With the continuous expansion and extension of China's traffic road network, the construction equipment of the road is constantly developing and improving. In the construction of high-grade roads, asphalt concrete is increasingly used by road designers as a surface layer, and the asphalt mixing plant has taken on the mission of producing asphalt concrete.
The speed of road construction is accelerating, and small and medium-sized asphalt mixing buildings can no longer meet the needs of road construction. The asphalt mixing plant building with a production capacity of 120t/h 10 years ago has gradually smashed the stage of market competition. Instead, it has been the high-speed asphalt mixing station of 360t/h and 400t/h, and they have gradually become the mainstream products in the market.
2, mixing station installation
As the output of the asphalt mixing plant increases, the structure of each part increases accordingly. As a large-scale machine, the foundation and equipment installation of the mixing station should be highly valued.
2.1 Basic and equipment installation
Asphalt mixing plant in the construction process, industrial noise and dust generation is difficult to avoid. While selecting the site and considering the size of the mixing plant site, we must pay attention to the asphalt building should be as far away as possible from the residential areas and farmland, to avoid the noise and dust pollution caused by the mixing station affecting the residents' lives. The second consideration should be the resource factors such as electricity and water resources.
According to the geological conditions, we choose to divide the site of the asphalt mixing station into two types: soft foundation and solid ground. Generally, the ground has a hard soil quality. After the depth of the excavation, it is only necessary to carry out the general bunking treatment of the bottom layer, and then the concrete construction can be carried out; The quality of the base, after the excavation and excavation, must carefully examine the degree of filling after excavation, and then choose different treatment processes to carry out the foundation bottom foundation reinforcement. Generally, the plum blossom piles, the vibration protection cylinders, etc., or the base area of ​​the bottom are increased to increase the bearing capacity of the foundation, and the purpose of preventing the hidden dangers of the mixing equipment and production due to the cracking or sinking of the foundation in the future. In the production, the vibrating screen, the stirring tank and the aggregate drying cylinder of the main part of the asphalt mixing building are strong components of the whole set of equipment to generate vibration. When carrying out the foundation construction, we should pay special attention to the basic pouring of the main building part and the aggregate drying cylinder part, so as to prevent hidden dangers caused by human factors such as cutting corners during construction and the lack of flatness requirements. Long-term mechanical resonance can cause mechanical fatigue of a high-strength screw of M30 and break straight. Therefore, when we install the foundation, we must ensure that the same horizontal plane of the foundation does not exceed the range of ±2cm of the elevation, and the damage caused by the resonance of the equipment is reduced to small.
After many equipment disassembly practices, we believe that the following installation procedures are more feasible:
Centering on the main building, it is installed on three sides, so that when the large items are vacated, the lifting task of the large crane can be ended in a short period of time, and the installation cost can be saved. In addition, the mixing building is installed. The order required is to be installed as required.
2.2 Cable installation
The output of the mixing plant has been continuously improved, and the power consumption of the whole machine has also increased. Now it generally reaches 600 kW to 1000 kW. The power supply line has a large cross-sectional area. In addition to the control components and control lines, cable trench grooving is generally used. We carefully check the cable for damage before wiring, to avoid short circuit or open circuit. When installing high-power motor cables, be sure to use a self-adhesive high-pressure tape to wrap the terminals to prevent the motor vibration terminals from being short-circuited after the tape is worn through the tape to avoid the danger of burning the motor. In the control system circuit, the signal screen cable must be connected in strict accordance with the requirements to reduce the impact of external electromagnetic interference on the control system. At the same time, the line should pay attention to concealment and protection, and make safety warning signs. The circuit should be as far away as possible from the oil circuit and high temperature and humidity areas to reduce the corrosion and aging of the wires. In the wiring process, if you encounter some ambiguous lines that you can't see clearly, don't care. If you take the wrong line, you may burn the electrical components. Zui is good to put it down first. After debugging to the part of Zui, check the circuit carefully, check the leaks, and improve one by one.
3, production personnel supporting the management of the asphalt mixing plant in addition to the main building, storage, powder supply, asphalt supply, aggregate supply, control system, dust removal system seven systems, there are many system-affiliated components, once one of the components have problems There is a possibility of paralysis in the entire asphalt mixing plant. Such a large number of systems and components require a variety of personnel with a certain level of maintenance to ensure the normal operation of the mixing building. After trying out the team combination of several teams, we optimized the personnel of each class to achieve the purpose of effectively maintaining production while controlling the crew structure too bloated.
The optimized staff structure is as follows (two shifts):
Webmaster: Responsible for the overall coordination of the various relationships between the mixing building and the external department, including reporting and summarizing the work to the next level;
The squad leader: needs to have a certain ability of reading and writing in English, has a certain degree of knowledge and coordination of automation control, and is proficient in operating equipment;
Operator: Understand basic mechanical principles, have basic electrical welding repair skills, and operate the skilled mixing equipment;
Electrician: With the operation certificate of generator operation, master the principle of strong electric power and electric drag control;
Coordinator: Have a certain basic mechanical knowledge, understand the workflow of the mixing building, cooperate with equipment management, and have a high sense of responsibility and enthusiasm;
4. Production technology management
The asphalt mixing plant control system is generally completed by the working server as the terminal industrial computer and PLC. The degree of automation is high. In the production process, the machine operator should operate the machine strictly according to the operating instructions, prohibit unlicensed unlicensed employment, illegal start and stop. The server works.
