球磨机通用说明书.doc

下册（干 式 球 磨 机） Dry Ball Mill 一、工作原理及结构概述. Working Principle and Structure Introduction本系列磨机常规均为边缘传动形式，磨内一般分成单仓、双仓或者三仓结构。This series ball mill normally adopts edge transmission. The inner part is commonly divided into single chamber, double chamber or triple-chamber. 物料由进料斗通过中空轴螺旋筒进入磨内，经过粗粉磨后进入粉磨仓，终粉磨后的物料由中空轴内的螺旋筒经出料罩卸出。当用于闭路粉磨时，不合格的物料由选粉机选出并回到进料端形成循环作业。Materials go into the mill through feed hopper and the spiral tube in the quill shaft. After coarse grinding, materials go into the powder grinding chamber and are ground into fine powder, and then are discharged trough the spiral tube in the quill shaft. If it is closed-circuit grinding, , the disqualification materials go back to the feeding side and form cycle operation, after being separated by the powder separator. 磨机筒体内装有研磨介质，当筒体回转时，研磨介质由于惯性离心力的作用，贴附在磨机筒体内壁衬板面上，与筒体一起回转被带到一定高度后，借助于重力作用自由落下，将筒体内的物料击碎。Grinding media is loaded inside the mill. When the shell rotates, grinding media attaches to the inner lining in the force of centrifugal inertial force and then is taken to a certain height together with the shell, finally falls in the force of gravity, in this way the materials are crushed. 研磨介质在回转的筒体内除有上升、下落的循环运动外，还会产生滑动和滚动，致使研磨介质、衬板和物料之间发生研磨作用，将物料磨细。In addition to the rising-and-falling circulatory movement, grinding media also can slide and roll. So that the grinding media, lining and materials grind with each other and finally materials are ground into fine powder.在磨机筒体中，当研磨介质装填的数量很多时，分布在靠近筒体横截面中心部分的研磨介质，不足以形成抛落运动，从而产生较多的滚动和滑动，致使物料受到研磨作用而磨细。所以在细磨粒径较大或较硬物料时，研磨介质平均尺寸要大些，装填数量可少些。从而保证研磨介质具有足够的抛落高度，加强冲击破碎作用。反之，在细磨粒径较小或较易磨的物料时，研磨介质平均尺寸可以小些，但装填数量应多些。这样会加强研磨磨碎作用。由此可见，研磨介质的装填量、尺寸大小、级配情况都会直接影响到磨机粉磨的效果。When the shell is filled with too much grinding media, those near to the shell cross section cannot do throwing-and-falling movement, but usually slide and roll. In this way materials will be ground into fine powder. Hence, when materials are in bigger particle size or harder, the grinding media size can be smaller, while the media number should be increased. That can enhance the grinding effect. This shows that, the ball load, ball size and level-match condition can directly influence the grinding effect. 磨机筒体的回转速度对物料粉磨的作用影响很大。当筒体的转速适中时，研磨介质的运动呈“抛落运动状态”，粉磨的效果最好。所以磨机的转速都是按照这个速度范围设计和制造的。The shell rotation speed also influences the grinding effect a lot. When it is appropriate, the grinding media move in the throwing-and-falling way, and the grinding effect is the best. Hence, the rotation speed is all designed according to this speed range. 磨机的主要结构由以下几个部分组成：Main Structure of the Ball Mill:1、进料装置 Feeding Device进料装置主要是一个进料斗。上法兰与喂料装置相联，料斗不设衬板，进入的物料自然堆积，形成一定坡度的料衬，以防止物料直接磨损料斗，料斗的前端是圆柱管，伸入装在中空轴上的螺旋筒里，物料经此进入磨内。The inlet device is mainly a feed hopper. The upper flange connects with the feeding device. The hopper is without lining. Materials accumulate naturally and form a material lining with a certain slop to avoid the direct abrasion to the hopper. In the front of the hopper, a parallel tube is installed inside the spiral tube of the quill shaft. Materials go into the mill trough the tube. 2、回转部分 Rotating Part 回转部分是一个由钢板焊接的筒体，两端分别用螺栓与进、出料中空轴相连，并通过水平的轴承支承着，在进、出料中空轴内装有进出料螺旋筒。回转部是通过固定在筒体出料端的大齿轮与由电动机经减速机减速的小齿轮相啮合使其回转的。并借助筒体内的衬板将物料和研磨介质带起而进行粉磨作业的。Rotating part is a steel plate welded shell, supported by horizontal bearing shaft. Both ends respectively connect with the inlet and outlet quill shaft in which the inlet and outlet spiral tube is installed. The big gear fixed in the discharging end meshes with the pinion whose speed is lowed by the gear box. In this way, this part can rotate. Also materials move together with the grinding media, and are ground. 