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The manual of MB series ball mill
  1. 磨机工作原理及用途PRINCIPLE OF OPERATION AND USES OF MILL
      管磨机是水平的回转圆筒,内装研磨体(一般为钢球、钢锻)。主要靠筒本回转时将研磨体升举落下的冲击能量将物料磨碎。在工作过程中,反复进行的冲击粉碎和滚动、滑动研磨,使块状物料逐渐变小,成为细粉。本机主要用于水泥生料及水泥熟料的粉磨。
Tube Mill is a horizontal rotary cylinder, load in abrasive mediums (general they are steel grinding balls, cylpebs). To crush the materials mainly by percussion energy of the abrasive bodies when the shell rotary to lift and fall them. And the material to be crushed. During the operational progress, by roll and slide repeatedly crushing. So massive material become powder.
This machine is mainly used in grinding for cement raw meals and cement clinkers.
2.结构概述SUMMARY  FOR  STRUCTURE
  2.1传动系统Transmission system
  传动系统包括电动机、减速器、传动轴、大小齿轮(中心传动无大小齿轮)和联轴器等。电动机与减速机之间、减速器与小齿轮之间以弹性联轴器联接。此种联轴器吸震性好,可以减少磨机冲击震动对减速器的影响,可以提高设备使用寿命,且维修十分方便。大齿轮固定在筒体上。由电动机通过减速器、传动轴、小齿轮、大齿圈带动筒体回转。为了增加传动齿轮的使用寿命。磨机采用“大变位”齿轮。
  Transmission system is comprises of motor, reduction unit. Transmission shaft. Girth gear and pinion(central drive mill don’t use girth gear and pinion), coupling, etc. The reduction unit is connected to the motor by spring coupling, and the pinion is connected to the reduction unit by spring coupling which has a good damping capacity and may reduce the shock and vibration influence of mill shell on the reduction unit and increase the service life of the equipment and convenient to maintain. Girth gear is fixed on the flange of shell body, shell body is rotated by motor passing reducer transmission shaft pinion shaft pinion and girth grar rim. Inorder to increase service lift of transmission gears. The mill uses the “large modified” gear.
2.2进料装置Feed device
   进料装置主要包括进料斗支架、观察门、进料斗等。进料斗内装有衬板,同时利用物料本身作衬垫以减少物料对进料斗的磨损。进料斗与支架间有垫片,用增减垫片的方法来调节中心高度。
Feed device mainly consists of charging hopper supports, observation door.etc.liner is fixed in the charging hopper.But it also uses materials as liner to reduce its wearing for charging hopper. The spacers are used between the hopper and the supper by increasing or decreasing the spacer pieces.
2.3回转部分Rotating part
回转部分是由进出料螺旋筒、进出料中空轴、大齿轮(中心传动无大齿轮)、筒体、衬板及隔仓板等部件组成。
筒体用钢板卷制焊接而成,筒体两端焊有同类钢板的平端盖。筒体上开有人孔,人孔用相同材料的加强板加强。磨体内分为粗磨仓、细磨仓。在粗磨仓中装有ZGMn13(铸造锰钢)衬板用螺栓将其联接在筒体上。为了减轻应力集中,衬板的螺栓孔采用椭圆形。细磨仓中亦有用螺栓固定的或镶嵌的衬板,隔仓板为单层隔仓板,材质为ZGMn13(铸造锰钢)。整个回转部分依靠两个中空轴支承在两个主轴承上。中空轴与平端盖之间用螺栓联接。
Rotating part has charging and discharging screw. Charging and discharging Trunnion shafts, girth gear, (central drive hasn’t girth gear)shell body,liners and compartment separators,etc.
Shell body is made of steel plates which are rolled up and welded .The plain-end covers of the same kind of steel plates are welded on the shell body ends. There are manholes on shell body with each one has a strengthen edge. The mill has a coarse grinding compartment and a fine grinding compartment. The circular liners of ZGMn13 manganese casting steel are bolted on the shell body in the coarse grinding compartment. The shape of boltholes is oval to prevent the stress concentration. Liners are uses in the fine grinding compartment by bolt . The compartment separators of ZGMn13 manganese casting steel are single layer. The two main bearings support the whole rotating part by two quill shafts. Quill shafts are connected with plain-end covers by bolts.
 2.4主轴承  Main bearing
主轴承由球面瓦、轴承座与上盖等主要零部件组成。为保证中空轴轴线保持在一个轴线上,采用球面体的轴承瓦,以保证自动调心和主轴承正常油润滑。
在中空轴上装有固定油圈(即“带油圈”),由固定油圈带油润滑。为了防止漏油,主轴承两端装 小油刷,在靠近筒体一侧装有刮油板。(根据用户亦可用稀油站润滑)
为保证主轴承在正常温度下进行工作,在主轴承和球面瓦之间通以冷却水进行冷却。由于粉磨产生大热量传出影响主轴承正常工作,在螺旋筒和中空轴之间的缝隙中填以隔热材料。
Main bearings are comprised of globe bearings, bearing seats and upper covers, etc. The globe bearings are used for purposes of automatic alignment shaft lines of trunnion shafts each other, and make regular oil lubrication for main bearings.
