鼠笼电机安装和维修

1、 INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR SQUIRREL CAGE MOTORS鼠笼电机安装和维修说明Contents目录Page1. STRUCTURE结构1.1 General概要1.2 Bearings轴承1.3 Phase windings相位绕组2. INSTALLATION安装2.1 Receipt and storage验受和存放2.2 Location位置2.3 Driven machinery驱动机械2.4 Connection to main supply电源联接3. START-UP启动3.1 Operational

2、check运转前检查3.2 Insulation resistance绝缘电阻4. MAINTENANCE AND INSPECTION维修行检查4.1 Periodic inspection周期检查4.2 Service of the bearings轴承保养5. REPAIRS修理5.1 Exceptional vibration异常振动5.2 Hints to determine the cause of winding damage绕组损坏原因迹象5.3 Disassembly of the motor拆卸电机5.3.1 Disassembly of N-end拆卸N端5.3.2 Di

3、sassembly of D-end拆卸D端5.4 Re-assembly of the motor重装电机5.5 Recommended lubricants推荐润滑剂6. ORDERING SPARE PARTS备件订货1. STRUCTURE结构1.1 General概述The squirrel cage motors used in Konecranes cranes are completely enclose motors. Some motors contain one or two plugged drain holes. These holes are located at

4、the lowest points of the frame. The stator frame and bearing shields are made of cast iron or aluminum alloy. The fan located outside of the N-bearing shield (Figure 1) is made of aluminum alloy or plastic. In larger motors, the fan is made of steel.KCI 鼠笼电机整个密封，一些电机下面有排水孔。定子框架和轴承室由铸铁合铝合金制成。铝合金或塑料风扇

5、在N轴承室的外边。 大电机的风扇是用钢制成。Figure 1: Totally enclosed squirrel cage motor without lubricating device不带润滑装置并整个密封的鼠笼电机D-END (Driving end)驱动端N-END (Non-driving end)从动端1.Ball bearing球轴承6.Terminal box接线盒2.End shield D-end驱动端轴承室7.Lifting eyebolt吊点螺栓3.Inside bearing cover轴承内盖8.End shield N-end从动端轴承室4.Rotor and

6、shaft转子和轴9.Fan风扇5.Stator frame and stator10.Key键定子框架和定子11.Fan cover风扇罩Figure 2:Bearings in a motor with lubricating device带润滑装置的轴承1.Grease valve disc油脂阀盘 5.Grease nipple油嘴2.Outside bearing cover轴承外盖 6.Inside bearing cover轴承内盖3.End shield轴承室 7.Felt sealing strip密封圈4.Ball bearing轴承1.2 Bearings轴承The mo

7、tors are furnished with series 62 or series 63 ball bearings. To fix the axial position of the rotor, lock the bearings specified in the axial direction. In motors M08 - M24 lock the Dbearing. In motor M25 lock the N-bearing.电机带有62或63系列球轴承。为了固定转子轴向位置，特别要轴向固定轴承。M08 - M24电机固定驱动端轴承，M25电机固定从动端轴承。Motors

8、M22 and M25 are supplied with a lubricating device (Figure 2). For these motors, the axial locking of the bearing is achieved by means of the grease valve disc. There is a thread in the Ngrease valve disc of motor M25. The other grease valve discs are removed by pulling.M22 - M25电机带有润滑装置(图2)。 这些电机用油

9、脂阀盘来轴向固定轴承。M25电机从动端上的油脂阀盘带有螺纹。其他电机的油脂阀盘靠用力拖拉来移动。1.3 Phase windings相位绕组The insulation class of the stator windings is stated in the rating plate. The insulation class is typically class F. Dynamo wire used in motors up to size M22 is IEC 182-1 and 182-2 grade2.Installation铭牌上标明了定子绕组的绝缘等级。典型绝缘等级是F级。M2

10、2以下的电机的绕组线符合 IEC 182-1 和IEC182-2 的 2级标准。2. INSTALLATION安装2.1. Receipt and storage验收和存放Inspect the motor immediately upon receipt. Verify that there is no damage due to transport.收到电机后立即检查，保证电机在运输中无损坏。Verify that the rating plate values correspond to the order. Verify that the power supply is compati

11、ble with the values specified on the rating plate.保证铭牌上的参数和定单上一致。保证电源和铭牌上的参数一致。If the motor is to be stored prior to installation, it must be kept indoors at room temperature in order to keep the insulation dry. If the motor is stored for more than six months, manual rotation of the shaft is recomme

