第八章 PFG輥壓機各系統聯動空載及加載試車
Chapter 8 Each System Linkage No-load and Load Test
一.各系統空載聯動試車的條件
1. Conditions for the no-load linkage test of each system
1.主機部分
1. Main machine part
①所有地腳螺栓均已擰緊;
①All anchor bolts have been tightened;
②所有聯接件及螺栓組均已按規定安裝完畢;
②All connecting parts and bolt groups have been installed according to regulations;
③移動輥水平移動自如,無任何可能妨礙其運動的雜物;
③The moving roller moves freely horizontally without any debris that may hinder its movement;
④磨輥轉動靈活;
④The grinding roller rotates flexibly;
2.傳動部分
2. Driving part
①傳動系統空載試車完畢;
①The no-load test run of the driving system is completed;
②檢查確認主電機、扭矩支承的地腳螺栓是否擰緊;
②Check whether the anchor bolts of the main motor and torque support are tightened;
③萬向節傳動軸安裝完好,法蘭盤聯接螺栓及傳動軸軸承座與底盤的聯接螺栓均已按規定擰緊;
③The universal joint drive shaft is installed intact, and the flange connecting bolts and the connecting bolts between the drive shaft bearing seat and the base plate have been tightened according to regulations;
④減速器在空載試車中未發任何不正常現象,溫升較小;
④The reducer did not show any abnormality during the no-load test, and the temperature rise was small;
⑤主電機及控制柜接線正確;其散熱條件符合產品規定要求,溫升較小;
⑤The main motor and control cabinet are wired correctly; Their heat dissipation conditions meet the product requirements, and the temperature rise is small;
3.液壓系統
3. Hydraulic system
①液壓油箱內液壓油量合適;
①The amount of hydraulic oil in the hydraulic oil tank is appropriate;
②蓄能器充氣壓力合適;
②The charging pressure of the accumulator is appropriate;
③液壓缸進退移動靈活;
③The hydraulic cylinder moves forward and backward flexibly;
④所有壓力控制閥和壓力控制儀表調整完畢;
④All pressure control valves and pressure control instruments have been adjusted;
⑤液壓系統靜態保壓性能良好,控制在規定所要求的壓降范圍內。
⑤The static pressure holding performance of the hydraulic system is good, and it is controlled within the required pressure drop range.
4.檢測系統
4. Detection system
①位移傳感器反應,檢測靈敏;
①Displacement sensor response, with sensitive detection;
②熱電阻溫度指示正確;
②The temperature indication of the thermal resistance is correct;
③壓力傳感器及二次顯示儀表可正常檢測;
③The pressure sensor and secondary display instrument can be detected normally;
5.主機控制柜內各儀表的聯鎖控制接線正確。
5. The interlocking control wiring of each instrument in the main machine control cabinet is correct.
6.潤滑系統
6. Lubrication system
①潤滑泵工作壓力正常;
① The working pressure of the lubricating pump is normal;
②各分油器及各管路均暢通;
②All oil separators and all pipelines are unblocked;
③主軸承內已加好充足的潤滑脂;
③Sufficient grease has been added to the main bearing;
④分油器正常工作檢測完好;
④The oil separator is in good condition when working normally;
⑤潤滑油泵貯油筒空油報警正常;
⑤The alarm for empty oil in the lubricating oil pump reservoir is normal;
⑥泵站油脂過濾網清干凈;
⑥ Clean the grease filter of the pump station;
⑦泵站限壓閥調節完畢。
⑦The pressure limiting valve of the pumping station has been adjusted.
二.整機空載聯動試車
2. The whole machine no-load linkage test run
1.啟動順序
1. Startup sequence
①啟動主機控制柜;
①Start the main machine control cabinet;
②啟動集中潤滑系統;
②Start the centralized lubrication system;
③啟動主電動機;
③Start the main motor;
④啟動液壓泵電機。
④Start the hydraulic pump motor.
