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360型对辊式压块机设计【说明书+CAD】,360,辊式压块机,设计,说明书,CAD
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黄河科技学院毕业设计（文献翻译） 毕业设计文献翻译 院（系）名称工学院机械系 专业名称机械设计制造及其自动化 学生姓名张国辉 指导教师康宏伟2012年 03 月 8 日压块机的结构组成及其应用前景Bergendahl一台对辊成型机可以分成以下几个部件,安全联轴器，压辊、轴承、用于支承压辊的系统、给料系统、承压支架、传动系统、润滑系统及液压施压系统,机架。图3 是一台典型的对辊成型机的水平剖面图。两个压辊支承在可自动调准的球面滚柱轴承上, 而该轴承安装在机架上。传动齿轮通过安全联轴器与齿轮减速器的输人轴相连。通过齿轮减速器 电机速度被降到高压辊的速度。在齿轮加速器中，两个斜齿轮与两个输出轴同步。压辊与带有牙嵌式齿轮联轴器的双输出轴齿轮减速器相连。压辊的上表面（图3中看不到）安装着给料系统。没有表示出来的还有提供给主要齿轮的润滑系统装置，支架上的齿轮箱的滑断面，联轴器以及使压辊在一起的液压系统的施压装置。图3 一个典型的机器辊部分意见与反馈 参加有道翻译用户满意度调查！ 1. 安全联轴器成型机工作时, 物料( 粉煤) 不可避免地带有小件铁器等坚硬物进入辊轮啮合区而阻止辊轮的转动。在这种情况下, 为了确保成型机辊轮安全正常工作, 活动对辊组件必须具有一定距离的平移退让功能, 并能在严重过载情况下, 联轴器能脱开传动。所以设计的联轴器应具有适应这种退让和安全保护的功能。本设计采用双摩擦滚子式安全联轴器, 它兼有“滚子” 摩擦离合器”和“的功能, 即利用滚子链传动, 满足成型机活动对辊组件轴承座较大“可移式”的退让要求; 利用摩擦片传动, 设置过载保护。本安全联轴器还具有安装方便、调整和维护简便、工作可靠、寿命长、不受环境因素影响等特点。图4凸缘联轴器2. 压辊对辊成型机的最主要部分是压辊本身。不同的设计方案均是可以的。首先, 压辊由具有坚工作表面的坚固的锻造件制成。表面坚硬可使之适于选择各种表面结构用于生产高强度的饼。另外一种方式是,压辊的辊芯可能是可更换的。这样, 对辊本身易于进行水冷。这种辊环的工作表面通常被加工成浅的球窝。最新设计的成型机采用了这种方式。因为, 通常由于给料的温度较高, 为了避免在物料表面发生“ 熔融” , 或当传导给压辊的温度必须降下来以确保轴承低温工作时, 必须使辊环的表面得到冷却。坚硬的压辊的优点是它可以取代简单的机器部件。当压辊表面严重磨损后, 可以在外径规的范围内对表面进行重新焊接 这样可使设备始终保持高效运行。当然, 使用经过预处理的部件可以确保由于人料传给的热而不致于使压辊过热。使用内表面具有冷却系统的热套套筒（ 图4） 将更经济, 并要求使用更清洁的冷却水。为了避免与辊芯接触的处理不当的水对压辊的腐蚀, 用一个冷却装置使冷却水系统封闭起来是合适的。大多数设备采用的是浅的长方形的可以摇动的铁箱, 以便于空气的排出和确保料饼具有高而均匀的密度和强度。根据图 , 设备中选用齿轮联轴器的优点是易于脱开。在左边, 在压辊中心线的上边所示的是联轴器的一半已被移到左边, 而压辊被很容易的脱开的情景（也可看支架的剖视图）。图4 具有热套筒和冷却系统的压块机压辊的剖面图3.轴承（压辊的支撑装置）在现代大型的压块机中, 压辊安装在高效而体积小的、能自校准的球面滚柱轴承上。这样, 尤其在采用宽的压辊时, 可移动的压辊能随给料的不均匀程度和给料的厚度（ 多少）自由调整。为确保压块机更安全地工作, 正确选用适当的轴承是至关重要的。最重要的考虑因素包括轴承的设计以及密封、冷却和润滑。在轴承套内轴承的受力及分布必须为最优。这就要求进行精确的计算。就象Koppern公司提供的最新型的压块机中, 轴承套的实际变形是采用有限元方法进行了详细计算后得出的。进行这些计算的目的是为了使轴承套的变形量与轴承负荷的理论分布相一致（图5）。图5能自校准的球面滚柱轴承负载分布图如果需要的话, 冷却系统将确保轴承低温工作,并能改善润滑效果, 润滑脂低温工作还能确保轴承在轴承套内具有良好的密封性能。较高的负荷、低速运转的轴承要求采用特殊润滑脂, 它具有大约高达10-3/m2的粘度, 并加了一定的添加剂。4. 给料系统给料系统位于压块机支架正对着压辊辊隙的上边。在给料为细粒和 或需要较大产量以及一些其它的特殊原因, 简单的重力给料滑槽可能不被采用, 在这些情况下, 螺旋给料是必须的。由于螺旋给料的特征是在螺距的中心及边缘的给料量是不一样的及螺距的几何尺寸与辊隙面积的尺寸不同, 所采用的螺距的直径受到限制。为使压辊机沿辊宽得到均匀的给料分布, 采用了多螺旋给料机。例如, 一台生产能力为80100t/h的压块机, 要求其单辊的工作宽度在于10001200mm之间, 这样就要求安装多螺旋给料机。螺旋成一定角度安装在给料中心的两边, 在重力的作用下,物料进人给料机, 通过螺旋的螺距向下输送, 迫使物料直接进人压辊间的辊隙（ 图6）图6 螺旋给料机的示意图特别是在细粒物料压实过程中, 物料中空气的排出对于压块机的高效工作起着重要的作用,例如, 在钾盐的压块中, 散料的密度大约为1g/cm3，而料饼的密度大约为2 g/cm3,，如果产量为100t/h，那么大约有50m3/h的空气被排出, 这么大量的空气必须能通过散料中的孔隙排出。由于散料中孔隙随压实过程而变小,因此, 这种物料的压块将变得更困难。在压辊辊隙间压实成块，由于物料紧紧地填满了压辊，向下移动的物料中的空气必须逆着物流向上溢出，如果不是这样, 机器的颤动将导致机器设备的损。因此, 在设计时必须实现（1）允许空气从给料器低部和辊面间排出：（2） 保证两边和压辊的肩角的缝隙（ 图7 ）。图7 压块机中空气的溢出研究表明, 如果辊宽不超过500 一600mm , 空气仅仅能有效地从两边溢出, 这样辊宽的极限也总是取决于散料的颗粒粒度分布或散料的透气性。随着辊宽的增大, 空气可能被迫夹在辊隙间的物料中不能逸出而导致压块机负荷的进一步增加。为避免出现这一问题,对总宽度1000 一1200mm 的压块机, 其总的工作宽度将被分成2个500 一600mm 的两部分,每一部分设置两个螺旋。为了使空气能够溢出, 所有 台螺旋是相同的( 见图4 ) , 为了满足各种不同给料速度和设备生产能力的要求, 螺旋的速度必须能被分别调整。5.承压支架在设计压块机的承压支架时, 必须使之能够承受压辊传来的高压和支承给料系统, 通常采用双支架。所谓的标准支架要求维修方便, 比如, 由于磨损或者检修时必须将压辊移开。不仅如此, 像Koppern公司又发展了一种“ 铰接” 支架( 图8 ) , 这种支架易于移开或更换压辊。支架垂直部分的底端与水平部分的上面相连, 而垂直支架可以通过铰接处放下, 在移开一部分压辊附件和浮辊端的液压箱, 以及断开齿轮连轴器、润滑脂的管路、冷却水的连接系统之后, 压辊可以被拉出到一个易于用桥式吊车吊起的地方。