12、nded every two months. The rotation will distribute the oil in the bearing grease.电机必须存放在常温的室内来保持绝缘干燥。如电机存放超过6个月， 应每2个月用手转动一次轴使润滑脂布置均匀。WARNING!警告！When lifting the motor, use the lifting eye bolt on the stator frame (Figure1, item7) or twolifting slings placed under the stator frame.起吊电机必须用吊点。2.2. Lo

13、cation位置If there are drain holes in the motor, the motor must be mounted in the position specified on the rating plate.带有排水孔的电机必须按铭牌上所指示的位置安装Ambient temperature must not exceed 40 oC, unless otherwise stated in the order. The flow of the cooling air must not be obstructed. Expelled air must be freel

14、y discharged and it must not be directed back immediately.除非定单上游说明，环境温度不得超过40 oC。空气必须流通以便电机散热2.3. Driven machinery驱动机械The rotor is balanced with a full-length key in the keyway of the shaft extension. Pulleys and couplings connected to the motor must be balanced without the use of a key.转子已是平衡的。外接的滑

15、轮，联轴器等必须也是平衡的。Use solvent to clean the shaft ends and the contact faces of the flanges. Note that the shaft ends and the contact faces of the flanges are treated against corrosion.用溶剂来清洗轴端和法兰的接触面。注意轴端和法兰的接触面经过防腐处理 CAUTION!注意！The solvent must not penetrate the bearings.溶剂不允许渗入轴承。WARNING!警告！To prevent

16、 damaging the bearings, do not hammer or strike the shaft of the motor.为保护轴承，不允许锤击电机轴2.4. Connection to main supply接电源In motors M08 - M16, the terminal box is located on top of the stator frame. In motors M18 - M25, the terminal box is located on the right hand side of the stator frame as shown on t

17、he Dend motor (Figure 3). The terminal box on motors M18 - M25 may be moved to the opposite side of the frame by disassembling the motor (section 5.3) and by turning the stator frame around.在M08- M16电机上，接线盒在定子框架顶部，在M18- M25电机上，接线盒在定子框架右边，或转动定子框架使接线盒在左边。D-endD-endM08 - M16M18 - M25Figure 3: Location

18、of the terminal box接线盒位置The terminal board strips are in the position corresponding to the type of connection stamped on the motor rating plate (Figure 4).端子板的位置和电机铭牌上标示接线位置相对应(图4)。Y-connection Y-联接D-connection D-联接Y-D-starting(strips are removed)Y-D-联接(取走连接片)Figure 4: Position of the terminal board

19、 strips端子板的位置Motors with an output of 3 kW or less may have only three wires from the stator winding to the terminal box. They are connected to terminals U1, V1 and W1. In this case, the terminal board strips are removed.功率等于或小于3KW的电机可以只有3根从定子绕组到接线盒的U1，V1和W1。这种情况没有连接片。On two speed motors with two se

20、parate windings (i.e. poles marked 2/8 or 2/8), the low speed winding is connected to terminals U1, V1 and W1. The high-speed winding is connected to terminals U2, V2 and W2 (Figure 5). Follow the wiring diagram provided with the motor for all other pole-changing motors.带有两组绕组的双速电机(如极标记为2/8或8/2)中，低速

21、绕组和U1, V1 及 W1连在一起，高速绕组和U2, V2及 W2连在一起(图5)。其它的变极电机接线须按电机上的接线图进行。Figure 5: Connection of pole-changing motor with two separate windings双速电机接线3. START-UP启动3.1. Operational check运转前检查Before operating the motor, check the following:运转电机前，检查下列1. Free rotation of the rotor. Verify that all temporary trans

22、port supports for the bearings, if any, have been removed.转子自由运转。保证无任何临时轴承支架。2. Insulation resistance. Check the insulation resistance in accordance with section 3.2. Check the insulation a few days before use since the winding may need drying.绝缘电阻。因为绕组需要烘干，应提前几天按3.2.节检查绝缘。3. Direction of rotation o

23、f the motor. The direction of rotation of the motor, in accordance with section 2.4, is clockwise, as viewed from the D-end. The direction of rotation may be reversed by interchanging any two main supply wires which connect to the pole screws (U1, V1, W1) of the motor. Verify that the direction of r

