φ3200x4500球磨机说明书en.docx

φ3200×4500
球磨机
Ball Mill

使用说明书

Operation Manual

上海明工重型设备有限公司
Shanghai Minggong Heavy Equipment Co., Ltd.

地址：上海嘉定区马陆镇申霞路33号
Add: No.33 Shenxia Road, Jiading District, Shanghai, China
目录catalogue

一、 概述Summary

二、 性能Performance

三、 主要结构及工作原理
Main structure and working principle

四、 安装要求Installation

五、 试车、使用和维修保养
Test, operation, and maintenance

六、 易损件明细wear parts list

七、 地基图Foundation drawings

一、 概述/Summary
本机主要用于选矿、陶瓷、化工、水泥等行业，有干、湿两种。近年来新开发出来轴承传动节能球磨机，节约能源25-30%。球磨机的主要部件都是一个缓慢旋转的筒体，筒体内装有磨碎介质，由于球磨机结构简单坚固、操作可靠、维护管理简单、能长期连续运转、对物料适应性强、破碎比大（可达到300以上）和生产能力大，所以能满足现代化大规模工业生产的需要。
This mill is mainly used to the benification equipment, ceramics, chemical and cement industry etc. with two types, the dry one and the wet type. In recent years, the bearing transmission energy saving ball mill are newly developed, which can save 25-30% energy. Its' main parts are slowly rotated cylinder, with grinding media inside. As the ball mill is of simple and solid structure, it can be safe operated, and easy to maintain, which can ensure the mill to be in operation continually. With strong adaptation, the mill has big crushing ratio( up to 300 and beyond) and big production ability, so that it can meet the industry requirement of modern large scale production.

二、 性能/性能/Performance
规格型号 Φ3200×4500球磨机
Model Φ3200×4500 ball mill
进料粒度 0-25mm
Feeding size 0-25mm
出料粒度 0.074-0.4mm
Discharging size 0.074-0.4mm
电动机型号 YR560-8 800KW
Model of motor YR560-8 800KW
频率 50Hz
Frequency 50Hz
电压 6KV
Voltage 6KV
筒体转速 18.4r/min
Rotate speed 18.4r/min
充填率 27%
Filling ratio 27%
减速机型号及速比 JDX71-6.3-NO.102 i=6.3
Reducer model & speed ratio JDX71-6.3-NO.102 i=6.3
外形尺寸 12100X6770X4660
Overall dimensions 12100X6770X4660

三、 主要结构及工作原理/Main structure and working principle
1、主要结构/ Main structure
本机为边缘传动,中心卸料,开流式球磨机。
The mill is of fringe transmission, central unloading, and open style.

主要由圆柱形筒体、进、出料装置、中空轴、主轴承、传动小齿轮、大齿圈、减速机、电动机等部件组成。
It consists of cylinder body, material input and output device, hollow shaft, main bearing, transmission pinion, big gear ring, reducer,motor etc.

回转部分（筒体）Rotating part(cylinder)

回转部分是由钢板卷制焊接而成的筒体，两端用螺栓分别与进、出料、中空轴相连接，并水平地支撑在两个调心轴承上。进出料中筒内装有进出料螺旋。
The rotating part is the cylinder made of welded steel plate, the two ends are connected by screws with the material input & output device, and hollow shaft. They are supported by the central adjustment bearing horizontally. The material input & output device has the screws inside.

筒体的回转由电动机、减速机、小齿轮、通过固定在筒体一端的大齿圈来实现的。
The cylinder rotation is made by the motor, reducer and pinion through the fixed gear ring on the cylinder end.

筒体的内部设有衬板，它既可以保护筒体，又可以把球带到适宜的高度，以提高粉磨效率。
The liner inside the cylinder can protect the cylinder but also carry the balls to the proper height, to improve the grinding efficiency.

筒体上设有人孔门，用于装卸磨体、修理更换筒体内部的零件之用。
The manhole on the cylinder is used to load & unload the material and to repace the part inside the cylinder.