如果使用标准的支架, 更换一次压辊可能化费一周的时间,而使用铰接式支架, 可能只需要1 一2 个班即可。为了使维修工作更方便, 设计中采用了一个压辊移开装置和一个提升横杆, 二者均与压辊的轴承箱相连。图8 铰链式支架的示意图6.驱动齿轮系压辊机的驱动齿轮系由两个大型齿轮联轴器, 包括同步斜齿轮在内的减速器齿轮, 和在电机与齿轮箱输人轴间的一个安全联轴器组成。通常, 安全联轴器是一个能自动复位的机构, 它可以在通常工作时驱动转矩的1.71.9倍范围内调整。减速齿轮包括两部分：减速器和同步转矩分配齿轮, 一般情况下, 减速器的安全系数为 , 而同步转矩分配齿轮的安全系数为2。大型齿轮减速器装有油冷却和过滤装置, 以确保设备能连续运转。最主要的是, 同步齿轮和齿轮联轴器的连接保证了提供给压辊完全均匀的线速度。仅仅在没有剪切力作用的情况下设备才能获得较高的产量。7. 润滑一个连续润滑系统能提供给主要齿轮和浮辊的滑面一种连续的、可靠的特殊润滑脂。为确保有效地工作, 润滑系统被监控。大型机器往往也总是具有对齿轮联轴器的自动润滑系统, 这样可使设备长期连续运转而不必停车进行润滑维修。8. 液压施压系统液压施压系统用于提供给液压箱压力，改压力迫使辊向被压实的物料和固定辊靠近。为满足特殊的工作需要，压力的高低和大小可自由调整。压力的梯度随间距的变化而升高, 通过改变液压储能器中氮的分压可以在很大范围内调整压力的梯度。在物料被压人压辊的间隙时液压系统也用作安全装置。一台电控系统监控它的功能。9. 机架为了改进老式对辊成型机低速重载、刚性不足的毛病, 本设计采用分别由左、 上、右、 下四个端架组成的机架结构, 各端架间用销轴连接,使机架制作简便、拆装方便, 而且机架的承载能力强, 满足了大型对辊成型机的工作要求。10.应用前景 GXM 600/ 45 型对辊式工业型煤成型机的研制成功, 为工业型煤走向规模生产提供了可靠的设备, 本机可面向年产 10 万 t 的工业型煤厂, 可作为加工锅炉型煤和气化型煤的主机。在我国利用粉煤生产型煤具有较高的节能、环保和社会效益, 并越来越受到人们的重视, 其产量也将不断增加。由此可见, GXM 600/ 45 型对辊式工业型煤成型机也将具有广阔的应用前景。为了改进老式对辊成型机低速重载、刚性不足的毛病, 本设计采用分别由左、 上、右、 下四个端架组成的机架结构, 各端架间用销轴连接,使机架制作简便、拆装方便, 而且机架的承载能力强, 满足了大型对辊成型机的工作要求。Press block machine structure and its application prospectBergendahlA roll forming machine can be divided into several parts, safe coupling ，pressure roller, bearings, used to support pressure roller system, feeding system, the pressure bracket, the transmission system, lubrication system and hydraulic put pressure on the system，frame.Fig 2 Horizontal profile of a typical roll forming machine. Two pressure rollers supported on the automatic alignment of the spherical roller bearings, the bearings installed in the rack. The drive gear through the safety coupling with gear reducer input shaft. By the gear reducer motor speed is reduced to the speed of the pressure roller. Gear accelerator, the synchronization of the two helical gear and output shaft. Pressure roller and connected to double output shaft gear reducer with a the Jaw gear couplings. The pressure roller surface (Figure 3 can not see) the feeding system is installed. Did not indicate there to the main gear lubrication system device, the sliding section of bracket on the gearbox, coupling, and the pressure roller with hydraulic pressure from the device. Fig3 Atypical of the machines to roller section1. Safe coupling Molding machine work, material (adding) do not avoid zone ，A small iron and hard thing into the roller gear area and prevent roller the rotation of the wheels. In this case, in order to ensure that the molding machine the roller security work, the activities of the component must have a certain distance .The concessions from the translation of the function, and in serious cases can overload, united the open transmission shaft can take off. So the coupling design should have comfortable should this concession and safety protection function. This design USES the double friction roller type safe coupling, it with roller friction clutch and function, namely, use rolling the son chain, meet the molding machine activities on roller bearing a component big will