The fixed oil rings (belt oil rings)are installed on the trunnion shafts for lubrication . To prevent oil leakage small oil brushes are installed on the both sides of main bearing and oil scrapers are installed on the side of near shell body. (thin oil station is used according to custom’s requirement)
Because the grinding produces a large amount of heat. The main bearings are cooled by water to keep the normal operation of the main bearings. Heat-insulating material is filled into the gap between the screw tube and trunnion shaft to prevent heat transfer.
2.5出料装置 Discharging device
出料装置是由出料罩、支架、出料筛子等零件组成。出料筛是用螺栓和出料螺旋筒联接在一起的。经粉磨后的物料经过筛选后落入出料罩,其中杂质(如铁块、螺栓等)则从排渣口自动排出。在出料罩上部装有管道收尘器联接,为防止漏风,下部应装锁风装置,再与输送设备连接,否则会影响磨机的粉磨和产量。
Discharging device consists of discharging cover、 supports、discharging screen, etc. The discharging screen is connected with discharging screw tube by bolts. The ground material drops into discharging cover through the screen. Some objects (such as iron pieces,bolts,etc.) will be removed from exit. The pipeline connected with dust collector is installed on the discharging cover. Air lock device is installed on the lower part of discharging cover which is connected with conveying equipment in order to avoid air leak.
3.安装   INSTALLATION
3.1 基础 Foundation
3.1.1 基础验收 Foundation check and accept
(1)在磨机安装之前,应对基础进行清理和质理检查,其强度应符合有关技术文件。
  Before installing the mill, the foundation should be cleared up and checked over for quality, its strength should conform to requirements of relevant communications.
 (2)地脚螺栓孔的布置与尺寸应当允许有可能把机器底板往任意一方偏移10~20mm。地脚螺栓与基础孔壁的距离和螺栓下端到坑底的距离不小于15cm。地脚螺栓预留孔尺寸可参照表1。
  Arrangement and dimension of eyelet bolt holes of foundation should be appropriate to allow machinery base drift probably on arbitrary direction 10~20mm.Distance between eyelet bolts and foundational hole wall and between low end of eyelet bolt and hole bottom, must be not less than 15cm. Dimension of eyelet bolt reserve hole refer to table 1.
表1  地脚螺栓横断面尺寸
Table 1 Eyelet bolt hole dimension on cross section
螺栓规格
bolt specifications
基础孔尺寸
foundational hole dimensions
方 square 圆 circle
M12 80×80 Φ100
M16 90×90 Φ110
M20 100×100 Φ120
M24 120×120 Φ140
M30 140×140 Φ160
M36 150×150 Φ170
M42 160×160 Φ180
M48 170×170 Φ190
M56 180×180 Φ200
M64 190×190 Φ220
(3)地脚螺栓孔内不得有杂物和积水。在安装前应加防尘盖以防杂物掉入。
 There should be no sundry article and water in eyelet bolt holes. Before installing, should cover them to avert any sundry article fall in.
 (4)检查基础外形尺寸,以及标高相对于厂房和其它设备的尺寸是否符合设计要求。
 Foundation overall dimensions should be inspected, and its elevations relative to factory building and other equipments should fit design.
(5)基础的平面标高应当比设备的下表面标高低30~50mm,以便在基础与底板之间放置垫铁进行调整。
 In order to adjust (height of equipment)by fitting spacers that between foundation and machinery base plate, therefore, foundation elevation should be lower 30~50mm than base surface of equipment.
 (6)为了保证二次浇灌时与原基础结合紧密,必须把将要进行二次浇灌的表面铲成麻面(凹坑直径可为Φ30~50mm),各凹坑间的距离一般为150mm左右。在基础的边角处应铲出缺口。
  In order to get integrative combination between second pour and former foundation therefore should shovel surface that will be to second pour and let them become pockmarks (pit diameter may be Φ30~50mm), distance between pits each other may usually be about 150mm.Shovel up notches on their borders of foundation.
 (7)基础处理   Foundation treatment
(a)当标高过高时,用扁铲铲低;过低时,在原基础上铲出麻面,再补灌原标号混凝土。
 (a)Shovel it and cut down by flat shovel when elevation is too higher; shovel up pockmarks and patching pour by former grade of concrete when it is too lower.
 (b)若地脚螺栓位置偏移,可采用扩大预留孔的方法解决,或把地脚螺栓烤红矫正到正确位置。
 If eyelet bolts drift, may extend reserve holes, or bake and manifest eyelet bolts as dull red and correct them.
3.1.2中心标板     Centre marking boards
   基础经过检查并符合要求后,就可根据按磨机实测尺寸修改的图样,在基础上埋设中心标板。(注意应使用同一把量具)
   When  foundation  has been inspected and fit requirements, according to drawings which have been measured mill and have been altered, then may fix centre marking boards in foundation.(Note: using the same measuring tool).