进、出料装置/Material input & output device

进料装置主要用于进料和添加钢球；出料装置用于输出成品物料及磨损的钢球、硬物等。
The material input device are mainly used for feeding material and steel ball, while the output device are for the output of finished material,worn steel ball and hard substance etc.
支撑装置/Supporting device
主轴承支撑着回转部分、磨球、物料等全部质量，是保证磨机正常运转的主要部件之一。主轴承能自动调心，以适应制造、安装的误差。
The main bearing support the total weight of the rotating part, ball and material inside, which is one of the main parts to ensure the normal operation of the mill. It can make adjustment for the central line to adapt the tolerance in manufacturing and installation.
传动装置/Transmission device
由电动机通过弹性联轴器、减速机、小齿轮、大齿圈形成传动链。
It is a transmission chain by motor through the elastic coupling, reducer,pinion and gear ring.
特别提示：球磨机传动装置的布置，不允许随意变动，。如需变动，必须要保证小齿轮对大齿轮的作用力垂直向上，并由此决定球磨机的回转方向，同时必须改变所有带方向性的零、部件结构。通常情况下，这是不允许的。
Note: The transmission device's layout of ball bill must not be changed casually. If needed, it must ensure the action between gear and pinion is vertical & straight up, by which the rotating direction of ball mill is decided. Meanwhile we must change all the parts'structure with direction. Usually, it is not allowed.

2、工作原理：/ Working principle
当电动机通过联轴器、减速机、小齿轮、大齿圈带动筒体旋转，装在筒体内的破碎介质（钢球）与不断进入筒体内的物料在离心力和摩擦力的作用下，随着筒体上升到一定高度，然后脱离筒壁自由落下。物料的破碎主要是靠介质落下时的冲击力和运动时的磨剥作用来实现。物料是从进料段的中空轴内不断地输入，而磨碎以后的产品经筒体的另一端的中空轴不断排出。湿磨时，成品被水的流动而带走。
The cylinder get rotated by motor through coupling, reducer,pinion, and gear. The grinding media(steel ball) and continuously feeded material inside the mill will go up to a certain height with the cylinder under the centrifugal and friction force, then dropping down freely off the cylinder. The material crushing is realized mainly by the impact force of the dropping media and grating &shucking function during moving. The material is fed in gradually from the hollow shaft of input end, and the grated ones are discharged through the other end of the hollow shaft consistently, which will be carried away by water in wet ball mill.

球磨机分左、右旋磨矿。客户可根据自己的现场决定，需要在采购合同中注明。
The ball mill can be divided into left direction rotation mill and right one. It need to be noted in the contract according to the customer's plant.

四、 安装要求/Installation
球磨机安装要求除按图纸的技术要求外，同时要按下述要求进行。
The ball mill must be installed as following beside the drawing technique requirement.

①安装前，应对筒体、齿轮、中空轴、轴承座、传动轴承、减速机等重要零件进行检查，如有损伤和变形应事先修复。
It need to make inspection for main parts as cylinder,gear,hollow shaft, bearing base,transmission bearing,reducer etc.before installation and need to be repaired in advance if there is damage or deformation.

安装时应先将要装的零件清洗干净（特别注意结合面和滑动面）,设备上已装好的零件，在试运转前应检查其清洁度，不合要求时应予清洗。带有方向性的零部件，如蓖板、螺旋筒等，应按图纸要求安装，不得装反。
The components should be cleaned before installation (especially the connecting and sliding face). The installed components should be checked again for the cleanliness before test running. If not up to the requirement, it should be cleaned again. Components with directions, such as grid plate,spiral tube etc. should be installed by the drawing strictly, and must not be done oppositely.

③根据实测尺寸，修正两个主轴承的中心距，然后根据此进行基础划线（带整体支架时不需要）
The central distance between two main bearing shall be modified according to the actual measured size, upon which the foundation line can be made( no need when it has the whole frame)

④基础划线的质量要求如下（不带整体支架设备）：
The fundation line is qualified as the following(without whole frame).
A)两基础墩上的纵横向中心线距离的误差≮±3mm；
The distance tolerance of the longitudinal and transverse central line is ≮±3mm on the two foundation base.
B)标高的误差为±5mm（指一次浇注的混凝土表面）
The tolerance of the marked height is ±5mm( refer to the concrete surface first injected).

二次灌浆 （Secondary grouting）
设备的二次灌浆应在设备粗校后进行。设备在安装前，应彻底清除地脚螺栓孔中的垃圾，被油污染的混凝土应予凿除，需要灌浆的表面要做拉毛处理。设备的底座、底面应保持清洁。
Secondary grouting for the equipment should be made after the equipment primary adjustment. The waste should be rid of from the bolt hole of the anchor and the concrete contaminated by oil should be chiseled off, and also the grouted surface should be dealt with by rubbing sting. The base and the bottom of the equipment should also be kept clean.