24、otation of the motor corresponds to the direction of the control commands. Symmetrically installed bridge travelling machine units operating on different rails have opposite directions of rotation.电机旋转方向。根据2.4节，从D端看电机的旋转应是顺时针方向。交换任两极的接线可改变旋转方向。保证电机的旋转方向和控制方向一致。对称在两根轨道上的大车电机旋转方向应是相反的。4. Operating noi

25、se. A loud growling sound from the motor indicates that the connection is faulty, and the motor must be stopped immediately. 噪音。如电机发出很大的噪声则表明接线有错。电机必须立即停止。5. Vibration. The cause of any exceptional vibration in the motor must be determined 振动。必须查明异常振动原因。6. Load condition (recommendation). Measure th

26、e stator current from each phase. Measure the speed of rotation with a tachometer or by slip-measurement. Compare the values obtained with the values specified on the rating plate.负荷状况。从每一相测量定子电流。用转速表或滑环表测量转子速度。比较测量值和铭牌上标定值。7. Running temperature. Running temperature. Check the temperature after the

27、 first long-term use. The motor will reach it's final running temperature in approximately three to five hours after starting. To check the temperature, first feel the stator frame. If the temperature of the stator frame feels as though it has exceeded 50 oC, use a thermometer to obtain an

28、accurate temperature reading. Place the bulb of the thermometer in the bolt hole of the lifting eye or on the surface of the stator frame inside the terminal box. The temperature rise of the winding must not exceed 100 oC in motors with Fclass insulation.运转温度。第一次长时间运转后应检查温度。电机在3-5小时运转后达到最终温度。可用

29、手触摸定子外壳来检查温度。如感觉温度超50 oC，应用温度计来测量出精确的温度。将温度计的的触头放在起吊螺丝孔内或接线盒内的外壳表面上。F级绝缘电机的绕组温度不允许超过100 oC。 3.2. Insulation resistance绝缘电阻The most convenient method of evaluating the condition of the insulation is to measure the insulation resistance. When the winding is clean and dry, the insulation resistanc

30、e is high. A low insulation resistance value is usually the result of dampness or dirt.最简便的检查绝缘的方法是测量绝缘电阻。当绕组干净和干燥时，绝缘电阻高。而当绕组潮湿和肮脏时，通常绝缘电阻低。The stator winding may be damp due to transportation conditions or storage of the motor in a cold, damp or poorly ventilated location for a long period of time

31、. 由于电机运输和或长期存放在冷潮或通风差的地方，定子绕组可能会潮湿。Measure the insulation resistance with a 1000V MW meter. Take the reading when the test voltage of the meter has been connected to the winding for approximately one minute.用1000V MW 表测量绝缘电阻。当表和绕组连接大约一分钟后读数。The insulation resistance for a cool winding (10 to 40 

32、;oC) should be at least 5MW. The insulation resistance for a warm winding (over 40 oC) should be at least 1MW. If the insulation resistance is lower, the motor must be dried out.冷绕组(10 to 40 oC)的绝缘电阻至少应达到5MW。热绕组(大于 40 oC)的绝缘电阻至少应达到1MW。如绝缘电阻比这低，必须烘干电机。The drying process is controlled b

33、y heat and ventilation. Drying may be controlled in the following manner:烘干方法是加热和通风。有下列方式：1. Use a heater fan to blow hot air (approximately 100 oC) onto the windings inside the motor.用电吹风将热风(约100 oC)吹在电机里的绕组上。2. The windings may be dried in an oven at a temperature of approximately 100 oC

34、 provided that there is reasonable ventilation. If the temperature is increased slowly, the evaporation of the moisture will not damage the windings.如通风较好，可在约100 oC的烘箱中烘干绕组。如温度增长缓慢，湿汽蒸发不会损坏绕组。Initially, as the temperature of the damp winding begins to increase, the insulation resistance will de

35、crease. However, as drying continues, the resistance will begin to increase. The drying may be stopped when the resistance no longer changes.一开始，绝缘电阻随着潮湿的绕组的温度升高而降低。但当烘干继续绝缘电阻将变大。当电阻不变化时，可停止烘干If the winding is dry and the insulation resistance is still too low, the winding is dirty or damaged. A dus

36、ty winding may be cleaned carefully. The winding may only be washed by a specialist.如绕组已烘干，绝缘电阻还是太低，绕组就是肮脏或损坏了。肮脏的绕组可仔细清洁。只有专家才能清洗绕组。4. MAINTENANCE AND INSPECTION维修和检查4.1 Periodic inspection定期检查Periodic inspection is recommended at intervals of two months.建议每两个月作一次定期检查Check the following items: 检查下列

