friction between the wheels and the tracks.

Grade resistance: If the tunnel has an incline (crawling ability).

Acceleration torque: The force needed to start and increase the speed of the trolley.

Total weight of the trolley: This includes the steel formwork, hydraulic system, concrete if present during movement (though usually it’s poured after positioning), and any auxiliary equipment or personnel.

Short-distance movement: For precise positioning, motors need to provide accurate control.

Hydraulic System Operation: Most modern lining trolleys use hydraulic cylinders for various operations:

Lifting and lowering the formwork: This involves overcoming the weight of the formwork and the concrete pressure during pouring.

Opening and closing side templates: For demolding and adjustment.

Horizontal and vertical adjustments: For precise alignment.

Vibrating concrete: Some trolleys have attached vibrators to ensure proper concrete compaction. The hydraulic pump motor needs sufficient power to drive these cylinders and vibrators.

Auxiliary Functions:

Lighting: For visibility within the tunnel.

Control systems: Power for the electrical and electronic components.

2. Key Factors Influencing Motor Power Selection:

Trolley Specifications:

Length and weight of the trolley: Longer and heavier trolleys require more power for movement and lifting.

Maximum lining length per unit: This indicates the scale of the operation.

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