  中心标板一般用钢轨、工字钢或槽钢制成,其尺寸约为(150~200mm)×(30~60mm)。将其牢固地埋设在基础表面里,然后标上中心标点。用冲子打出一个很小的冲眼(可使用经纬仪投点)作为安装设时挂中心线找正设备位置的依据。
   Centre marking boards are usually made from steel rail. I-steel or channel beam (channel bar) their dimensions about(150~200mm)×(30~60mm). Fixed durably them in foundation,then mark out centre points, punch very small holes by puncher (ou by theodolite.) These holes are regarded as bases of obtaining the positions of equipment for installation.
3.1.3基准点   Datum points
   基准点是供作安装机械时测量标高的标准依据,是根据厂区零点测出它的标高并示明。
   基准点一般用铆钉制作,在铆钉杆端焊上一块50mm×50mm,厚10mm钢板,或焊上两根50mm长的已扳弯的螺蚊钢。将其埋在预定的地方,也可将基准点点焊在相应的钢筋上。
Datum points are regarded as standard bases of elevations for installation, to measure up their elevations against “zero point of plant district”, and make marks on them.
Datum points are usually made of rivets, and weld up a piece of 50mm×50mm,thickness 10mm of steel plates on the heads of rivets, or weld up two pieces of 50mm long , have been bent of screwy steel . They are buried in predetermined area. Also datum points may be spot welded on relevant reinforced steel bar .
3.1.4 基础划线索Drawing lines on base
    基础划线的质量要求如下:
The requirements of drawing lines on base should be as following:
  1. 两主轴承基础上的横向球心(可用注水法确定)中心距离,误差不得超过磨机膨胀量的1/10,最大不得超过2mm;
Distance between two crosswise centre lines on base of two main bearings, its error should be not above 1/10 of mill expansion, moreover should be not above 2mm;
  1. 中心标板上所示的纵向中心线与图样上纵向中心线的位移不得超过±3mm;
The position of lengthwise centre line that is indicated by centre marking board, as compared to drawings, their displacement should be not above ±3mm;
  1. 磨体中心线与传动轴中心线必须严格平行,其误差不超过±0.5mm。
Mill centre line must parallel severely to centre line of transmission shaft , its error should be not avove ±0.5mm.
  1. 对相邻基础必须测定对角线上等,以保证纵横向中心线呈90º。
Diagonal lines of adjacent bases should be measured, and adjust them being equal each other, to obtain appearing 90º between crosswise centerline and lengthwise centerline each other.
  1. 挂中心线      Hang centre line
挂中心线的目的是在安装过程中检查各部相互关系。
The purposes of hanging centerline are to check (positional) relations of every part each other in installing.
  1. 借助标板检查两主轴承的底板所在基础的实际中线距离及标板中心点的位置。
       To check the distance between two actual centerlines of main bearings on base plates, and the position of centre point of marking board by centre marking boards.
  1. 借助标板检查磨机筒体中心线与传动轴中心线的垂直距离,及电动机中心线与传动轴中心线的距离。
To check the vertical distance between mill shell centerline and transmission shaft centerline, and the vertical distance between the motor centerline and transmission shaft centerline by centre marking board
  1. 检查地脚螺栓孔的位置等是否符合图样要求。
To check the positions of the eyelet bolt holes should fit drawing.
3.2地脚螺栓的安装  Installing of eyelet bolts
3.2.1
地脚螺栓必须去除油质,锈垢及油漆,螺纹部分涂上油脂以防止生锈。在安装前严防杂物掉入基础孔内。
Eyelet bolts should have been cleaned down oil stains and rust, and smear grease on screw threads make antirust. Before installing, should avert strictly foreign matters fall in base holes.
3.2.2
地脚螺栓在基础孔内应垂直,垂直度公差为5/1000。
Eyelet bolts should be perpendicular in the base holes, their perpendicularty  tolerances are 5/1000.
3.2.3
地脚螺栓的螺母下面应加垫圈,应有锁紧装置锁紧。(锁紧螺母或弹性垫圈)
Below the nut which is on the eyelet bolt, should add washer. Moreover. Check device should be used for locking them.(locking nut and spring washer)
3.2.4
拧紧地脚螺栓时,应从设备的中间部开始,然后往两头交错进行,同时扭力要均匀。拧紧螺母后复查一次设备水平。
The order of tighten eyelet bolts, should beging at centre. Then toward staggeringly and successively moreover. Exert forcing even. After tighten. Check equipment level again.
3.2.5
减速机安装应符合«减速机安装使用说明书»的规定。
电动机安装应符合«电动机安装使用说明书»的规定。
Reducer is installed according to «Operation instruction of reducer».
Motor is installed according to «Operation instruction of motor».
4.操作、维修及检修OPERATION, MAINTENANCE AND OVERHAUL
磨机安装后必须经过空载、部分载荷和满载,试运转合格后才能正式投入生产。为保证磨机的长期正常运转,必须注意磨机操作,维护和检修,制定操作规程和维修制度。
The mill can be put into production after qualification of testrun of no-load, partial-load and full-load. The rules of operation and carried out to keep the normal operation of mill for long term.