2.空載聯動試車內容:
2. No-load linkage test run content:
①電接點壓力表可控制油泵電機的啟閉靈敏;
①The electric contact pressure gauge can control the opening and closing of the oil pump motor;
②將電接點壓力表上限調至超過所調壓力傳感器的上限,試驗液壓系統壓力達到壓力傳感器表上限時,主電動機可否立即停機;
② Adjust the upper limit of the electric contact pressure gauge to exceed the upper limit of the adjusted pressure sensor. When the test hydraulic system pressure reaches the upper limit of the pressure sensor gauge, can the main motor be stopped immediately;
③把液壓系統各閥調至使移動輥退回狀態,使移動輥退到最大輥縫(即60mm)位置,檢驗主電動機是否在此時立即停機;
③Adjust the valves of the hydraulic system to the retracted state of the moving roller, so that the moving roller is retracted to the maximum roller gap (that is, 60mm), and check whether the main motor stops immediately at this time;
④將液壓系統壓力調至壓力傳感器的調定壓力上,檢驗其是否可在此壓力下液壓系統自動卸壓;
④ Adjust the pressure of the hydraulic system to the set pressure of the pressure sensor, and check whether it can automatically relieve the pressure of the hydraulic system under this pressure;
⑤集中潤滑系統是否按規定的停、開時間工作,分別將4只端面熱電阻取出,施加一大于80℃的溫度負荷,檢驗主電動機是否立即停機;
⑤Whether the centralized lubrication system works according to the specified stop and start time, take out the 4 end face thermal resistors, apply the temperature load greater than 80 ℃, and check whether the main motor stops immediately;
⑥在運轉過程中,注意檢查各系統及零部件工作是否正常;
⑥During operation, pay attention to check whether each system and parts work normally;
⑦輥壓機空載聯動試運轉需2小時,在此期間,應按規定給各潤滑點加好所需的潤滑脂,并注意檢查集中潤滑系統是否按規定定時為各集中潤滑點供油。
⑦The no-load linkage test operation of the roller press takes 2 hours. During this period, the required grease should be added to each lubrication point according to the regulations, and attention should be paid to check whether the centralized lubrication system supplies oil to the centralized lubrication points regularly.
三.加載試車條件
3. Load test conditions
1.所有出料系統設備空載試運轉正常:
1. The no-load test operation of all discharge system equipment is normal:
①各輸送設備運轉靈活,空載電機工作電流正常,無較大摩擦聲音;
①The conveying equipment operates flexibly, the working current of the no-load motor is normal, and there is no loud friction sound;
②各出料輸送設備與主機聯鎖正常,一旦出料系統中某一設備出現故障,主機隨即停止。
②The interlocking of each discharging conveying equipment and the main machine is normal. Once a certain device in the discharging system fails, the main machine will stop immediately.
2.主機空載聯動試車完畢,各系統及零部件工作正常;
2. The main machine no-load linkage test is completed, and all systems and parts are working normally;
3.進料系統各設備空載試運轉正常。
3. The no-load test operation of each equipment of the feeding system is normal.
①各輸送設備運轉靈活,空載電機工作電流正常,設備工作聲音正常;
①The conveying equipment operates flexibly, the working current of the no-load motor is normal, and the equipment working sound is normal;
②各進料輸送設備與主機聯鎖正常,若主機或出料系統發生故障,可立即停機;
②The interlocking of each feeding and conveying equipment with the main machine is normal. If the main machine or the discharge system fails, it can be shut down immediately;
4.進料系統中的除鐵器和金屬探測器工作正常,并已與主機聯瑣。
4.The iron separator and metal detector in the feed system are working normally and have been connected to the main machine.
5.進料系統中的稱重料倉必須是放空狀態,防止安裝中的一些鐵塊及異物混于倉中,損壞設備.
5. The weighing bin in the feeding system must be emptied to prevent some iron blocks and foreign objects from mixing in the bin and damaging the equipment.
※注意：禁止在系統未設除鐵器和金屬探測器或除鐵器和金屬探測器未檢測正常的狀況下啟動輥壓機帶料運行，否則輥間高壓狀況下物料中的金屬鐵件會給輥面帶來不可預料的損傷。
※Note: It is forbidden to start the roller press with material running when the system is not equipped with iron remover and metal detector or the iron remover and metal detector are not detected normally. Otherwise, the metal iron parts in the material under the high pressure between the rollers will cause unexpected damage to the roller surface.
※注意：禁止輥間有物料或物件時，輥壓機帶料啟動。
※Note: It is forbidden to start the roller press with materials when there are materials or objects between the rollers.
四.加載試車及調試
4. Loading test run and debugging
※注意：輥壓機加載試車的壓力采用逐步加壓的方式以保證設備的磨合，禁止在首次加載試車時直接將壓力加至 9MPa。
※Note: The pressure of the roller press during the test run is gradually increased to ensure the running-in of the equipment. It is forbidden to directly increase the pressure to 9MPa during the first test run.
※注意：輥壓機物料粒度必須滿足要求，即 95%≤40mm，Fmax≤60mm，否則由于進料粒度過大會導致輥壓機運行不穩定或跳停。
※Note: The particle size of the roller press must meet the requirements, that is, 95%≤40mm, Fmax≤60mm, otherwise the roller press will run unstable or stop due to excessive feed size.
