After receiving the instructions for the installation, use and maintenance of the ball mill in the manufacturing unit, the user should communicate with the design, civil construction, installation and operation personnel in a timely manner, read and operate in strict accordance with the instructions, design auxiliary equipment, plan, operation position of the electric control cabinet, preparation of materials such as connecting cables.
1. Drum feeder 2. Main bearing seat
3. Feed end cover 4. Cylinder
5.Big gear 6.Discharge port
7. Transmission department
1. Ball mill foundation construction
1. The user shall construct according to the basic drawing provided by the equipment manufacturing unit. The foundation must be on tight soil and can withstand the weight of the equipment and a certain amount of vibration.
2. The foundation must be poured as a whole, and the foundation, plane, elevation and left and right drawings provided by the equipment manufacturing unit only meet the installation of the equipment, and cannot be used as construction drawings.
3. Users should consider their own soil conditions, design the overall construction drawings of the foundation, should comply with the relevant provisions of civil engineering, and the maintenance period must be more than 15 days.
Two. Ball mill installation
Special attention: The user should bring their own adjusting skew iron 60 pieces. Figure 1:
1. Prepare
A. The foundation shall be comprehensively inspected, measured, and mapped out the relevant coordinate lines according to the size and elevation of the foundation drawing to calculate the error of the relevant reserved bolt holes, which can meet the installation requirements of anchor bolts. Otherwise, the reserved holes shall be reworked. The elevation should consider the highest point of the equipment, with sufficient adjustment margin.
B. After the equipment is delivered to the site, check the two hollow shafts, big gears, small gears and other parts. If there is damage, deformation and rust, it should be dealt with in time. The motor and electric cabinet shall be equipped with measures to prevent rain and dust.
C. Clean the two bearing seats, hollow shafts, (bearings) and big gears with diesel.
D. The user shall check and check the list of the manufacturing unit by full-time personnel for the equipment on site. If there is any error, contact the shipping unit in time.
2. Lift the two bearing seats (according to the mark on the bearing seat) to the foundation, put on the anchor bolts, and use 8 groups of inclined iron pads under the bearing seat. Figure 2:
Special attention: feed hollow shaft bearing on both sides should leave a gap (thermal expansion and contraction margin)!
A. The feed end of the main bearing seat should be higher than the discharge end,L≤5000mm, and its tolerance is 0.8~1.4. L≥5000mm, its tolerance is 1.5mm~2.2mm. (L is the distance between the center lines of the two main bearings)
B. The longitudinal center line of the two main bearing seats should coincide, not greater than 0.8mm, and the horizontal center line parallel should not be greater than 0.8mm.
C. After the two main bearing seats are adjusted, first put on the pinion seat, put on the anchor bolt, lift to the pinion seat foundation, and then connect the lower part of the big gear cover to the pinion seat in place, temporarily not adjusted, and the cylinder begins to place (lift to the main bearing seat). The main bearing seat of the feeding end should be adjusted according to the actual center distance of the cylinder body. Note that the gap around the wool felt of the two bearing seats should be adjusted equally. Figure 3
D. The anchor bolt of the bearing seat is poured cement until it is equal to the reserved opening. When the cement is dry, the anchor bolts can be tightened (pay attention to the maintenance of cement setting).
E. Assemble the hollow shaft and big gear on site. The joint surface should be cleaned, deburring, coated with sealant, assemble according to the red mark and steel number, put on the fastening bolts, and tighten the bolts.
F. Installation of liner
(1) The end liner is allowed to use metal, rubber material liner.
(2). Strict construction according to the lining plate installation diagram, pay attention to the eccentricity and displacement of the lining plate
(3). The lining plate should adjust the adjacent gap, and allow cutting when accumulating errors.