move a type concession request; Use of friction transmission, setting overload protection. This safe coupling also has easy installation, adjustment and convenient maintenance, reliable working, long service life, not affected by environmental factors influence characteristics. Fig4 Flange coupling2. Pressure rollerThe most important part of the roll forming machine is the pressure roller itself. The different designs are possible. First of all, the pressure roller has Caine work the surface of solid forgings made. The hard surface allows suitable to choose a variety of surface structures for the production of high strength of the cake. Another way, the pressure roller of the roller core may be replaced. In this way, the roll itself is easy to be water cooled. The work surface of the roll ring is usually processed into a shallow ball and socket. The latest design of the molding machine used in this way. Conduction to the pressure roller temperature must be down to ensure that the bearings at low temperatures the surface of the roller ring must be cooled, usually due to higher feed temperature, in order to avoid the occurrence in the material surface melt.Fig 3 Profile of a typical roll forming machineThe hard pressure roller advantage is that it can replace the simple machine parts. When the severe wear of the pressure roller surface, within the scope of the regulations in the outer diameter surface of the re-to welding . This will enable the device is always to maintain efficient operation. Of course, the use of pre-processed components can ensure that the people expected to pass the hot and would not make the pressure roller overheating. The inner surface of the heat of the cooling system sleeve (Figure 4) will be more economic use, and require the use of cleaner cooling water. In order to avoid improper handling of water in contact with the roller core corrosion, pressure roller and a cooling device cooling water system closure is appropriate. Most of the equipment used can shake a shallow rectangular metal box, with high and uniform density and strength in order to facilitate the discharge of air and ensure that the material bread. Advantages the figure, equipment selection of gear coupling is easy to disengage. Shown on the left, the upper pressure roller centerline is half of the coupling has been moved to the left, the pressure roller is easily torn off and the scene (to see cutaway view of stent).Fig 4 Briquetting machine with thermal sleeve and the cooling system pressure roller profile3. Bearings (pressure roller support device)In modern large-scale briquetting machine, the pressure roller in the efficient and small size, self-calibrated spherical roller bearings. In this way, free to adjust especially in the wide pressure roller, pressure roller with removable feeding uneven and to the material thickness (how much).To ensure that the briquetting machine work more safely, it is crucial to the correct selection of the appropriate bearing. The most