筒体内部根据需要可设置隔仓板，将筒体分为双仓或者三仓，隔仓板的位置可以根据生产需要进行调整，每个粉磨仓可装入不同大小的研磨介质，在出料尾端设有出料篦子板，其目的是防止研磨介质出磨。If necessary, the partition panel(s) can be installed inside the shell to divide it into double chamber or triple chamber. Position of the panel is adjustable. Every grinding chamber can load grinding media in different size. The discharge grate plate is installed in the discharge end, to avoid the grinding media going out of the mill. 在出料篦子板后设有扬料板，它把进入的物料及时的送入中空轴内的出料螺旋筒中，以便及时卸出。The lifting plate is installed behind the grate plate. It can send the material into the discharging spiral tube in the quill shaft in time, so that the product can be discharged in time. 筒体内部设有衬板，它既可以保护筒体不受磨损又起到把研磨介质带到适宜的高度，以达到最佳粉磨的目的。The lining inside the ball mill can protect the shell from abrasion and also can take the grinding media into an appropriate height, to get a best grinding effect. 若有隔仓板的磨机，在粉磨过程中因一仓的物料颗粒较大，应以冲击粉磨为主，故选用阶梯衬板；在细磨仓应以研磨为主，均采用波纹衬板。If the mill has partition panel, during the grinding process, for materials in the first chamber are in bigger size, so impact grinding method and stepped lining board is used; and in fine grinding chamber, the grinding method and corrugated lining is used. 衬板均用螺栓与筒体固定，易于安装和更换。All the linings are fixed on the shell with bolts, to make the installation and replacement easier. 为修理或更换磨内零件和装卸研磨介质，每个仓均设置了人孔，三仓配备了双人孔。For the convenient of maintenance, replacement of parts and the loading and unloading of grinding media, every chamber has manhole. Three chambers mill have two manholes.3、出料装置 Discharge Device 出料装置是用钢板焊接而成的构件，上面留有不同直径（根据磨机型号而定）的出气管法兰（出气管及除尘设备由客户现场自行配备），其下面或侧面留有与输送设备相连的方法兰，出料装置内装有随磨机一起回转的筛子，筛出的渣子等由出料罩后面的出渣口排出。Discharge Device is made by welding the steel plate. The outlet pipe flange (the users shall choose the out let pipe and the de-dusting equipment separately according to their jobsite) with different diameters (depending on the Ball Mill Model) is on the top; the flange connected with the delivery equipment is at the bottom or in the side. The sieve rotating with the mill is installed inside the discharge device. The screened slag will be discharged through the slag hole behind the discharge cover. 4、主 轴 承 Main Bearing Shaft 磨机全部回转部分的重量（包括研磨介质和物料）皆由一对结构相同的主轴承支承，当磨机运转时轴承可以自动调心，以适应制造和安装时的误差。 The weight of the entire rotating part is completely supported by a pair of main bearing shaft which are in the same structure. When the ball mill is running, the bearing shaft is auto-aligning, to adapt to the error caused during manufacture and installation. 根据生产工艺的要求，当进磨物料温度过高时，在轴承座下部可设置冷却水腔，用循环水进行冷却。它既可以冷却润滑脂同时又可以冷却轴承（根据工艺及订货要求添加，无要求时均不配冷却水腔）。According to the requirements of the production process, when the material temperature is too high, the cooling water house can be installed in the lower part of the bearing seat, to cool them with recycling water. 5、传动装置 Transmission Device磨机的动力是通过一对大小齿轮传动的，大齿轮通过筒体上的法兰与筒体相连，小齿轮由一对滚动轴承支承并通过联轴器与减速机、电动机相连接。磨机传动装置的布置以及所有带方向性的零部件结构是不许随意变动的。The power of the mill is transferred by a pair of big gear and pinion. The big gear connects with the shell by a flange. The pinion is supported by a pair of rolling bearing and connects with the gear box and motor with shaft joint. The arrangement of the transmission part and the structure of directional components cannot be changed at random. *6、润滑装置（使用单位自配） Lubrication Device 两个主轴承均采用滚动轴承。