37、项目：1. Overheating (cleanliness, ventilation).过热(清洁，通风)2. Operating noise噪音3. Vibration. 振动4. Mountings.附件Check the condition of the bearings by listening to them i.e. by means of a rod. An even humming sound indicates that the bearing is working satisfactorily. If a distinct rattling is heard, the b

38、earing is damaged.利用一根棒来听轴承的声音来检查轴承状况。均匀的嗡嗡声表示轴承状况良好。如听见明显的咔嗒声则轴承坏了。必须立刻更换轴承4.2. Service of the bearingsThe lubricating intervals for motors with a lubricating valve are as follows:带有油阀的电机加油间隔：- horizontally mounted motors, 7000 operating hours水平安装电机，7000工作小时- vertically mounted motors, 3500 operati

39、ng hours垂直安装电机，3500工作小时Lubrication must be done while the motor is running to prevent grease from entering the motor.为防止油脂进入电机，加油必须在运转时进行For all other motors, the bearings must be cleaned and re-lubricated in the following intervals:其他电机的轴承的清洁和换油间隔：- one shift working5 years一轴工作5年- two shifts workin

40、g4 years二轴工作4年- three shifts working3 years三轴工作3年5. REPAIRS修理5.1. Exceptional vibration异常振动If there is exceptional vibration in the motor, the cause must be determined i.e. as follows:如有异常振动，按下列步骤检查原因1. Dismount the motor from the driven machinery. Start the motor while it is on the bed plate and li

41、ft it by means of the lifting eye.将电机从驱动机械上拆下来，将它放在支座上时启动，然后利用吊点将它提升起来。CAUTION! Do not start or stop the motor while it is suspended.注意！不要让电机在悬挂时启动If the motor no longer vibrates, possible causes of the vibration are:如电机不再振动，则振动原因可能如下：- twisted bedplate- misalignment or eccentricity between the shaf

42、ts- improper compression in the coupling pin bushing or an incorrect division of pins(This is often the cause if the vibration increases with load.)- a defect in the driven machinery- 支座变形- 轴心线不在一条线上- 联轴节销套不正确的压缩或联轴节销不均匀布置。(当振动随负荷增加而加大常是这个原因)- 电机故障2.If the motor continues to vibrate while suspended,

43、 remove the coupling. Place a full-length key in the keyway and secure it with adhesive tape. Repeat the test described above. If the motor continues to vibrate, there is an imbalance in the rotor. If the motor does not vibrate, there is an imbalance in the coupling.如电机在悬挂运转时继续振动，将联轴节拆下。将键放在键槽内并用胶布粘

44、牢，然后在一次按上述方法试验。如继续振动，则转子不平衡。如不振动，则联轴节不平衡。5.2. Hints to determine the cause of winding damage绕组损坏原因迹象A winding which burned out due to overload is usually uniformly black and brittle.由于过载烧坏的绕组通常整个发黑和发脆Cut-off of one phase causes the other phases to darken in various stages.某一相的短路会引起其它相变黑。A short circ

45、uit due to an insulation defect usually burns only a few coil sections black. There is also localized burning at the location of the defect.由于绝缘缺陷而引起的短路只引起缺陷部位的部分线圈烧黑。If a motor, which has been running well, becomes weak (slip increases at a certain torque), the defect is often in a cage winding. Th

46、e brazed joint in a copper or brass winding has failed, or some bars in an aluminum winding are broken. A defective brazed joint can usually be repaired. The rotor must be replaced if a cast aluminum bar is broken.如一个电机运转良好，但容易在某一力矩是打滑，这常由鼠笼绕组缺陷引起。可能是铜接点脱焊或铝合金棒损坏。铜接点脱焊可以修复。铝合金棒损坏则必须更换转子。5.3. Disasse

47、mbly of the motor电机拆卸Typically, it is not necessary to completely disassemble the motor. 一般不必将电机完全拆开。When detaching the motor parts with an extractor, protect the edges of the threaded hole at the shaft end from being damaged.当用提取器拆电机零件时，要保护好轴段上的螺纹孔。WARNING!Never disassemble or re-assemble the motor