important considerations include the design of bearings and seals, cooling and lubrication. Bearing comprising a bearing force and distribution must be optimal. This requires a precise calculation. Come like Koppern latest briquetting machine, the actual deformation of the bearing is carried out detailed calculations using finite element method. The purpose of these calculations is consistent with the deformation of the bearing sleeve and the theoretical distribution of bearing loads (Figure 5).Fig 5 Self-calibration of spherical roller bearing load distribution mapIf necessary, cooling systems will ensure that the bearings at low temperatures, and can improve lubrication grease at low temperatures but also to ensure that the bearings in the bearing kit has a good sealing performance. High load, low speed bearing using a special grease, it has about as high as 10-3/m2 viscosity, and the addition of certain additives.4. Feeding systemTop of the feeding system in the bracket is facing the pressure briquetting machine roll gap. Feed fine and of or require large production, and some other special reason, a simple gravity feed chute may not be adopted in these cases, the screw feeder is a must. The diameter of the pitch characteristics of the screw feeder is in the center of the pitch and the edge of the feeding is not the same and the pitch of different geometric dimensions and the size of the roll gap area is restricted.To make the pressure roller machine uniform feed distribution along the roll width, using a multi-screw feeder. For example, a production capacity of 80 100t / h briquetting machine, single roller width is between 1000 1200mm, this requires the installation of multi-screw feeder. Spiral into a certain angle installed on both sides of the feeding center, under the action of gravity, the material into the feeder, conveying spiral pitch down, forcing the material directly into the pressure nip between the roll (Figure 6)Fig 6 Spiral to the schematic of the feederIn particular, fine-grained material in the compaction process, the materials in the air discharge plays an important role for the efficient work of the briquetting machine, for example, in the briquetting of the potassium salt, the density of the bulk material is about as 1g/cm3material the density of the cake is about 2 g/cm3, if the output of 100t / h, then approximately 50m3 / h air is discharged, so a lot of air through the pores of the bulk compound excreted. As the bulk compound pores become smaller with the compaction process, therefore, a tablet of this material will become more difficult.Pressure roll roll band to band compacted into blocks, because the material tightly fill the pressure roller, moving down the material in the air must be going against the logistics up the overflow, if not the quiver of the machine will result in the loss of machinery and equipment. Therefore, the design must implement (1) allow air discharged from the lower part of the feeder between the roll