※注意：輥壓機最高喂料溫度必須<100℃, 過高物料溫度會大為縮短輥面壽命。
※Note: The maximum feeding temperature of the roller press must be <100℃, too high material temperature will greatly shorten the life of the roller surface.
1.首次加載及調試
1. First loading and debugging
①初調進料裝置的插板于最低位置;
① Initially adjust the insert plate of the feeding device to the lowest position;
②開啟進料系統,將稱重倉的料位加到設定的高度,并保持料位高度在60～80%之間,注意調節給料量;
②Turn on the feeding system, add the material level of the weighing bin to the set height, and keep the material level between 60% and 80%, pay attention to adjusting the feeding amount;
③起動液壓油泵電機,給液壓系統加壓,使壓力逐步上升(即5,6,7,7.5,8×105 Pa),每次上升都要取樣分析;
③Start the hydraulic oil pump motor and pressurize the hydraulic system to gradually increase the pressure (i.e. 5, 6, 7, 7.5, 8×105 Pa), and sample and analyze each time it rises;
④在加載過程中,應注意觀察移動輥是否一直在作水平移動,若移動輥靜止不動或偶然移動一次,并且主電機工作電流較小,則應將進料插板適當提高,使工作輥縫大于原始輥縫,移動輥水平移動頻繁。每次對擠壓物料的取樣均應在該狀態下進行;
④ During the loading process, pay attention to observe whether the moving roller has been moving horizontally. If the moving roller is stationary or accidentally moved once, and the main motor working current is small. The feed insert should be appropriately increased to make the working roll gap larger than the original roll gap, and the moving roll moves horizontally frequently. Each sampling of the extruded material should be carried out in this state;
⑤在加壓和調試過程中,應注意觀察主電動機的電流變化情況,其平均電流不允許超過主電機額定電流；
⑤In the process of pressurization and debugging, pay attention to observe the current changes of the main motor, and the average current must not exceed the rated current of the main motor;
⑥首次加載試車時間1小時，在此期間應注意觀察機械和電氣各部分設備的運轉及工作情況。注意檢查主軸承、減速機及電動機的溫度。注意各檢測儀表和顯示儀表的變化情況。仔細傾聽設備有無異常聲音。
⑥ The first loading test time is 1 hour, during which time, attention should be paid to observe the operation and working conditions of the mechanical and electrical equipment. Pay attention to check the temperature of the main bearing, reducer and motor. Pay attention to the changes of the detection instruments and display instruments. Listen carefully for abnormal sounds from the equipment.
⑦關閉輥壓機及其附屬設備。將所有的聯接螺栓、地腳螺栓重新擰緊一遍。對于重要的螺栓，縮套聯軸器縮緊螺栓，萬向節傳動軸承座與底座的聯接螺栓，減速機聯接螺栓等均應按規定的力矩重新擰緊，對設備其他部分進行仔細檢查，及時發現設備隱患；
⑦Close the roller press and its auxiliary equipment. Tighten all the connecting bolts and anchor bolts again. For important bolts, shrink sleeve coupling tightening bolts, connecting bolts between universal joint drive bearing seat and base, and reducer connecting bolts should be re-tightened according to the specified torque. Carry out the careful inspection of other parts of the equipment and discover hidden dangers in time;
⑧在正式啟動前必須對設備的關鍵部分定人員、定崗位、定責任進行操作和監視；
⑧ Before the official start-up, the key parts of the equipment must be assigned personnel, assigned positions, and assigned responsibilities to operate and monitor;
⑨所有人員必須預先熟悉和了解設備的性能及主要結構；
⑨All personnel must be familiar with and understand the performance and main structure of the equipment in advance;
⑩啟動時同意指揮，未經許可不得啟動設備；
⑩Agree to command when starting, and not start the equipment without permission;
11）發現異常情況及時報告，及時處理。一般處理故障時應停機、卸壓。
11) Report the abnormal situation in time and deal with it in time. Generally, stop and relieve the pressure when troubleshooting.