3. Pinion assembly adjustment, based on the big gear
A. The tooth side clearance of the big and small gears shall comply with the provisions of the following table:
|
Mill type number
|
1200 |
1500 |
1800 |
2100 |
2200 |
2400 |
2700 |
3200 |
|
Distance between centers |
1073.5 |
1181 |
1266 |
1845 |
1845 |
1823.84 |
2182.11 |
2507.35 |
|
Max |
1.2 |
1.6 |
1.8 |
2 |
2 |
2.2 |
2.6 |
2.8 |
|
Min |
0.8 |
1.2 |
1.4 |
1.8 |
1.8 |
1.8 |
1.8 |
2 |
Size gear center vertical height difference
|
Mill type number
|
1200 |
1500 |
1800 |
2100 |
2200 |
2400 |
2700 |
3200 |
|
Vertical height difference（mm） |
260 |
235 |
238.5 |
450 |
450 |
260 |
350 |
390 |
D. Push the pinion seat in the direction of the big gear until the two bars are stuck.
E. Adjust the pinion axis based on the big gear, and the margin on both sides is even (see Figure 5). All pinion seats are adjusted. After meeting the requirements, pour the anchor bolt holes. (flush with reserved hole)
4.减速机的调整，以小齿轮轴为基准：
A.联轴器的间隙调整，外套在轴向串动3-5mm（如图6）
B. The concentricity and height difference between the reducer shaft and the pinion shaft are adjusted with inclined iron. The radial runout diameter of concentricity is not more than 0.08mm per 100mm. The end runout diameter is not more than 0.05mm per 100mm. After the adjustment is completed to meet the requirements, pour the anchor bolt hole. (flush with reserved hole)
5. The adjustment of the motor is based on the reducer, and the adjustment method and requirements are the same as that of the reducer.
6. Check the insulation performance of the motor and all electrical cabinets. The cable joints should be firm and tightened to meet the electrical design and use requirements.
Iii. Ball mill test machine preparation
1. 15 days after pouring the anchor bolt holes, carefully adjust the two bearing seats, pinion seats, reducer and motor to meet the requirements, and tighten the anchor bolts. Weld the inclined iron firmly with electric welding.
2. Take off the motor coupling, run the motor without load for half an hour, check the motor and all electrical. Adjust the motor direction to meet the requirements of use.
3. Check whether the bolts of each component are firm and reliable, and eliminate the safety hazards near the ball mill.
4. Reducer with gear oil to meet the oil standard requirements. High temperature lithium grease is added inside the bearing seat.
5. Connect the motor coupling, check the sealing device, rotate the mill manually, and prepare to start after confirming that there is no safety hazard.
4. No load test of ball mill
Continuous operation for 8-16 hours without installation of media and materials.
Check:
A. Check the vibration and swing of the reducer during operation, and the shell temperature does not exceed 80℃.
B. The temperature of the two main bearings is not more than 60℃.
C. The size of the gear shall not have abnormal abnormal noise.
D. Check whether the connection bolts are loose.
The load test machine can be carried out after the no-load test machine is qualified.
V. Load test machine, can be divided into three stages:
1. Load 1/3 of the steel ball and appropriate materials for 12-24 hours of operation. Check the temperature of the motor, current, bearing and reducer, and stop the machine if there is no fault. Tighten the big gear, hollow shaft, liner bolt.
2. Load 2/3 steel balls and appropriate materials for 36-72 hours of operation. In the meantime, check whether the oil temperature of the bearing is normal. Check the connection bolts after shutdown.
3. After the above test machine is qualified, the rated load of the ball mill can be operated.
A. Start the mill. During the operation of the mill, add balls and materials continuously for 2 hours to achieve the rated ball loading capacity and material handling capacity of the ball mill.
B. In the meantime, a comprehensive inspection should be conducted to check whether there is material blocking and spitting at the inlet and outlet.
C. Check whether all electrical cabinets, motors and currents are normal. (The periodic swing of the ammeter is a normal phenomenon, the current rises sharply in a short period of time, should be shut down immediately, and then start up after the fault is removed.)
E. Check whether the bearing, reducer, pinion (bearing) is hot, which should comply with the provisions in use. The big and small gears have no jamming and biting phenomenon.
F. Check cylinder liner and hollow shaft bolts, do not allow leakage of powder phenomenon. Check the dust-proof and sealing devices. There should be no water or oil leakage.