48、 parts by hammering.警告！不允许用锤击来拆卸和重装电机零件。5.3.1. Disassembly of N-end拆卸N-端1. Unscrew the fastening screws on the fan cover. Remove the cover.松开风扇的固定螺栓，拆下风扇。2. Steel or aluminum fan: Unscrew the locking screw (1) of the fan. Pull the fan from the shaft with an extractor using the threaded holes (2) in

49、the fan.钢和铝合金风扇：松开风扇的固定螺栓(1)，利用风扇上的螺孔，用提取器将风扇从轴上取下来。Plastic fan: Remove the retaining ring from the fan and pull the fan from the shaft.塑料风扇:取下安装挡圈,将风扇从轴上拖下来。3. Unscrew the fixing screws of the end shield. Unscrew the fixing screws of the inside bearing cover, if any.松开端盖的固定螺栓，松开内轴承盖(如果有)的固定螺栓4. For

50、 motor M22, open the locking screw of the grease valve disc. Remove the grease valve disc by pulling with an extractor in the threaded holes (2) in the ring. For motor M25 remove the grease valve disc by unscrewing it (counter-clockwise).对M22型电机，松开油脂阀盘的锁紧螺栓，利用环上的螺孔(2)，用提取器拖下油脂阀盘。对M25型电机，反时针方向旋下油脂阀盘。

51、5. Pull the end shield off. For motors M20 and M25, do this by using an extractor in the threaded holes in the shield. The bearing is to remain in the rotor shaft.拆下端盖。对M20和M25型电机，要利用端盖上的螺孔(2) 用提取器将端盖拆下。WARNING!When removing the end shield, do not damage the ends of the stator windings.警告！当拆端盖时，不要损坏

52、定子绕组。6. Pull the ball bearing from the shaft either:将轴承从轴上拖下来。5.3.2. Disassembly of D-end拆卸D-端1. Unscrew the fastening screws of the end shield. Unscrew the fastening screws of the inner bearing cap and remove the outer bearing cap, if any.松开端盖的固定螺栓，松开内轴承盖的固定螺栓，拆下外轴承盖(如果有)。2. For motors M22 and M25,

53、 unscrew the locking screw (1) of the grease valve disc. Remove the grease valve disc by using an extractor in the threaded holes (2) in the ring.对M20和M25型电机，松开油脂阀盘的锁紧螺栓(1)，利用环上的螺孔(2)，用提取器拖下油脂阀盘。3. Remove the end shield and the bearing as described in sections 5 and 6.按5.3.1中的5，6节拆下端盖和轴承。4. Remove t

54、he rotor if necessary.必要时拆下转子。5.4. Re-assembly of the motor重新安装电机1. Remove all of the old grease from the bearings. Renew the grease in the lubrication channel if necessary. Wash the old bearings. Grease them lightly to prevent them from rusting. 清除旧油脂，必要时更换润滑管道中油脂，清洗用过的轴承然后涂上一些油脂防锈。2. Replace the r

55、otor if it was removed. Heat the bearings to a temperature of 80 to 90 oC in an oil bath or in an oven. Push the bearings onto the shaft.如转子已被拆下，应将它放回原处。轴承在油或炉里加热至80 - 90 oC 后装到轴上。WARNING!Use protective gloves when handling hot bearings. Make sure to keep the gloves clean to prevent them f

56、rom collecting dirt.警告！安装热轴承时要用保护套。保护套要保持清洁。3. Use the appropriate lubricant as listed in section 5.5 to lubricate the bearings as follows:按下所示，用在5.5节中列出的合适的润滑脂来润滑轴承- Completely fill in the space between the inner and outer race of the bearing with grease. 用润滑脂填满轴承内外圈之间的空间。- If the bearing has a gre

57、ase valve (M22 - M25), also fill the inside bearing cover with grease.如轴承有油脂阀(M22 - M25)，轴承盖内也要填满润滑脂。- If there is no grease valve in the bearing, fill the space in the inside and outside bearing cover half-way with grease.如轴承没有油脂阀，轴承盖内只要填一半润滑脂。- Lightly grease the sealing surfaces of the inside and

58、 outside bearing cover against the bearing housing and the shaft.内外轴承盖上和轴承座及轴接触的油封表面要抹点油脂4. To install the grease valve discs, heat both rings of motor M22 (heat only the Dring of motor M25) to a temperature of approximately 100 oC. Push them onto the shaft. Replace the locking screws of the grease valve discs. Screw the N-ring of motor M25