润滑方式：干油脂润滑，有手动或自动形式之分，使用单位根据自行情况进行选配。The two main bearing shafts are rolling shafts. Lubrication: dry oil lubrication, manual type or automatic type, the unit should be chosen according to the situation. *7、慢传装置 Slow Transmission Device 为保证磨机的检修和装载研磨体等需要，本磨机配备了慢传装置，它由制动电动机、减速机及牙嵌离合器构成。当需要时，将牙嵌离合器合并，就可使用。当要开主电动机时，切记要将牙嵌离合器脱开，此处应与主电动机电气联锁。即离合器处的行程开关，应串入主电动机的主控制回路中。 In order to meet the requirements, such as the overhaul and the loading of grinding media etc, this mill is equipped with slow transmission device which is composed of brake motor, gear box and tooth-embed clutch. When it is necessary, just combine the tooth-embed clutches, then the slow transmission device can run. When the main motor runs, please be sure to uncouple the tooth-embed clutch, where should be electric interlocked with the main motor. That means the position switch on the clutch should be strung into the main control loop of the main motor. 说 明：“*6”处为自行,配置项目，使用单位根据自行情况配备。Note: “*6”is Self-configuration items, the used unite should be chosen according to the users own situation “*7”处为选配项目，可根据要求增加该装置。若订货时对该装置无要求，生产制造厂家均不配置（一般情况下，2700mm以上磨机才配该装置。同时，2700mm磨机在无要求时均不配置）。 “*7”is the optional items, can be added if necessary. if it is not needed when ordering the mill, the manufacturing factory will not deploy it(generally, when diameter is bigger than2700mm , this device shall be used. 2700mm ball mill will not be equipped with it if no requirement.)二、磨机的安装 Installation of the mill磨机应安装在牢固的混凝土基础上。磨机的基础设计和施工参看总装图和基础图。为了保证使用过程中磨机各部件的位置精度不发生大的变化，磨机的基础应采用整块式结构。The mill should be installed in the solid concrete foundation. Design and construct mill foundation as per the general installation drawing and foundation drawing. The mill foundation should adopt monoblock structure to avoid translocation.混凝土基础耐压强度达到75%以上后即可在上面安装磨机。在安装之前应对基础的质量进行检验，要求混凝土没有影响强度的缺陷，预留孔的数量和位置符合要求，预留孔内无杂物、积水和油污。Install the mill when the compressive strength of the concrete foundation comes to 75%. Before installation, inspect the foundation to make sure the concrete has no defect that will affect the strength; check the preformed holes, make sure the qty and the place are right; clear up the sundries, water and the greasy dirt in the preformed hole.采用“地线法”进行安装作业时，在基础表面上应预埋“中心标板”。安装前在基础上画出所有中心线，并在“中心标板”上做出醒目的冲点标记，作为安装时的中线基准。While installing with geodesic line method, embed a “center object board” on the surface of the foundation. Draw up all center lines before installation and make an obvious mark on the center object board as the center line standard.磨机安装除按图纸的要求外，还应按如下要求进行：Other Installation Notice:1、安装注意事项Important Notice of Installation（1）安装前，应对主要零件进行质量检验，如有损伤和变形等缺陷，要事先进行修复。Before installation, check the quality of the main parts. If damaged or deformed, do repair first.（2）安装时，要十分重视对零件的清洗，特别是各配合面等。When install, attach importance to clear the parts, especially the fitting surface.（3）凡是带有方向性的零件，如：衬板及进、出料螺旋筒等均需按图纸中的要求安装，不得装反。Install all the directional parts (such as lining, feed and discharge spiral barrel) as per the drawing. No opposite install is allowed.2、基础划线的质量要求quality requirements of foundation line（1）两主轴承底板的中心线距离，一般应符合设计要求。 Distance between center lines of the 2 main bearings baseboard should fit the design.（2）两主轴承底座的纵向中心线应平行，其平行度误差不得大于0.5毫米。 The longitudinal center lines of 2 bearing foundation should be parallel. Error of depth of parallelism should be no bigger than 0.5mm.（3）标高的允许误差为5毫米（一次混凝土表面）。 