第八章 PFG辊压机各系统联动空载及加载试车
Chapter 8 Each System Linkage No-load and Load Test
一.各系统空载联动试车的条件
1. Conditions for the no-load linkage test of each system
1.主机部分
1. Main machine part
①所有地脚螺栓均已拧紧;
①All anchor bolts have been tightened;
②所有联接件及螺栓组均已按规定安装完毕;
②All connecting parts and bolt groups have been installed according to regulations;
③移动辊水平移动自如,无任何可能妨碍其运动的杂物;
③The moving roller moves freely horizontally without any debris that may hinder its movement;
④磨辊转动灵活;
④The grinding roller rotates flexibly;
2.传动部分
2. Driving part
①传动系统空载试车完毕;
①The no-load test run of the driving system is completed;
②检查确认主电机、扭矩支承的地脚螺栓是否拧紧;
②Check whether the anchor bolts of the main motor and torque support are tightened;
③万向节传动轴安装完好,法兰盘联接螺栓及传动轴轴承座与底盘的联接螺栓均已按规定拧紧;
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减速器在空载试车中未发任何不正常现象,温升较小;
④The reducer did not show any abnormality during the no-load test, and the temperature rise was small;
⑤主电机及控制柜接线正确;其散热条件符合产品规定要求,温升较小;
⑤The main motor and control cabinet are wired correctly; Their heat dissipation conditions meet the product requirements, and the temperature rise is small;
3.液压系统
3. Hydraulic system
①液压油箱内液压油量合适;
①The amount of hydraulic oil in the hydraulic oil tank is appropriate;
②蓄能器充气压力合适;
②The charging pressure of the accumulator is appropriate;
③液压缸进退移动灵活;
③The hydraulic cylinder moves forward and backward flexibly;
④所有压力控制阀和压力控制仪表调整完毕;
④All pressure control valves and pressure control instruments have been adjusted;
⑤液压系统静态保压性能良好,控制在规定所要求的压降范围内。
⑤The static pressure holding performance of the hydraulic system is good, and it is controlled within the required pressure drop range.
4.检测系统
4. Detection system
①位移传感器反应,检测灵敏;
①Displacement sensor response, with sensitive detection;
②热电阻温度指示正确;
②The temperature indication of the thermal resistance is correct;
③压力传感器及二次显示仪表可正常检测;
③The pressure sensor and secondary display instrument can be detected normally;
5.主机控制柜内各仪表的联锁控制接线正确。
5. The interlocking control wiring of each instrument in the main machine control cabinet is correct.
6.润滑系统
6. Lubrication system
①润滑泵工作压力正常;
① The working pressure of the lubricating pump is normal;
②各分油器及各管路均畅通;
②All oil separators and all pipelines are unblocked;
③主轴承内已加好充足的润滑脂;
③Sufficient grease has been added to the main bearing;
④分油器正常工作检测完好;
④The oil separator is in good condition when working normally;
⑤润滑油泵贮油筒空油报警正常;
⑤The alarm for empty oil in the lubricating oil pump reservoir is normal;
⑥泵站油脂过滤网清干净;
⑥ Clean the grease filter of the pump station;
⑦泵站限压阀调节完毕。
⑦The pressure limiting valve of the pumping station has been adjusted.
二.整机空载联动试车
2. The whole machine no-load linkage test run
1.启动顺序
1. Startup sequence
①启动主机控制柜;
①Start the main machine control cabinet;
②启动集中润滑系统;
②Start the centralized lubrication system;
③启动主电动机;
③Start the main motor;
④启动液压泵电机。
④Start the hydraulic pump motor.
2.空载联动试车内容:
2. No-load linkage test run content:
①电接点压力表可控制油泵电机的启闭灵敏;
①The electric contact pressure gauge can control the opening and closing of the oil pump motor;
②将电接点压力表上限调至超过所调压力传感器的上限,试验液压系统压力达到压力传感器表上限时,主电动机可否立即停机;
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把液压系统各阀调至使移动辊退回状态,使移动辊退到最大辊缝(即60mm)位置,检验主电动机是否在此时立即停机;
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将液压系统压力调至压力传感器的调定压力上,检验其是否可在此压力下液压系统自动卸压;
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集中润滑系统是否按规定的停、开时间工作,分别将4只端面热电阻取出,施加一大于80℃的温度负荷,检验主电动机是否立即停机;
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在运转过程中,注意检查各系统及零部件工作是否正常;
⑥During operation, pay attention to check whether each system and parts work normally;
⑦辊压机空载联动试运转需2小时,在此期间,应按规定给各润滑点加好所需的润滑脂,并注意检查集中润滑系统是否按规定定时为各集中润滑点供油。
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.加载试车条件
3. Load test conditions
1.所有出料系统设备空载试运转正常:
1. The no-load test operation of all discharge system equipment is normal:
①各输送设备运转灵活,空载电机工作电流正常,无较大摩擦声音;
①The conveying equipment operates flexibly, the working current of the no-load motor is normal, and there is no loud friction sound;
②各出料输送设备与主机联锁正常,一旦出料系统中某一设备出现故障,主机随即停止。
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.主机空载联动试车完毕,各系统及零部件工作正常;
2. The main machine no-load linkage test is completed, and all systems and parts are working normally;
3.进料系统各设备空载试运转正常。
3. The no-load test operation of each equipment of the feeding system is normal.
①各输送设备运转灵活,空载电机工作电流正常,设备工作声音正常;
①The conveying equipment operates flexibly, the working current of the no-load motor is normal, and the equipment working sound is normal;
②各进料输送设备与主机联锁正常,若主机或出料系统发生故障,可立即停机;
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.进料系统中的除铁器和金属探测器工作正常,并已与主机联琐。
4.The iron separator and metal detector in the feed system are working normally and have been connected to the main machine.