Before production, the crew on duty should carefully check the lubrication of the bearings in each part, whether the oil circuit leaks, whether the protection switches and manual valves are in the correct position, whether the asphalt pump is warm enough, and whether the system parameters are within the allowable range. After the safety is prepared, the machine can be started and the machine can be warmed up.
In order to save costs, heavy oil is generally used as the energy material to heat the aggregate. However, since the heavy oil itself does not have the characteristics of normal temperature ignition, it must be fueled by diesel before the preheating machine, and then converted after the flame is stable. For heating heavy oil, in order to obtain better fluidity and flash point, heavy oil is generally heated to 100-120 °C.
The preheating process of the cold machine generally takes 10-15 minutes. When the temperature of the exhaust gas in the bag dust box reaches 90 °C, the moisture accumulated in the bag can be evaporated before it can be cooled. It must not be too urgent, such as heating in the bag. Cold aggregate, when the moisture in the bag adheres to the dust, it will block the air gap of the bag and affect the dust removal effect. During this time, the server and the industrial computer can work online, observe the connection between the server and the industrial computer, whether it is normal, and prepare for production.
After the server sets various parameters and production tasks, under the coordinated control of PLC and industrial computer, the production of asphalt mixing plant is an automated assembly line operation, from cold aggregate to hot material to asphalt mixture production. , can continue to complete the set tasks until the end of the set task. In the control system circuit, the signal screen cable must be connected in strict accordance with the requirements to reduce the impact of external electromagnetic interference on the control system. At the same time, the line should pay attention to concealment and protection, and make safety warning signs. The circuit should be as far away as possible from the oil circuit and high temperature and humidity areas to reduce the corrosion and aging of the wires. In the wiring process, if you encounter some ambiguous lines that you can't see clearly, don't care. If you take the wrong line, you may burn the electrical components. Zui is good to put it down first. After debugging to the part of Zui, check the circuit carefully, check the leaks, and improve one by one.
(a) changes in the current of each motor;
(b) Whether the aggregate temperature is within the allowable deviation range;
(c) whether the supply of hot and cold silos is balanced;
(d) Whether the powdered asphalt is supplied smoothly;
(e) Whether the various parts of the machine are functioning normally and whether there is abnormal noise;
(f) Whether the receiving vehicle is queued for receiving as required.
Once an abnormal situation is found, the production task must be stopped immediately, and the production can be continued after the troubleshooting.
5. Cost control management
Transportation vehicles are prone to waste dumping during the process of picking up the mix. The processing cost of one ton of asphalt mixture is generally four or five hundred yuan. The more waste, the higher the cost of the project. If there is a waste of 10 tons of mixed materials per day, the construction period is 60 days, it is possible to waste 600 tons of asphalt mixture, and the direct economic loss reaches more than 300,000 yuan. Therefore, the cost control of the asphalt mixing plant must firstly avoid unnecessary waste of the mixed materials, and a special vehicle commander can be set up.
In the construction of the project, a lot of energy materials are needed to heat the asphalt aggregates, and reasonable and effective control of the energy materials can reflect the cost saving value.
Asphalt mixing building automatic control combustion system has developed into a series of models, such as light diesel oil, heavy oil type, coal powder type and gas machine, oil and gas dual-purpose machine. In our country, natural gas and coal are not very abundant. The road construction industry has always focused on the use of fuel-burning machines due to its working conditions and special factors in the use of the site. In recent years, with the market factors of rising prices of light diesel oil, light diesel oil as a traditional aggregate heating energy material has been slowly replaced by heavy oil with relatively low price. Many asphalt mixing buildings and users use it to improve their own For the purpose of competitiveness and cost savings, the combustion system has been modified and optimized to adapt to the burning of heavy oil.
You can budget a good burner, burn the aggregate to 180 ° C, need about 8l / t, to achieve the same combustion value, and heavy oil is about 9 ~ 10l / t, such as the production of 200,000 tons of aggregate, diesel At 4.26 yuan / l, the cost is 6.816 million yuan, while the heavy oil is 3 yuan / l, the cost is 540 ~ 6 million yuan, the use of heavy oil project can save costs 81.6 ~ 14.16 million, so in the case of ensuring stable operation of equipment The rational use of fuel can increase the overall efficiency and reduce the production cost to a low level.
In the asphalt mixing plant, before the batch production of the mixture, the temperature of the mixing pot is low, and the produced *pot mixture is often wasted due to low temperature or discharged from the hot silo for several tons to more than ten tons of hot aggregate. The wrong operation and waste is also a taboo for cost control. After we have predicted this situation, we can properly raise the temperature of the hot aggregate, carry out manual mixing control, slowly supply the cold material, wait until the production of 3 to 4 pots, the temperature of the mixing pot and the temperature of the hot silo rise. It is possible to carry out mass production, thus eliminating the innocent waste of raw materials. In addition, the production mix ratio is optimized, and the accuracy of each weighing system involves cost control.
6, production data archive management
Asphalt mixing building is a set of equipment integrating mechanical and electrical appliances. The technical parameters of related components are also relatively many. We often need to use these parameters to maintain and repair the equipment. In the usual production, attention should be paid to the collection, registration, and sorting of all relevant materials and the model relationship and component mechanism of important components of each part, so that it can be checked in the future, and the backup of the program and the backup of the computer system can be done in the computer. At the time of starting the work, the daily production and maintenance status of the starting machinery will be registered.
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