彩涂板生产线如何防止钢带跑偏

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彩涂板机组运行时钢带跑偏是最常见的故障，钢带跑偏轻则造成各辊的辊面磨损，彩涂板两边出现混色现象;重则由于钢带与机架剧烈摩擦引起钢带两边的张力不均匀或磨损变形，严重时还需要停机处理，因而，正确地处理好钢带的跑偏问题，是关系到整个生产系统的正常运转。

其实，较常见的彩涂板钢带跑偏原因综合起来只有一种，就是钢带在一定的速度下同时受到种横向的分力，这种横向的力是怎样产生的呢?如图35所示，假设钢带经过的某一根转向辊在安装时没有与机组运行的中心线垂直，彩涂板钢带向前运行时给此转向辊一个向前的牵引力F，这个牵引力分解为使转向辊转动的分力F，和一个横向分力F。，这个横向分力使转向辊轴向窜动，由于转向辊支架的固定是无法轴向窜动的，它必然就会对钢带产生些个反作用力F，它使彩涂板钢帯向另一侧移动，从而导致了跑偏。

搞清楚转向辊安装偏斜时的受力情况，就不难理解彩涂板钢带跑偏的原因了，调整的方法也就明白了，最好的方法就是在制造时转向辊的两侧安装孔都加工成长孔，以便进行调整。具体调整方法见图3-6，调整时，钢带偏向哪一侧，转向辊的哪一侧就要朝机组钢带前进方向前移，或另外一侧后移。

除了属于辊子或机架因安装问题所引起的横向力的情况外，还有以下几种跑偏现象都是由于钢带受到外来的横向力而引起，但最终都可通过受力的分析找出原因和处理方法。

A跑偏现象

(1)彩涂板钢带板形不好，两端的厚度不均，造成钢带两端的张力不均匀，钢带始终往张紧力大的一边跑偏，针对这种情况，可以通过调整传动辊或改善辊子两边的张紧力来消除，对调整不过来的就必须对钢带接头重接。

(2)机组中心线歪斜。机架歪斜包括机架中心线歪斜和机架两边高低倾斜，这两种情况都会造成严重跑偏，并且很难调整。这属于机组的安装质量问题，安装质量对钢带跑偏的影响最大，由安装误差引起的钢带跑偏最难处理。は

(3)张力装置的缓冲压辊压力不均匀，造成钢带两边运行阻力不一致，引起跑偏，这种情况的处理相对较容易，只要重新检测和调整好机组所有缓冲辊和压辊的压力即可。

(4)运行中振动引起的跑偏。机组在运行时的机械振动是不可避免的，在钢带运行速度越快时，振动越大，造成的钢带跑偏也越严重。在生产线运行期间，所有与钢带接触的辊子的径向跳动引起的振动都有可能引起钢带的跑偏。

(5)钢带张力过大或过小，应重新计算并调整机组各段的张力值。

(6)转向辊的轴承被卡死引起辊子不转动，钢带与辊面的摩擦力增大。

(7)钢带板形差，有太大的镰刀弯或浪边。

(8)辊子外表面加工误差，呈锥形、粘有脏物或磨损不均造成直径大小不一，钢带会向直径较大的一侧跑偏。其受力情况如图3-7所示，钢带的牵引カF。产生一个向直径大侧的移动分力F，在分力F，的作用下，钢带产生偏移。

B钢带跑偏处理方法

针对钢带跑偏的原因，要采用相应的对策来进行调整，对安装误差引起的跑偏，首先要消除安装误差，对机架歪斜严重的必须重新安装，在确保安装无误差的前提下才能针对运行中的跑偏实施调整方案

(1)清理干净转向辊表面粘污物，加工误差和磨损不均的就要更换下来重新加工包胶处理。

(2)机组要求加速平稳，不能突然加快或有冲击现象，并保证有合适的张力

(3)加装纠偏辊。该方法可防止各种原因引起的特别是因钢带长距离没有设置纠偏辊而引起的跑偏，但会增加成本。

(4)张力调整。张力辊的调整是机组跑偏调整的一个非常重要的环节。

(5)紧固辊子的机架，防止加张和加速时引起振动。

总之，对于钢带的跑偏现象，只要我们加强日常巡检，及时清除引起钢带跑偏的各种因素，掌握规律，就能找出相应的解决办法。

Running off of steel strip is the most common faults in color coating machine. Wear of rollers is caused by slight running of steel strip, and color mixing occurs on both sides of the coating plate. Heavily, the tension on on both sides of the strip is uneven or the wear deformation is caused by severe friction between the steel strip and the rack. When serious, it is necessary to stop the machine to deal with the steel strip correctly. The problem of deviation is related to the normal operation of the whole production system.