4.1 磨机的操作         The operation of mill
磨机必须由经过专门训练或熟悉磨机操作的人员操作。
The mill should be run by skilled  workers.
4.1.1
磨机运转前的准备
磨机在起动前必须做好充分准备工作和检查工作。
Preparations before operation
Full preparations and checkup of the mill should be made before mill start.
  1. 磨机各零部件完整无缺,符合有关技术规定。所有的紧固螺栓和地脚螺栓、螺母均应紧固。
The every mill components and parts are complete and in conformity with technical regulations. Every fixed bolts and eyelet bolts should be screwed tightly.
(2)筒体内各零部件的安装均应符合规定要求,各个筛板上的筛孔应畅通。
The installation of every components and parts should be up to the technical requirements. Every fixed screen openings should be unobetructed.
(3)各仓研磨体应符合要求。
The grinding compartments should meet the technical requirements.
  1. 筒体上入孔盖和进出产装置检查门等均应关严,牢固密闭。
Manhole cover of the mill shell and inspection door of charging and discharging devices should be closed and sealed.
  1. 主轴承冷却水道应畅通;主轴承不得有漏油、漏水、渗油渗水等现象;主轴承的润滑油质量和油位高度均应符合规定要求;润滑表面及存油处以及润滑油本身应清洁;主轴承刮油板、刮油刷安装方向应正确。
Cooling water circuit of main bearings should be passable and the water and oil leakage of the main bearings is not allowed. The lubrication oil quality and oil level of the main bearing should satisfy the technical requirements. The lubricated surfaces. Oil receiver and lubrication oil should be clean. The oil scraper and oil wiper should be installed in corrdct positions and directions.
(6)所有带有密封装置的地方要求将密封与磨擦面之间的压力调节松紧适当,保证既能密封又不至于压得过紧,造成密封很快磨损。
The pressure between the sealing elements and friction surface should be adjusted properly to avoid leakage or worn-off.
(7)仪表、照明、动力、信号、等系统应完整、灵活、可靠。
Instrumentation, illumination, power and signaling, etc, systems should be integrated, flexible and reliable.
(8)设备组装应符合安装技术和图样要求,电动机、减速器应符合说明书中和有关技术文件中的各项规定。
The assembly of motor and decelerator should be in keeping with drawing and regulations of operation instructions and relevant technical documents.
(9)辅助设备如输送、提升、分级、收尘、风机等设备试运转后均能保证正常生产,符合技术要求。
Auxiliary equipments such as conveying device. Lifting device and classifier, etc. can satisfy the technical reqirements for normal production after test-eun.
(10)磨机附近不得有防碍运转的杂物。开车前必须认真检查各运转部件,设备危险点附近不得有人。
The objects which hamper the operation of mill must be removed from the places near the mill.every running components and parts should be checked before operation and the personnel should nlt appear in the dangerous places of equipment.
4.2.1
磨机试运转   The test-run of mill
上述准备工作完成后,即可进行试运转。
The test-run can begin after the completion of above mentioned preparations.
(1)空转:No-load operation
 磨机不加研磨体,连续运转12小时,要求轴承温度在60℃以下。停磨后检查所有坚固螺栓有无松动现象,设备有无不符合设备安装要求的缺陷,如发现应及时调整和处理。(特别是中空轴与筒体连接螺栓)
The grinding compartment are not loaded with grinding media and the mill is confinuously operated for 12 hours. The temperature of main bearing should not be higher than 60℃. Every fastening bolts should be checked to see if they are loose. After machine halt, the adjustment and treatment should be done in time if some installation defects are found. (Especially check joint central bolt between trunnion shaft and shell)
(2)半负载运转:Partial-load operation:
   在粗磨仓,细磨仓中各加入研磨体装载的1/3,喂入相应数量的物料,连续运载48小时,观察并检查所有轴承的温度应符合要求,各零,部件应符合安装要求的规定。若出现不正常现象应及时(特殊检查中空轴与筒体连接螺栓,拧紧力矩为每平方毫米0.9~1.1N.m,且所有螺栓力矩要保持一致.)
The coarse and fine grinding compartments are load with grinding media of 1/3 loading capacity, and the mill is fed with material of corresponding quantity. After 48 hours and every elements should be checked, and should fit the technical requirements. If any abnormal conditions appear should be treated in time. (especially) check joint bolt between trunnion shaft and shell. Tighten moment  is 0.9~1.1n.m/mm²).
再将研磨体加至总量的2/3,喂入相应数量的物料,运转96小时,检查我异常现象后,再将研磨体加至5/6,喂入相应的物料,运转96小时。
Afresh add grinding media to 2/3 of total quantity, feed in appropriate quantity of material, run 96 hours, if never abnormal condition appeared by checking, therefore, afresh add grinding media to 5/6 , feed in corresponding quantity of material, run 96 hours again.