灌浆一般宜采用细碎石混凝土（或水泥砂浆），其标号应比基础的混凝土标号高一级灌浆时，应捣固密实，捣固时不得撞动设备、垫铁、地脚螺栓等，以免影响设备的安装精度，当灌浆层的耐压强度达到设计强度的75%以上后，方可对设备进行精校。
The slurry grouted should be the fine stone concrete(or cement slurry), and the mark's height should be one grade higher than the foundation concrete. When grouting, it should be dense and solid and must not strike the equipment, mat block, and anchor screw etc. Which is to avoid affecting the definition of installation. When the anti-pressure force of the grouted layer get to 75% it designed and beyond, the precise adjustment can be made for the equipment.

主轴承的安装 Installation for main bearing
轴承装配前应进行检查，组装时，用油加热轴承使轴承内孔涨大后压装至轴承的装配部位。压盖用耐油石棉橡胶板做碘，调整间隙。
Bearing should be checked before assembling, during which, the bearing should be heated by oil to expand the inner hole so that it can press on the fixed part of the bearing. The cover should be made from anti-oil asbestos rubber plate which can adjust the gap.

回转部分的安装（设备散装运输时）
Installation for Rotary Part(Equipment by bulk transportation.)
筒体与中空轴组装时，结合面应清除干净，涂以铅油，结合应紧密，不得加入任何调整垫片。回转部分应符合以下规定：设备放置后，应检查两端标高，在中空轴颈的母线上测量，相对标高差、（进料端的标高高于出料端20mm）。两中空轴的轴线应在同一轴线上（对散装件），大齿圈与筒体，齿圈端面与中空轴端面之间不得大于0.15mm的间隙，大齿圈与小齿轮装配时的齿侧间隙应为0.4-1.5mm，轮齿的接触面积在齿高方向≥45%、齿宽方向≥60%。
When assembling cylinder and hollow shaft, the junction surface should be cleaned and smeared by lead oil. The combination should be close and must not have any cushion in for adjustment. The rotary part should comply with the following principles: when the equipment is placed, the marked height should be checked on both end. Measuring the basic line of two hollow shaft and marks the relative difference of the mark's height(the height of the input end is 20mm higher than the output end.) The axis line of the hollow shaft should be on the same line(for bulks), and the gap between the gear ring and cylinder, the end surface of the gear and the hollow shaft must not be larger than 0.15mm. The gap of gear and the pinion should be 0.4-1.5mm, and the teeth junction surface should be toward the height direction ≥45%, and the width ≥60%.

五、 试车、使用和维修保养/
Test, operation, and maintenance

(一) 球磨机安装完毕并符合安装要求后，才能进行试车运转工作，试运转程序如下：
Test running for ball mill can be made after the installation is finished, complying with the installation requirements. The procedure for test running are as follows:
1) 将减速机内按要求加注润滑油，齿轮护罩内加入齿轮油；
Lubricant should be added to reducer, and gear oil into gear cover.
2) 球磨机空运转24小时（不加研磨体）；
Keep ball mill running for 24 hours without grinding media.
3) 加入1/3研磨体并喂料，运转8小时
Get ball mill running for 8 hours with 1/3 grinding media and raw materials inputing.
4) 加入2/3研磨体并喂料，运转72小时；
Get ball mill running for 72 hours with 2/3 grinding media and raw materials inputing.

设备试运转过程中，要注意转动部位的温度，主轴承、传动轴承的温度不得超过70℃。减速机在试运转期间应密切注意个润滑点的供油情况是否正常，电动机的负荷、大、小齿轮及减速机声音是否有异常等。每次试运转中的震动情况应严格注意。停机后，要检查轴颈与轴承的情况、传动齿轮的啮合情况、检查地脚螺栓、中空轴螺栓、衬板紧固螺栓、大齿圈螺栓等紧固情况，检查各处有无漏料等情况。
During the test running of ball mill, please note that the temperature of rotary part, main bearing and transmisson bearing can not surpass 70℃ . It should be noticed closely for each lubricating point on reducer to confirm if the oil supply is normal or not; if it is normal for the motor load, the sound of gear and pinion and reducer. The vibration of test running should be noted strictly. When the mill is stopped, it should be checked for the situation of the bearing neck and the bearing, transmission junction, the screw fixing on anchor, hollow shaft and liner fixed one, and gear etc.and the leakage per place.

