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Instructions for MB Ball Mill(一)
  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.
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