(3) 全负荷运转:Full-load operation:
 在空载和半负荷运转正常的基础上,装入全部装载量的研磨体,补充相应物料,连续运转72小时以后,如情况正常,可投入正常转。
On the basis of normal operation of no-load and partial-load operation, load with total loading capacity of grinding media, complement corresponding quantity of material, after 72 hours normal and continous operation, the full-load operation of mill can begin.
磨机在负载试运转时应达到下列要求:
When the mill is test-run of load operation, it should make achievement as following:
(a)工作平稳,无急剧周期性的振动。
Operation is smooth and stable. There is no rapid periodic vibration.
(b)主电机的电流无异常波动。
There is never abnormal wave motion on electric current of main motor.
(c)磨机的端衬板、筒体衬板、隔仓板和磨门等的螺栓部位应无漏浆或漏灰现象,如有则应立即停磨消除。
 Around the bolts of the liners of mill end covers, of the liners of the shell. Of the compartment separators and the mill doors. Etc. should be never mortar or ash leakage, or should stop the mill and eliminate them soon.
(d)检查各部位的螺栓是否松动、折断或脱落,如发现上述问题应及时处理,特别注意拧紧中空轴与筒体连接螺栓,拧紧力矩为0.9~1.1N.m/mm²且所有螺栓拧紧力矩应保持一致.
Check over all bolts, treat them on time if the bolts became flexile, were broken or were dropped. Especially check joint bolt between trunnion shaft and shell. Tighten moment is 0.9~1.1N.m/mm²
(e)主轴承的轴瓦温度应不高于65℃;主轴承的回油温度应不高于50℃
 The temperature of main bearing bushes should be never higher than 65℃, the temperature of main bearing return oil should be never higher than 50℃.
(f)减速器内润滑油的温升可为20~25℃.
The temperature rise of lubricant oil in decelerator may be 20~25℃.
(g)新安装的减速器经过运转250小时后,减速器内的润滑油应更换或用滤油机将油过滤后再用.
After 250 hours operation for new installing decelerator, the ludricant oil in decelerator should be changed, or to be filtered by filtrator before to be operated again.
(4)全负荷运转一星期,打开磨门在各仓中每一米长的地方取样,检查物料粉粉磨细度以确定研磨体的装卸量及级配.再次拧紧中空轴与筒体连接螺栓,拧紧力矩为0.9~101N.m/mm².
After one week full-load operation. Open the mill doors, sample the material in the places of every meter along the mill axis to check the fineness of the material powder for determining the loading capacity and grading of the grinding media .(check joint bolts between trunnion shaft and shell. Tig  hten moment is  0.9~101N.m/mm²)
4.1.3磨机起动 The start of mill
经严格检查并完全符合要求后,即可发出磨机起动信号,待磨机及运输设备附近的人员离开设备以后可以起动磨机.
After careful check over and fit requirements, may emit driving signal, await personnel who around the mill and transport equipments have departed from the equipments, may start the mill.
磨机起动顺序:
The mill can be started as following sequence;
(1)接通主轴承冷却水系统,并向主轴承上浇注相当的润滑油.(用稀油站的则先开动稀油 ,大型磨机应同时开动电机和减速机的供油系统和冷却系统)
Turn on the cooling device of the main bearings , and pour adequate lubricant oil into the main bearings.(if using thin oil station, we firstly open it . For large-sized mill, suppling oil station cooling system are open at the same time)
(2)开动选粉机及收尘设备.
Start the classifier and dust collectors.
 (3)开动输送设备(提升机,卸料设备).
Start the conveying equipments (lifter and discharging equipment).
(4)开动主电动机.
Start the main motor.
(5)开动喂料设备.
Start the feed equipment.
4.1.磨机的动转4Operation of the mill
当磨机运转后,有关人员应及时进行下列各项工作:
When mill is in operation, the following items should be checked on time;
  1. 所有外露坚固件有无松动现象.
If all exposed fastening bolts have come loose.
  1. 主轴承、滚动轴承、减速器和电动的润滑是否正常, 各个轴承是否有过热现象.
If the lubrication lf main bearings, rolling bearings decelerator and motor is normal, and if superheat of every bearing happens.
  1. 磨机运转是否正常平稳,有无不正常的剧烈振动.
If the lubrication of main bearings, rolling bearings decelerator and motor is normal, and if superheat of every bearing happens.
  1. 各密封处是否严密,有无漏料、漏灰、漏油、漏水等现象.
If the phenomena of material, ash, oil and water leakage happen in the place of sealing places.
  1. 主轴承冷却水系统是否正常.
If the cooling system of main bearings is in normal operation.
  1. 减速器是否正常(减速器的使用注意事项见其说明书),大小齿轮的啮合是否正常.
If the decelerator is normal (matters needing attention of decelerator see the instructions), and if the engagement of the girth gear and pinion is normal.
  1. 电动机的电流数值及波动情况.
The value and fluctuation of motor electrical current.
  1. 各测温点的温度是否正常.