Accepted error of elevation is 5mm. (each concrete surface)3、灌 浆 Grouting（1）灌浆前应使设备底面保持清洁，油污和泥土等杂物应清除。 Before grouting, do keep the underside of the machine tidy, and clear the greasy dirt and soil away.（2）灌浆层应紧密粘贴在基础上，灌浆前应清除地脚螺栓孔中的垃圾，需灌浆的表面应凿成麻面，被油污的混凝土应凿去，并用水清洗干净，凹孔内不得积水。 Before grouting, get rid of the dirt in the anchor bolt; chisel the surface into pitted surface; chisel away the greasy concrete, clean it with water and no water storm before grout. The grout blanket should be integrated with the foundation.（3）灌浆一般宜采用细碎石子混凝土（或水泥砂浆）其标号至少应比基础的混凝土标号高一级。灌浆时，应捣固密实，捣固时不得撞动设备、垫铁和地脚螺栓等，以免影响设备的安装精度。 Grouting basically adopts fine gravel concrete (or cement plaster) or at least one grade higher than the concrete grade. When grouting, tamp densely, do not strike the machine, shim plate and anchor bolt in order not to affect the installation accuracy.（1） 当灌浆层的耐压强度达到设计强度四分之三之后，才能拧紧地脚螺栓。Never screw up the anchor bolt until the compressive strength of grouting blanket come to design strengths three fourths.4、回转部分的安装 Rotating Part Installation 磨机回转部分的轴线应呈水平，在两端的中空轴大法兰上顶处测量，高度应一致，有误差时允许进料端高于出料端1mm。 在两端中空轴的轴承座压盖处看，中空轴与轴承压盖周围的缝隙应基本一致，并且内外压盖处都应使缝隙基本一致。The axes in the rotating part shall be in horizontal level. Measuring from the top of the hollow shaft flange, their height shall be consistent. It allows little inaccuracy that the feeding end can be 1mm higher than the discharging end. Seeing from the bearing seat gland of the hollow shaft on the two ends, the gap between the hollow shaft and the bearing gland shall be consistent. Also gaps around the inner and outer gland shall be consistent. 5、大齿轮的安装 Big Gear Installation 大齿轮与筒体安装时，齿圈法兰面与筒体法兰面之间不得有间隙(大齿轮侧面如有回油槽的磨机，回油槽的接口在安装时应焊好，防止漏油)。When install gearwheel and shell, there shall not be clearance between girth gear flange surface and shell flange (if there is mill with oil-return tank at the gearwheel side, the connect opening of oil-return tank shall be welded during installation for fear of oil leaking)大、小齿轮安装时，必须保证小齿轮对大齿轮的作用力垂直向上。大、小齿轮的齿面应平行接触良好，齿侧间隙符合要求。When install gearwheel and shell, the pinion force on gearwheel shall be kept vertically. The faces of pinion and gearwheel shall be in parallel and connected well, the gear backlash shall comply with the requirements.6、传动装置的安装 Driving device installation在回转部分调整好水平以后，方可进行传动装置的安装。首先检查传动装置组装的质量情况，主要是检查小齿轮轴与减速机低速轴的同心情况、检查减速机高速轴与电机轴的同心情况，并进行必要的调整和紧固。 Install the driving device after level adjustment of rotating part is made. First, check the assembly quality of driving device, especially the concentricity of pinion shaft and lower speed shaft of gear reducer, the concentricity of higher speed shaft of gear reducer and motor shaft, and make some adjustment and fastening.以回转部分大齿轮为基准，安装和调整传动装置。使小齿轮的齿宽与大齿轮的齿面两边宽度均匀一致。使小齿轮的齿面与大齿轮的齿面平行，齿侧间隙按最小处留0.5mm。可在齿轮啮合处压铅丝，观看铅丝厚度和对比厚度是否一致。从大、小齿轮的接触痕迹看，接触痕迹应占全长的60%以上，接触痕迹的高度占到全高的40%左右。The installation and adjustment of driving device shall be based on the gearwheel in the rotating part, making sure that the gear width of pinion is same to the two sides of gearwheel surface, the gear surfaces of pinion and gearwheel is parallel. The minimum gear backlash shall be 0.5mm. The lead wire can be pressed on the gear meshing part, check whether the thickness is same to contrastive thickness. Seen from the connecting trace between pinion and gearwheel, the length of connecting trace shall account for 60%, the height shall be 40%.如果接触痕迹偏向齿面宽度的一端，即表明齿面不平行。如果传动大齿轮一周有挤死的情况，说明齿轮间隙太小，应使小齿轮离开大齿轮一点。