In fact, there is only one common reason for strip deviation, that is, the strip is subjected to a transverse force at the same time at a certain speed. How does this transverse force come into being? As shown in Figure 35, assuming that a steering roll passed by the strip is not vertical to the center line of the unit during installation, the strip moves forward. The steering roll is given a forward traction F, which is decomposed into a force F that rotates the steering roll and a transverse force F. This transverse component causes the steering roll to move axially. Since the fixed support of the steering roll can not move axially, it will inevitably produce some reaction force F on the steel strip, which causes the steel to move to the other side, leading to deviation.

It is not difficult to understand the reason of steel strip deviation when the steering roll is deflected. The method of adjustment is also clear. The best way is to process the growing holes on both sides of the steering roll in order to adjust. The specific adjustment method is shown in Figure 3-6. When adjusting, which side of the steel strip deviates, which side of the steering roll will move forward towards the steel strip of the unit, or the other side will move backward.

In addition to the transverse force caused by the installation of rollers or racks, the following phenomena of deviation are caused by the external transverse force on the steel strip, but ultimately the causes and treatment methods can be found through the analysis of the force.

A deviation phenomenon

(1) The strip shape is not good, the thickness of both ends is not uniform, resulting in uneven tension at both ends of the strip, and the strip always deviates from the side with high tension. In view of this situation, it can be eliminated by adjusting the driving roll or improving the tension on on both sides of the roll. If the adjustment is not possible, the strip joint must be reconnected.

(2) The center line of the unit is skewed. The skew of the frame includes the skew of the center line of the frame and the high and low inclination of both sides of the frame, which will cause serious deviation and is difficult to adjust. This belongs to the installation quality problem of the unit. The installation quality has the greatest impact on the strip deviation, and the strip deviation caused by the installation error is the most difficult to deal with. A kind of

(3) he uneven pressure of the buffer roll of the tension device results in the inconsistency of the running resistance on both sides of the strip and the deviation of the strip. It is relatively easy to deal with this situation, as long as the pressure of all the buffer rolls and the roller of the unit is re-detected and adjusted.

(4) Running deviation caused by vibration in operation. The mechanical vibration of the unit is unavoidable in operation. The faster the speed of the steel strip is, the greater the vibration is, and the more serious the deviation of the steel strip is. During the operation of the production line, the vibration caused by the radial runout of all rollers in contact with the strip may cause the strip to run off.

(5) If the tension of steel strip is too large or too small, the tension value of each section of the unit should be recalculated and adjusted.

(6) The bearing of the steering roll is stuck, which causes the roll not to rotate, and the friction between the steel strip and the roll surface increases.

(7) The shape of steel strip is poor and there are too large sickle bends or wave edges.

(8) Processing errors on the outer surface of the roll are conical, sticky with dirt or uneven wear, resulting in different diameters, and the steel strip will run to the side with larger diameters. The force acting on the strip is shown in Fig. 3-7. The traction of the strip is F. It produces a moving component F toward the large side of the diameter, and under the action of the component F, the steel strip produces offset.

Processing method for deviation of B steel strip

In view of the reasons of steel strip deviation, the corresponding countermeasures should be adopted to adjust the deviation caused by installation errors. Firstly, the installation errors should be eliminated. The serious skew of the frame must be re-installed. Only on the premise of ensuring no installation errors can the adjustment plan be implemented for the running deviation.

(1) Clean up the dirt on the surface of the steering roll. If the processing error and uneven wear are not uniform, it is necessary to replace it and reprocess the coating treatment.

(2) The unit requires steady acceleration, no sudden acceleration or shock, and proper tension.

(3) Adding deviation correction rollers. This method can prevent the deviation caused by various reasons, especially by the absence of correcting rollers for long distance steel strip, but it will increase the cost.

(4) Tension adjustment. The adjustment of tension roll is a very important part of the unit deviation adjustment.

(5) Tighten the frame of the roll to prevent vibration caused by tension and acceleration.

In a word, as long as we strengthen routine inspection, clear up all kinds of factors causing strip deviation in time and grasp the law, we can find out the corresponding solutions to the phenomenon of strip deviation.

The working principle and forms of several kinds of deviation correction rolls are introduced in detail in Chapter 7 of this book.