2、第二次加載試車
2. The second test run
①在對首次加載試車時取出的試樣進行分析的基礎上，初選一較為合適操作參數。即在較大的處理量和較小的擠壓狀態下，達到好的擠壓效果；
① Based on the analysis of the samples taken out during the first loading test, the preliminary selection of more suitable operating parameters. That is, the good extrusion effect can be achieved under the larger processing capacity and the smaller extrusion state;
②開啟輥壓機及其附屬設備，用選擇好的參數進行操作，并將擠壓后的物料送入下一工序中。根據整個粉磨工藝系統的物料平衡和綜合粉磨效果調節輥壓機的操作參數，以求達到預計的粉磨效果；
②Turn on the roller press and its auxiliary equipment, operate with the selected parameters, and send the extruded materials to the next process. Adjust the operating parameters of the roller press according to the material balance and comprehensive grinding effect of the entire grinding process system to achieve the expected grinding effect;
③第二次加載應連續試車12個小時，此時設備各部分的溫度已基本平衡，應注意觀察。仔細傾聽主軸承和行星減速機中有無異常聲音，檢查主軸承的溫度及主電機的運轉狀況。主軸承的工作溫度一般不超過70℃，短時間不可超過80℃，減速機工作聲音正常，溫度適當，外殼偏轉平穩而有規律，主電機聲音正常，平均電流在額定范圍內。
③The second load should be tested continuously for 12 hours. At this time, the temperature of each part of the equipment has been basically balanced, and attention should be paid to observe. Listen carefully for abnormal sounds in the main bearing and planetary reducer, and check the temperature of the main bearing and the operating condition of the main motor. The operating temperature of the main bearing generally does not exceed 70°C, and should not exceed 80°C in a short time. The reducer's operating sound is normal, the temperature is appropriate, the housing deflection is stable and regular, the main motor sound is normal, and the average current is within the rated range.
對于系統加載試車的調試，主要是調試以下兩方面的內容：一、找到輥壓機的最佳運行參數，二、找到整個系統的運行平衡點，所謂最佳的運行參數，就是以最經濟的擠壓力獲得最佳的擠壓效果，液壓系統的工作壓力并不是越高越好，有實驗表明，當液壓力超過8Mpa時，被擠壓粉碎過的物料在高壓力作用下有重新聚結成塊的趨勢，因此，液壓系統的壓力并不是以高為原則，而是由物料物理性能所決定，同時受到電機額定電流的限制，液壓力的選擇原則是：在滿足擠壓物料的工藝性能前提下，盡可能降低操作壓力，壓力選擇的合適與否，可以從取出的物料中找出外形完整的物料顆粒，用手是否能碾碎來判斷，若絕大數這樣的顆粒都可碾碎，就可認為壓力選取基本合適，判斷系統運行的平衡與否，我們是直觀地從穩流稱重倉來獲取判斷的，若穩定稱重倉的料位始終平衡在60～80%，則我們認為系統處于平衡狀態。為了優化輥壓機的運行，在系統中輥壓機一般都有25%的回料，同時回料的多少可依據進料粒度的特性做一些調整，當進料粒度較小，顆粒分布均齊時，我們可以適當減少回料量，這樣可以在輥壓機通過量不變的情況下增加新給量，以提高系統的產量，當進料粒度較大，顆料分布不均齊時，應適當加大回料量，一方面回輥壓機的物料可填充大顆粒間的間隙，實行料層粉碎，增強擠壓效果，另一方面由于改善了進料粒度分布，輥壓機的振動也會減少，運行驅于平穩。
For the commissioning of the system loading test run, the following two aspects are mainly commissioned: 1. Find the best operating parameters of the roller press, 2. Find the operating balance of the entire system, the so-called optimal operating parameters is to obtain the best extrusion effect with the most economical extrusion force. The working pressure of the hydraulic system is not as high as possible. Experiments have shown that when the hydraulic pressure exceeds 8Mpa, the crushed materials have the tendency to re-agglomerate under high pressure. Therefore, the pressure of the hydraulic system is not based on the principle of high, but determined by the physical properties of the material. At the same time, it is limited by the rated current of the motor. The selection principle of hydraulic pressure is: Under the premise of satisfying the process performance of the extruded material, reduce the operating pressure as much as possible. Whether the pressure is selected properly or not, you can find out the complete shape of the material particles from the material taken out, and judge whether it can be crushed by hand. If most of these particles can be crushed, it can be considered that the selection of pressure is basically appropriate. To judge whether the system is in balance or not, we intuitively obtain the judgment from the steady flow weighing bin. If the material level of the stable weighing bin is always balanced at 60-80%, we think the system is in the balanced state. In order to optimize the operation of the roller press, the roller press in the system generally has 25% return material. At the same time, the amount of returned material can be adjusted according to the characteristics of the feed size. When the feed size is small and the particle distribution is uniform, we can appropriately reduce the amount of returned material, so that the throughput of the roller press is unchanged. Increase the new feed volume to increase the output of the system, when the feed size is large and the particle distribution is uneven, the amount of returned material should be increased appropriately. On the one hand, the material returned to the roller press can fill the gaps between large particles, pulverize the material layer, and enhance the extrusion effect. On the other hand, due to the improved particle size distribution of the feed, the vibration of the roller press will also be reduced and the operation will be smooth.