If connecting trace deviate from the side of gear surface width, it means the gear surface is not parallel. After one weeks operation, the gearwheel locks up, it suggested that the gear backlash is too small, so it is needed to enlarge the backlash.7、衬板的安装 Liner installation（1）安装衬板前应将筒体内的尘垢清除干净。Clean up the shell before installing the liners（2）安装衬板前应先对衬板进行检查和修整，其背面和四周应光滑平整，螺栓孔应彻底清砂和清除铸造飞边，使螺栓能顺利穿入。其背面和四周应酌情用砂轮修整，达到安装要求。Check and trim the liners before installing liners. The back and round of liners shall be smooth and flat. Clean up the sand and casting flash in the bolt opening to make the bolt fit in properly. Make proper trimming to back and around part of liner for complying with the installation requirement.（3）安装衬板时，应将其和筒体贴合面间填充水泥砂浆（水灰比例1：2），在砂浆凝固前将螺栓拧紧，所有衬板之间的间隙应用水泥砂浆填满。 Fill cement mortar into the connecting surface between liners and shell (water ratio to cement 1:2), fasten the bolts before the cement mortar solidified; all the gaps between liners shall be fully filled with cement mortar.（4）固定衬板螺栓，应仔细地垫好密封垫，以防止漏出矿浆。 Fix liner bolts; check carefully the sealing gasket to prevent the ore slurry leak out.（5）有方向性的衬板应注意方向不得装反。长磨机一般由隔仓板把磨筒隔成前后两仓。进料端为第一仓，第一仓为阶梯衬板。安装时，阶梯衬板的薄端应与磨机工作时回转方向一致。隔仓板的篦子孔是锥形的，安装时应使锥口的大端与磨机的排料方向一致。 Pay attention to the liners with designated direction, opposite direction is not allowed. For the long mill, there is usually partition plate, which takes the shell apart to two chambers. The first chamber is at the feeding end, it is stage lines. When installation, the direction of thinner part in stage liners shall be same to that of mill rotation direction; the grate hole in the partition plate is conical, the large part of conical opening shall be same to the discharging direction.（6）安装隔仓板时，应穿好全部螺栓，然后分三次逐步把螺栓拧紧。同时注意，应先紧筒体内中心圆盘上连接螺栓，后紧筒体上的螺栓。螺栓全部拧紧以后，把筒体内中心圆盘上螺栓的螺帽用电焊“点焊”，防止松动。 When install the partition plate, fit all the bolts and fasten them gradually in three times. Meanwhile, fasten the connecting bolts in the central disk of shell and shell bolts. After fastening all the bolts, weld the nuts of bolts in the central disk by spot welding, for fear that bolts become loose.（7）筒体衬板不得形成环形间隙。 Shell liners should not have annular gap.（8）水泥砂浆凝固达到强度要求后才可以投料试车。运转中发现螺栓松动应及时拧紧。 After the solidity of cement mortar reaches the strength requirement, it can be fed with materials for test running. If bolts loosen during operation, they shall be fastened timely.8、齿轮罩的安装 Gearwheel Cover Installation齿轮罩安装好后，不得有漏油和与齿轮相干涉现象。所有的密封圈一定要安装严密，罩内要严格清理干净。After gearwheel cover is installed, there should not be oil leaking and gear interference. All sealing gaskets shall be installed tightly; clean up the cover strictly.三、试运转. Test running1、磨机安装完毕并经过检查合格后，方可进行试运转。 （1）设备内部无遗留杂物，设备周围无妨碍运转的物体，操作人员均在安全区。 Keep the left foreign materials away from the mill. Make sure there is nothing obstructing the mill operation, and operators are in the safety working area. （2）检查所有的地脚螺栓均已拧紧。 Check all the bolts are fastened well. （3）冷却、润滑系统均应符合要求，油面达到规定要求，齿轮罩内的润滑油面应淹没一个全齿高。油太多会引起漏油和浪费，油浸不到大齿轮的一个牙，则会润滑不良。 The cooling and lubricating system shall comply with requirements. The oil level shall reach requirement. Lubrication grease shall submerge the whole depth of gear. Too much grease will cause leaking and waste. If the grease cannot reach the tooth of gearwheel, it will be short of lubrication. （4）各密封部位密封良好，无漏浆、漏油、漏水之处。 All the sealing part shall be well sealed, no slurry leak, grease leak and water leak. （5）所有仪表、照明、信号装置均应完整良