If the temperature in each measurement point is normal.
  1. 磨机产量及磨内物料流动情况.
The throughput and the material flow of the mill.
4.1. 磨机的停车:    5Machine halt of mill
磨机欲停车时,应先做好停车的准备工作.首先以预定的信号通知各附属的人员应做好停车准备工作,停车顺序如下:
Before machine halt, the preparations should be made, predetermined signals should be notified the operators of auxiliary equipment for them to make preparations for machine halt. The machine halt sequence in as following;
  1. 先停喂料设备. Firstly, stop feed device.
  2. 停止主电动机. Stop main motor.
  3. 停止输送设备. Stop conveying devices.
  4. 停止选粉同及收尘设备.Stop classifier and dust collectors.
  5. 停止润滑及冷却系统.Stop lubrication and cooling systems.
4.1.6 磨机的紧急停机: Emergency cut-off of mill:
在运行中发生下列情况之一,应紧急停磨:
When one of following conditions happens, the mill should be emergency cut-off:
  1. 主轴承的振动幅度超过0.15mm时.
The  vibration amplitude of main bearing exceed 0.15mm.
  1. 主轴承温度高于60℃.
The temperature of main bearing higher than 60℃.
  1. 衬板、人孔门、回转部分及其他联接螺栓松动或脱落时.
The bolts of liners, manhole door , rotating part and other parts have come loose or off.
  1. 隔仓板、出料篦板或出料筛堵塞影响生产时.
The blocking up of compartment separators, discharging grate plates or screen seriors affects the normal mill production.
  1. 磨机机件或衬板脱落或破裂时.
Components or liners of the mill have fallen off or broken.
  1. 润滑系统发生断油故障时.
Oil cut-off trouble arises in the lubricating system.
  1. 减速器或电动机发行异常现象(如啮合不正常,温升过高)时
Abnormal  phenomena arises in decelerator or motor (such as abnormal engagement, exceeding normal temperature).
  1. 冷却水温升过或突然中断.
The temperature of the cooling water is too high or the cooling water is suddenly cut-off.
  1. 主轴承冷却水有渗漏水进入润滑油中时.
The cooling water of the main bearings leaks into the lubrication oil.
  1. 磨机的其他机件,如传动部件的联接螺栓松动或部件损坏影响安全生产时.
Other loosed or damaged mill components and parts such as bolts of transmission components affect the production.
  1. 大齿轮的对口螺栓松动时.
Alignment bolts of girth gear are loosed.
4.2 维护和保养Maintenance
4.2.1维护和保养Maintenance
磨机的维护和保养是极其重要的,而且是经常性的工作,应与磨机的操作和检修密切配合起来进行.磨机的维护保养工作直接影响到磨机的运转率和使用寿命,因此应有专职人员值班检查,以便能及时排除故障,保证正常生产.
The maintenance of the mill is an important day-today work, and should be in harmony with operation and overhaul, it directly affects the utilization rate and service life of the mill, so full time personnel should be on duty to check and fix a breakdown to keep normal production.
  1. 主轴承、滚动轴承、减速器、电动机同甘共苦注入的润滑油、润滑脂必须清洁,装油处必须密封良好,使油保持干净.注油量应符合各油位指示器要求,润滑油要按规定定期添加和更换.
The lrbrcation oil grease of the main bearings, rolling bearings, decelerator and bearings of motor should be clean .The lubrication site should be sealed let oil and grease chean . The oil charge should be in accordance with oil level indicators. The oil should be added and replaced at regular intervals.
  1. 对新装或更换的摩擦润滑件,注油运转30天后,应将油全部倒出另换新油.换油时必须保证润滑清洁无杂质,并符合应采用的牌号(润滑剂表列地本说明书后部).同时应刷洗油池.
For newly installed of replaced frictional lubricating elements, after 30 days operation, the lubrication oil should be poured with fresh oil which is clean and non impurity, moreover, their trademarks should fit requirements (the lubricant table is tabulated on the rear of this instructions).
  1. 已变质的或不干净的油禁止使用.冬季加油或换油时,应预先将油加热至20℃左右.
The deteriorated or soiled oil is forbidden to be used, when oil is added or replaced in winter season, the oil should be pre-heated to about 20℃.
  1. 经常检查各轴承温度不得超过60℃,检查润滑点的油位高度和润滑油系统供油压力和供油量,主轴承温度控制在15~60℃.若低于15℃应将主轴承冷却水减少或暂时关闭.
The temperature of every bearing must not exceed 60℃. The oil level height of lubuication site, oil charging pressure and oil quamtity charge of the lubricating system should be checked regularly. The temperature of main bearing should be  controued between 15℃ and 60℃. If the temperature is lower than 15℃, the cooling water should be reduced or turned off temporarily.
  1. 新装衬板的螺栓,在开始数日运转中常发生松动,因此须隔一定时间检查并拧紧,并注意检查衬板螺栓有无断裂.
The bolts of newly installing linere happen loose frequently in first few days, so should be reduced or turned off temporarily.