（二）试运转合格后，允许正式使用，用户可根据具体情况，制订操作、维护、检修制度，以保证设备的正常运转。
After test running is qualified, the ball mill is allowed to run officially, customers can make the principle for operation ,maintenance, and inspection according to their own situations to ensure the normal running of the equipment.

（1）球磨机操作的知识 Operation method for ball mill
判断球磨机运转是否正常有两种常用的办法：第一种办法是检查物料的出料粒度，若合乎要求，且跳动不大，就说明球磨机的运转正常，说明加料恰当、物料的进料粒度、水分都合适，球级配合适。第二种办法是听球磨机的声音，设备运转正常时应该是“哗哗”夹杂着轻微的冲击声。如果声音变的暗哑，发出“轰轰”的声音，冲击声听不到，说明仓内物料过多，严重时出现满磨现象，这时应立即停止喂料，待设备正常运转后在继续喂料；如停止喂料后，正常的声音仍然听不到，物料很难喂入，而且出料很少，对于干式球磨机说明筒体内有严重粘磨现象，应立即进行处理，一般来说可用以下办法解决：若是入磨物料水分过高，则应降低入磨物料水分在2%以内，也可以加入部分干物料，研磨能消除上述现象，湿式球磨机不会出现此现象。球的冲击声很强，说明筒体内物料少，应增加喂料，喂料量不可过强，应逐步的调整过来。
There are two ways to judge whether ball mill works smoothly or not. The first way is to check the output size of materials. If it is close to the requirement with little tolerance, that means the ball mill is running smoothly with proper input material, the size, the moisture and the ball grade. The second way is to listen to the sound, the normal operation should have the slighter impacting sound with 'haha'. if it get lower, with'honghong', and no impacting sound, it means that the material inside is too much, and maybe of the whole mill so that we must stop feeding in immediately until it is normal operation. If stop feeding in material, the normal sound is still not available, and the material is hard to feed in, with little material output. It shows that there are serious mill sticking situation for dry type ball mill and must be handled at once. Usually the following method is used: if the moisture of the material input is too high, then it should be reduced by 2% or less or adding into some dry material for grinding to rid of that situation. The wet type ball mill has no such situation. If the ball has strong impact sound, it shows that the material is less, and we should increase the material feeding in, which should not be too much and get adjusted gradually.

（2）球磨机的操作程序：Operation procedure for ball mill
1、启动前的准备
Preparation before starting the ball mill.

清除球磨机周围有碍运转的杂物，检查安全设施；
To clean the litters affecting the running beside the ball mill, and check safty device.

检查球磨机内及危险地点是否有人；
To check if there is people inside the ball mill and around the dangerous area.

检查研磨体表面至蓖板中心距离（及填充率）是否符合要求；
To check if the distance from grinding media to the grid plate central line(filling ratio) meet the requirement.
将人孔盖可靠封闭和紧固；
To seal the lid of man hole closely and tightly.
润滑点、润滑油是否充足；
To check if the lubricating point or lubricant is sufficient or not.

第一次试运转或长时间停止运行时，在启动前，必须向中空轴颈上加润滑油，人工手动盘磨至少一周，确认无碰撞和卡滞现象后，才能由电机启动。
For the test run or long time not running, the hollow shaft must be added into lubricant before start. The mill must be checked manually for at least one circle to ensure there is no collision and stick, then the motor can be started.
在启动球磨机前，还应和有关工作岗位取得联系，允许后启动。
Before starting the ball mill, please get in touch with related worker for the permission to start.

2、 球磨机的启动顺序/Starting sequence for ball mill.

启动出料输送设备；
To start the material output device.
启动球磨机电动机；To start the motor of ball mill
启动磨机的喂料装置。To start the feeding device of ball mill
3、 停机顺序 The shut-down sequence for components of ball mill

停止向球磨机喂料的喂料设备的运行；
To stop the feeding device from delivering materials into the shell.
停止球磨机的运转；To stop ball mill from running
关闭出料输送系统。To stop the material output system.
4、 注意事项 Notes

当球磨机准备长时间停止运行时，要将研磨体从筒体内取出，避免筒体弯曲；
If the ball mill are to be stopped for a long time, the grinding ball must be picked out from cylinder to avoid the cylinder deforming.
要经常检查主轴承的润滑情况；
Lubrication for main bearings should be checked often.
在球磨