Apron feeder is a kind of feeding equipment with strong impact resistance, which is applied in industries such as mining, building materials, cement, chemical engineering and metallurgy. It is mainly composed of heavy-duty pan, usually in two forms: Casting and welding. The materials installed on the tank chain are received and the pan and materials are driven forward by the sprocket to achieve the purpose of feeding. In dealing with complex and harsh working conditions, due to the extremely strong impact of large pieces of materials, they are prone to cause damage to the pan and the frame. Therefore, our company has designed impact rails on heavy-duty apron feeders to absorb impact energy, disperse load pressure, and protect key components. Through the synergistic effect of mechanical buffering and structural optimization, impact rails play a key role in the following scenarios:
1. Initial falling stage of materials: Withstand the direct impact of high-level materials from the silo or loading equipment (such as excavators) (the impact force can reach 20-50 kn/m²);
2. During the continuous feeding process: Alleviate the dynamic friction and impact between the chain plate and the material, and avoid local deformation caused by stress concentration;
3. Under special working conditions: For instance, when handling frozen blocks or sticky materials, the additional load caused by material adhesion is offset through elastic deformation.
The mechanical effect of the impact rail:
impact rails usually adopt a multi-layer composite spring structure (as described in the "Composite spring" Design), converting the instantaneous impact kinetic energy into potential energy through the elastic deformation of the springs. Take a certain model of heavy-duty apron feeder as an example. Its impact rail can absorb approximately 60%-75% of the impact energy, significantly reducing the peak impact transmitted to key components such as the main shaft and sprocket (measured data show that the impact load on the main shaft bearing increases by more than 200% without the impact rail configuration).
Through the combination of the i-shaped steel structure frame and the buffer components (such as the described welded i-beam), the point-like impact force is transformed into a planar distributed force. In the apron feeder, the load dispersion efficiency of the impact rail can reduce the force per unit area of the chain plate to one-third of the original value. The impact rail can effectively attenuate mechanical vibrations within the range of 6-15 hz and avoid resonance phenomena. Comparative tests show that the vibration amplitude of the feeder equipped with a impact rail is reduced by 40% to 60% during operation. The function of the apron feeder impact rail:
Extend the service life of the equipment
After installing the impact rail, the service life of the chain plate was extended from 6 months to 18 months, and the replacement cycle of the main shaft bearing was extended from 3 months to 1 year. After adding support wheels in the middle of the feeding plate, the average annual failure downtime of the equipment was reduced by 72%.
When handling extremely large frozen blocks, the impact rail ensures that the wobbility of the chain plate during operation is controlled within ± 5mm (the national standard requires ≤ 15mm). Under the inclined installation condition (up to 25°), the anti-slip tooth structure of the impact rail reduces the material slip rate to less than 3%. The replacement cost of the worn parts (spring groups, slide liner plates) of the impact rail is only 1/4 of the maintenance cost of the traditional impact plate.
Through modular design, the overall replacement time of the impact rail has been shortened from 16 hours to 4 hours.
The above is a detailed introduction to the function and efficacy of the apron feeder impact rail. We are a manufacturer specializing in the supply of apron feeders. Our products are distributed in indonesia, russia, vietnam, mexico, colombia, kenya, mongolia, france and other parts of the world, and have received unanimous praise from domestic and foreign customers. They have a large output volume. It has the advantages of strong impact resistance, no material blockage or leakage, etc. Customers from all over the world are welcome to visit and tour our company.