  1. 要注意检查并记录电动机电流值的变化.若电流下降(这说明磨内研磨体和衬板磨损过多),应及时调整,更换研磨和衬板.
Variations of the motor current should be checked and recorded. If the current has dropped (this reflects the wear of grinding media and liners), the grinding media and liners should be adjusted and replaced without delay.
  1. 除日常维护外,要定期检查主轴承,中空轴,筒体,减速器,大小齿轮,衬板的磨损情况并做好记录,发现问题及时处理,做好检修计划.
Besides ordinary maintenance, wear condition of main bearings, trunnion shafts, mill shell. Decelerator, girth gear and pinion and liners should be checked and recprded at regular intervals. Treatment and overhaul should be given when troubles happen to the mill.
4.2.2 注意事项:  Points for attention:
(1)在冬季,若停磨时间较长,应将装在主轴承进水口处的三通旋塞(即三通阀)转到放水位置.利用虹吸作用,将球面瓦水道内积水排除,以免冻裂球面瓦或轴承座.
In winter season, if the mill is stop working for a long period of time. The three-way cock (namely “T cock”)which installed in the water inlet of the main bearing should be turn to “drain out” position to drain off the accumulated water in globe bearings by siphon principle to avoid frost crack of globe bearings and bearing seats.
(2)停磨后每隔5~10分钟,将磨机转动半圈(180º),反复进行直到磨身充分冷却为止,以防磨
机变形.
Every 5~10 minutes after machine halt. The mill should be turned semicircumference (180℃), and should be kept on doing until the mill shell cool down to prevent the mill shell deforming.
(3)若在运转中突然停电,应将磨机和附属设备的电动的电源拉开(即断开),以免来电时发生事故.
If power cut unexpectedly in operation, the power switches of motor and auxiliary equipments should be turned off (namely cut off) to prevent the accidents when power is suddenly on.
(4)长期停磨时应把研磨体倒出,以免筒体变形.
If the mill stop working for a long period of time. The grinding media should be discharged to prevent the mill shell deforming.
(5)在冬季,生产时要注意磨尾气保温工作,若温度低于露点,会出现冷却水,损坏收尘器.
In winter season. Hat preserving of cxhausting gases on the mill tail should be treated in operation. If the temperature is lower than dew-point. Condensating water will appear and damage the dust collector.
(6)在冬季(我国北方),停磨8小时以上,在开动磨机前应将主轴承润滑油放出,加热至20℃,再倒入主轴承内.
In winter season (in the northern part of our country). After machine halt for more than 8 hours, the lubrication oil should be poured out and heated up to 20℃, then poured into main bearing before mill starting.
4.3检修Overhaul
磨在运转过程中,某些零件或部件会产生磨损.若不定期检修,会影响设备正常运转,甚至会发生事故.为保证及时恢复每个零件部件的原来作用,使用单位必须根据设备磨损情况,制定出切合实际的检修计划(和使用周期).检修中包括对机件作全面检查、调整、清洗和修复及更换.
Partial parts and partial components will be worn down in mill operation. Irregularly scheduled overhaul oil influence the normal production of every components and parts, according to wear of equipments, the consumers should lay down practical overhaul scheme which includes check up ,adjustment , wash, replacement as well as repair of some mill components and parts.
4.3.1 传动装置的检修:  Overhaul of transmission device
(1)电动机的检修应按电动机说明进行.
The overhaul of the motor should be accordanced  with instructions of motor.
(2)减速器的检修应按减速器说明进行.
The overhaul of decdlerator should be accordanced with instructions of decelerator.
(3)大小齿轮磨损至原齿厚的75%或断裂掉齿时应及时更换与修复.
When the tooth thickness of girth gear and pinion is worn down to 75%of its original tooth thickness or the tooth is broken or fallen off, the replacement and repair should be conducted.
(4)传动轴出现深10mm裂纹应检修或更换.
The repair or replacement should be conducted when 10mm deep crack appears in the transmission shaft.
(5)滚动轴承密封不良有漏油现象,滚动轴承由于磨损使径向间隙大于0.3mm,应更换.
The rolling bearings should be replaced or restored if it has oil leak or its diametral clearance is larger than 0.3mm because of wear.
(6)齿轮罩中刮油器磨损或不起刮同作用,应修复与更换.
Oil scrapers and wipers in the gear corers should be replaced or restored if they are damaged or cannot work properly
(7)齿轮罩的密封装置如不能良好密封时,应及时调整或更换.
The sealing devices of gear covers should be adjusted or replaced promptly if it has oil leak.
4.3.2主轴承的检修:Overhaul of main bearings
(1)球面瓦的巴氏合金被压溃或磨损5mm时,须重新浇注巴氏合金.
The babbit metal should be pouring again when it is broken down or is worn down 5mm thickness.
(2)主轴承表面磨损出现拉丝深度超过1mm须修复,中空轴出现裂纹应修复与更换.