Rated load test machine
Instructions for loading steel balls
The drawing is designed for the maximum ball loading (forging) amount, and the user should determine the loading amount of the steel ball according to the hardness of the raw material and the fineness of the discharge and the amount of sand return, which shall not exceed the maximum ball loading (forging) amount.
After the rated load test operation is normal for 12 to 24 hours, the test machine is completed
A. Check whether the electric, reducer, pinion, main bearing seat, concentricity, spacing and adjusting skew iron are loose and displaced. After meeting the requirements, the inclined iron is welded to the bottom plate with electric welding, and if necessary, the steel bar is connected, and the cement is poured twice to fill the space of the bottom plate.
B. The user should design and make the protective cover of the rotating parts of the ball mill according to the on-site installation needs, and the operation and maintenance personnel should check the shaft bearing and oil amount. The guardrail and safety sign should be set around the escalator, platform and ball mill.
10 minutes before the shutdown shall not feed, water can reduce the load of the mill, such as the shutdown for more than 8 hours, the application of jack against the center of the cylinder (as shown) to prevent the deformation of the cylinder.
The user’s maintenance and repair of the mill is a regular work, and the operation, repair and maintenance of the mill should be closely combined, and the quality of the maintenance work directly affects the operating efficiency and service life of the equipment.
A. The operation and maintenance personnel should tour the equipment in operation several times per shift to observe the value of the ammeter and the temperature of the bearing. Speed reducer pinion (bearing) temperature, vibration, noise. Whether the cylinder has abnormal vibration, noise and water leakage phenomenon.
B. The operator should check the safety hazards around the ball mill before starting, and can start production only after confirming that it is correct.
C. It is strictly prohibited to start frequently when the mill is loaded to prevent damage to the electric control part and the motor. The first start is 10 minutes apart, the second time is 20 minutes apart, the site temperature reaches more than 30 ° C, the third time is 50 minutes apart, and it can be started when it falls to normal temperature.
D. Water and slurry at the inlet and outlet ends are strictly prohibited from entering the two main bearing seats.
|
Mill failure, causes and treatment measures |
||
|
Unsolved obstacle |
reason |
Elimination method |
|
The motor is overloaded when starting the mill |
The load in the cylinder is too large, and after the mill is stopped for a long time, because there are wet materials in the cylinder, the ball has no ability to throw and drop, so the motor load is increased and overloaded. |
Manually turn the cylinder or open the auxiliary drive, at this time can be water transmission, the cylinder turn 2-3 turns. |
|
The mill discharge is reduced, and the output per unit hour is too low. |
Too many balls in the cylinder.
|
Add balls as required to remove debris on the grid |
|
There is leakage of pulp at the screw of the shell of the cylinder |
The liner bolt is loose
|
Tighten the bolt
|
|
There was a crash in the gear drive |
Gear wear
|
Replace gears, tighten bolts, and replace bearings |
|
The mill is overloaded and the ammeter reading is unstable. |
Too much load in the mill, too little space inside the cylinder
|
Adjusted load
|
|
The reducer oil temperature is too high |
Too much or too little lubrication, no cooling water, water in the reducer, bearing damage, tooth collapse, gear wear serious |
Check whether the container is cracked, replace related components, and adjust the concentricity |
|
The motor won’t start |
Check the interlocking devices |
Adjusted load |
Bolt tightening torque series table
|
specification |
Torque (unit: N) |
specification Torque (unit: N) |
|
|
M20 |
331~368 |
M42 |
2631~2942 |
|
M24 |
581~646 |
M48 |
3958~4398 |
|
M27 |
752~940 |
M56 |
6400~7111 |
|
M30 |
1093~1215 |
M64 |
9596~10662 |
This equipment information list
1. Ball mill installation, use, maintenance manual 1
2. 1 copy of final assembly drawing, 1 copy of basic drawing and 1 copy of product certificate
3. The device comes with a list
4. 1 copy of motor installation and operation manual
Service hotline：
13809076689
Keye Mining Machinery