5.进料系统中的称重料仓必须是放空状态,防止安装中的一些铁块及异物混于仓中,损坏设备.
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：禁止在系统未设除铁器和金属探测器或除铁器和金属探测器未检测正常的状况下启动辊压机带料运行，否则辊间高压状况下物料中的金属铁件会给辊面带来不可预料的损伤。
※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：禁止辊间有物料或物件时，辊压机带料启动。
※Note: It is forbidden to start the roller press with materials when there are materials or objects between the rollers.
四.加载试车及调试
4. Loading test run and debugging
※注意：辊压机加载试车的压力采用逐步加压的方式以保证设备的磨合，禁止在首次加载试车时直接将压力加至 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：辊压机物料粒度必须满足要求，即 95%≤40mm，Fmax≤60mm，否则由于进料粒度过大会导致辊压机运行不稳定或跳停。
※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：辊压机最高喂料温度必须<100℃, 过高物料温度会大为缩短辊面寿命。
※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.首次加载及调试
1. First loading and debugging
①初调进料装置的插板于最低位置;
① Initially adjust the insert plate of the feeding device to the lowest position;
②开启进料系统,将称重仓的料位加到设定的高度,并保持料位高度在60～80%之间,注意调节给料量;
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起动液压油泵电机,给液压系统加压,使压力逐步上升(即5,6,7,7.5,8×105 Pa),每次上升都要取样分析;
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在加载过程中,应注意观察移动辊是否一直在作水平移动,若移动辊静止不动或偶然移动一次,并且主电机工作电流较小,则应将进料插板适当提高,使工作辊缝大于原始辊缝,移动辊水平移动频繁。每次对挤压物料的取样均应在该状态下进行;
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在加压和调试过程中,应注意观察主电动机的电流变化情况,其平均电流不允许超过主电机额定电流；
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首次加载试车时间1小时，在此期间应注意观察机械和电气各部分设备的运转及工作情况。注意检查主轴承、减速机及电动机的温度。注意各检测仪表和显示仪表的变化情况。仔细倾听设备有无异常声音。
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关闭辊压机及其附属设备。将所有的联接螺栓、地脚螺栓重新拧紧一遍。对于重要的螺栓，缩套联轴器缩紧螺栓，万向节传动轴承座与底座的联接螺栓，减速机联接螺栓等均应按规定的力矩重新拧紧，对设备其他部分进行仔细检查，及时发现设备隐患；
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在正式启动前必须对设备的关键部分定人员、定岗位、定责任进行操作和监视；
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所有人员必须预先熟悉和了解设备的性能及主要结构；
⑨All personnel must be familiar with and understand the performance and main structure of the equipment in advance;
⑩启动时同意指挥，未经许可不得启动设备；
⑩Agree to command when starting, and not start the equipment without permission;
11）发现异常情况及时报告，及时处理。一般处理故障时应停机、卸压。
11) Report the abnormal situation in time and deal with it in time. Generally, stop and relieve the pressure when troubleshooting.
2、第二次加载试车
2. The second test run
①在对首次加载试车时取出的试样进行分析的基础上，初选一较为合适操作参数。即在较大的处理量和较小的挤压状态下，达到好的挤压效果；
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开启辊压机及其附属设备，用选择好的参数进行操作，并将挤压后的物料送入下一工序中。根据整个粉磨工艺系统的物料平衡和综合粉磨效果调节辊压机的操作参数，以求达到预计的粉磨效果；
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第二次加载应连续试车12个小时，此时设备各部分的温度已基本平衡，应注意观察。仔细倾听主轴承和行星减速机中有无异常声音，检查主轴承的温度及主电机的运转状况。主轴承的工作温度一般不超过70℃，短时间不可超过80℃，减速机工作声音正常，温度适当，外壳偏转平稳而有规律，主电机声音正常，平均电流在额定范围内。
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.
对于系统加载试车的调试，主要是调试以下两方面的内容：一、找到辊压机的最佳运行参数，二、找到整个系统的运行平衡点，所谓最佳的运行参数，就是以最经济的挤压力获得最佳的挤压效果，液压系统的工作压力并不是越高越好，有实验表明，当液压力超过8Mpa时，被挤压粉碎过的物料在高压力作用下有重新聚结成块的趋势，因此，液压系统的压力并不是以高为原则，而是由物料物理性能所决定，同时受到电机额定电流的限制，液压力的选择原则是：在满足挤压物料的工艺性能前提下，尽可能降低操作压力，压力选择的合适与否，可以从取出的物料中找出外形完整的物料颗粒，用手是否能碾碎来判断，若绝大数这样的颗粒都可碾碎，就可认为压力选取基本合适，判断系统运行的平衡与否，我们是直观地从稳流称重仓来获取判断的，若稳定称重仓的料位始终平衡在60～80%，则我们认为系统处于平衡状态。为了优化辊压机的运行，在系统中辊压机一般都有25%的回料，同时回料的多少可依据进料粒度的特性做一些调整，当进料粒度较小，颗粒分布均齐时，我们可以适当减少回料量，这样可以在辊压机通过量不变的情况下增加新给量，以提高系统的产量，当进料粒度较大，颗料分布不均齐时，应适当加大回料量，一方面回辊压机的物料可填充大颗粒间的间隙，实行料层粉碎，增强挤压效果，另一方面由于改善了进料粒度分布，辊压机的振动也会减少，运行驱于平稳。
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.