The repair should be conducted when the depth of scratch appeared on the main bearing surface exceeds 1mm , and the repair or replacement should be conducted when crack appears in the trunnion shaft.
(3)刮油器处的油圈刮油,带油的情况不好,应及时修复或更换.
When oil ring of oil wiper cannot work properly, it should be repaired or replaced.
(4)主轴承的密封应良好.如发现漏油应检查密封垫是否磨损,如磨损应及时调整或更换.如刮油板,刮油刷安装角度不对,应及时调整.刮油板,刮油的安装位置和角度.与磨机回转方向有关.
Main bearing should be sealed well. When oil leakage happens , please check if the gaskets are woun down and the installtion angles of oil wipers and oil scrapers are correct. The worn down gaskets should be adjusted or reolaced. The right installation positions ad angles of oil wipers and oil scrapers are related to rotation direction of the mill.
(5)球面瓦或主轴承座漏水,以致水与油混合,应及时修复或更换.
When globe bearing or main bearing seat water leakage happens so lubrication oil is mixed in water therefore. Should repair or replace them on time.
4.3.3回转部分的检修Overhaul of rotating part
(1)进出料螺旋筒和叶片磨穿或磨损至原来厚度的70%须修复或更换.
When charging and discharge screw tubes are worn into holes or their thickness are worn down to 70﹪ of their original thickness. They should be repaired or replaced.
(2)篦板,单层隔仓板磨损超过原来厚度的50%应更换.
The grate plates and single layer compartment separator plates should be replaced when their thickness are worn down over 50﹪ of their original thickness.
(3)磨头衬板和(或)筒体衬板破裂,不完整等(掉边,掉角,裂纹)或磨损超过原来厚度70%,应更换.
The liners of mill header, and of shell body, should be replaced they are broken or incomplete, etc. (lost edge, lost angle. Cracked) or their thickness are worn down over 70﹪ of their original thickness. Or cracks or partial deformation appears.
(4)筒体厚度磨损了原来厚度20%或有裂纹,局部变形,应修复或更换.
The repair or replacement should be conducted when the thickness of the mill shell is worn down 20﹪ of their original thickness, or cracks or partial deformation appears.
(5)入孔盖及其密封垫损坏时,应时更换.
Manhole covers and their gaskets should be replaced when they are damaged.
(6)研磨体磨损应定期清仓,分选,及时补充.严禁从进料螺旋筒加研磨体入磨,以防止损坏进料螺旋筒等.
Because of wear, grinding media should be cleared away. Classified and complemented at regular intervals. It is prohibited severely to add grinding media from charging screw tube. In order to avoid its damage.
(7)衬板的螺栓磨损,松动,须更换螺栓.
The bolts of liners should be replaced when bolts are worn down or loosed.
4.3.4 进料部分的检修:Overhaul of charging part
(1)进料漏斗磨损,磨空,须焊补或更换.
Welding patches or replace should be conducted when charging funnel is worn down or worn into holes.
(2)进料漏斗与进料螺旋筒间的密封被磨损造成漏料或漏灰时应修复或更换.
When the sealing material between the charging funnel and charging screw tube is worn down  to cause material and ashes leak, it should be repaired or replaced.
4.3.5 出料部分的检修:Overhaul of discharging part
(1)出料罩密封失效造成漏灰时应及时修复或更换.
When the seal of discharging cover is failure to cause ashes leak, it should be repaired or replaced.
(2)出料筛孔磨损过大,筛孔间磨穿或堵塞应及时焊补,修复,清理,更换.
The discharging screen should be welded up. Repaired. Cleared up and replaced when screen. Is blinding. Worn down or worn through between its holes.
  1. 出料罩磨至1mm或磨穿时应焊补或更换.
Welding patches or replacement should be conducted when the thickness of the discharging cover is worn down to l mm thick or worn into holes.
5.附表ADDITIONAL LIST
润滑剂项目表Lubricant items
序号
NO.
润滑点
Lubricating site
润滑方式
Lubricating method
允许温度
Allowable temperature
润滑剂名称、牌号
Lubricant name, brand
更换期
Change period
1 主轴承
Main bearing
油圈带油
Oil ring bring oil
≤60℃ 冬季N220极压齿轮油
Witer: N220 Limitin pressure gear oil
夏季N320极压齿轮油
Pressure: N320 Limitin pressure gear oil
约6个月
about 6 months
2 滚动轴承
Rolling bearing
油杯
grease cup
≤60℃ 合成锂基润滑脂
ZL-1H combined Li lubricat grease
约3个月
about 3 months
3 减速器
Decelerator
飞溅润滑
splas lubrication
≤60℃ 按减速机使用说明书
According to instructions of decelerator
4 大小齿轮
girth gear and pinion
浸油润滑
oiled lubrication
≤60℃ 冬季N220极压齿轮油
Witer: N220 Limitin pressure gear oil
夏季N320极压齿轮油
Pressure: N320 Limitin pressure gear oil
约6个月
about 6 months
5 电动机
motor
  ≤60℃ 按电动机说明书
According to instruction of motor
 
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