In the early stage of production, we first complete the design and process preparation work. Based on the actual operating conditions of mine scraper conveyors (underground vs. open-pit), the characteristics of the conveyed materials (particle size and specific gravity), and the required conveying capacity, we develop and optimize the overall system’s production plan. Using advanced simulation technologies, we conduct multiple rounds of iterative analysis and optimization to evaluate the forces acting on the scraper chain, the stability of the conveyor body, and the compatibility of materials. This process enables us to determine the structural configuration of the conveyor body, the specifications of the materials, the precision requirements for key dimensions, and the production requirements for each processing step. As a result, we produce comprehensive design drawings, production process specifications, and quality control points covering all stages of the manufacturing process. We clearly define the technical parameters, operational standards, and acceptance criteria for each production step, providing precise guidance for subsequent production phases and ensuring that the final product is perfectly suited to the specific conveying scenarios in mining operations.
During the production phase of the main structural components of the machine body, high-strength, highly wear-resistant specialized materials suitable for the harsh operating conditions of mining environments are selected, and material preparation is carried out according to the production schedule. CNC precision cutting equipment is used to cut plates and profiles, with strict control over cutting dimensional tolerances to ensure consistent component dimensions. Subsequently, specialized molds are employed for precise bending and forming of the machine frame and trough structure, guaranteeing that the bending angles and radii meet production standards and ensuring smooth connections between trough sections. After forming, the components are secured using dedicated assembly fixtures, and positioning and welding operations are performed. A segmented welding and symmetrical welding process is adopted, with precise control of welding parameters to minimize welding distortion and internal stresses, thereby ensuring the strength and sealing integrity of the trough welds. Following welding, timely aging treatment is conducted to completely relieve residual internal stresses. Then, through precision correction and finishing processes, any defects such as weld spatter and burrs are removed, and the inner walls of the trough are polished to a smooth finish, preventing material blockages and wear during conveyance. This ensures the rigidity, dimensional accuracy, and installation reference consistency of the components, meeting all subsequent assembly requirements.
The core transmission components, along with the scrapers and chains, are manufactured according to a precision production process that ensures strict control over machining accuracy and surface quality throughout the entire procedure. High-precision equipment such as CNC lathes, machining centers, and external cylindrical grinders are employed in the manufacturing process. The production sequence for the transmission components is as follows: rough machining (removing excess material to achieve the initial shape), heat treatment (precisely controlling temperature, holding time, and cooling rate to enhance the component’s hardness, toughness, and wear resistance), semi-finishing (correcting minor deviations caused by rough machining and heat treatment), high-precision finishing (using CNC machine tools for cutting and grinding, strictly controlling dimensional and geometric tolerances to ensure transmission accuracy), and surface polishing (improving surface finish and reducing operational friction losses). The scrapers are integrally molded from wear-resistant materials, ensuring uniform thickness and smooth edges. The chains are manufactured using a precision forging process and subsequently strengthened through heat treatment, guaranteeing that their tensile strength and wear resistance meet the required standards. After the components are machined, they are assembled according to standardized procedures, using specialized jigs and tools to precisely control the fit clearance between transmission components and the alignment accuracy between scrapers and chains. This ensures even force distribution, smooth operation, and guarantees the stability and long-term reliability of the chain drive.
Surface protection is carried out in accordance with standardized production processes. All components are first subjected to sandblasting or shot blasting to remove rust, thoroughly eliminating surface scale, corrosion, oil stains, and impurities, thereby ensuring that the surface roughness meets the requirements for coating adhesion. After rust removal, dust and oil are promptly removed to prevent secondary contamination. Then, a multi-layer anti-corrosion and wear-resistant coating specially designed for mining applications is applied, with particular emphasis on reinforcing the protective measures for the machine’s body channels, scrapers, and chains. The coating thickness and uniformity are strictly controlled to avoid defects such as missed spots and sagging. Finally, the coated surfaces are cured under constant temperature conditions to ensure optimal adhesion and durability, effectively resisting the corrosive effects of the dusty and humid environments commonly found in mining operations and significantly extending the service life of scraper conveyors.
The final assembly process is based on a unified reference baseline and proceeds sequentially, assembling the main fuselage body, core transmission components, scraper chains, idler rollers, and other auxiliary systems. Professional measuring tools are employed to precisely adjust the fuselage’s levelness, straightness, transmission clearances, and chain tension, ensuring smooth connections and precise coordination among all components and thereby preventing issues such as scraper jamming or chain slackening. At the same time, the lubrication system is comprehensively upgraded and perfected—particularly by introducing specialized lubricants for transmission components and chains—and safety protection devices (covering transmission areas and chain running zones) as well as operational monitoring equipment are installed. After final assembly, the equipment undergoes an initial no-load trial run, during which continuous operation is used to identify and promptly address any abnormal noises, temperature rises, or chain misalignment. Subsequently, a loaded联动调试 is performed to simulate real-world material-handling conditions in mining environments, thoroughly testing key performance indicators such as the equipment’s load-bearing capacity, transmission stability, and smoothness of material conveyance. Only after all these tests meet the required standards will a test report and product certificate be issued, marking completion of factory acceptance.