surface: (2) to ensure that the gap on both sides and the pressure roller shoulder angle (Figure 7).Fig 7 The escape of air in the briquetting machineStudies have shown that if roller width 600mm, over 500 air only from both sides of the overflow, this roller width limit always depends on the particle size distribution of bulk materials or the permeability of the bulk material. With the roll width increases, the air may be forced to clip roll band to bands material can not escape, resulting in a further increase in the briquetting machine load. To avoid this problem, briquetting machine of 1000 a total width of 1200mm, the total working width will be divided into two 500 a 600mm two parts, each part of the set up two spiral. In order to allow the air to overflow, all spiral is the same (see Figure 4), in order to meet the requirements of various feed speed and equipment production capacity, the speed of the screw must be adjusted separately.5. Pressure stentPressure stent in the design of briquetting machine, you must make it able to withstand the pressure of the high-pressure roller coming and supporting feeding system, usually with double stent. The so-called standard stents require easy maintenance, for example, due to wear or maintenance must be the pressure roller is removed. Not only that, like knock Koppern company and the development of a hinge bracket (Figure 8), this bracket is easy to remove or replace pressure roller. Bracket connected to the bottom of the vertical part of the horizontal portion of the above, the vertical bracket can be hinged at the down, remove part of the pressure roller attachment and floating roller side of the hydraulic tank, and disconnect the gear couplings grease piping, after connection of the cooling water system, the pressure roller can be pulled out to an easy overhead crane to lift. If using a standard bracket, replacement of a pressure roller of the fee may a week, while the articulated bracket may only need two classes can be. In order to make maintenance work more convenient, the design of a pressure roller to remove the device and a lifting bar, both connected with the pressure roller bearing box.Fig 8 Schematic of the articulated bracket6. Drive gearThe pressure roller drive gear of the machine by two large gear couplings, including synchronized helical gears, gear reducer, and a secure coupling between the people axis in the motor and gearbox input. Typically, the safety coupling is an automatic reset of the institutions, it can drive torque range of 1.7 to 1.9 times usual hours of work adjustment. Reduction gear consists of two parts : Reducers and synchronous torque distribution gear, under normal circumstances, the safety factor of the reducer for synchronous torque distribution gear safety factor of 2. The large gear reducer is equipped with oil cooling and filtering devices to ensure that the equipment of continuous operation.The most important is the conn
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