第九章 PFG輥壓機設備的正常操作與運轉
Chapter 9 Normal Operation and Running of Equipment
一、系統(tǒng)工藝各設備的啟動順序
1. The startup sequence of each equipment of the system process
該工藝系統(tǒng)設備均由計算機程序控制其啟閉關系，但在調試或計算機出現故障，需要手動時，必須按規(guī)定程序開啟或關閉。
The process system equipment is controlled by computer program to control its opening and closing relations, but when debugging or computer failures require manual operation, they must be turned on or off according to the prescribed procedures.
1、啟動出料系統(tǒng)各設備；由后往前至輥壓機；
1. Start each equipment of the discharging system; from back to front to the roller press;
2、啟動進料系統(tǒng)中的除鐵器和金屬探測器；
2. Start the iron separator and metal detector in the feed system;
3、打開主機電源及控制柜，檢查確認各儀表正常工作；
3. Turn on the power supply of the main machine computer and the control cabinet, and check that the instruments are working normally;
4、開啟集中潤滑系統(tǒng)；
4. Turn on the centralized lubrication system;
5、啟動主電機；
5. Start the main motor;
6、開啟進料系統(tǒng)各設備；
6. Turn on the equipment of the feeding system;
7、開啟液壓油泵電機加壓，使系統(tǒng)壓力達到設定數值；
7. Turn on the hydraulic oil pump motor to pressurize to make the system pressure reach the set value;
8、觀察稱量倉的料位顯示，調節(jié)進料插板使料餅達到適當的厚度。
8. Observe the material level display of the weighing bin, and adjust the feeding insert to make the cake reach the proper thickness.
二、系統(tǒng)工藝設備的停機順序
2. The shutdown sequence of system process equipment
1、關閉進料系統(tǒng)各設備；
1. Turn off the equipment of the feeding system;
2、關閉除鐵器及金屬探測器；
2. Turn off the iron separator and metal detector;
3、將稱量料倉中的物料擠壓完畢，并關閉液壓油泵電機；
3. After squeezing the materials in the weighing bin, turn off the hydraulic oil pump motor;
4、關閉主電機；
4. Turn off the main motor;
5、關閉集中潤滑系統(tǒng)；
5. Close the centralized lubrication system;
6、關閉控制柜；
6. Close the control cabinet;
7、關閉所有出料系統(tǒng)設備。
7. Close all discharge system equipment.
三、輥壓機長時間停車必須采取的措施
3. The measures that must be taken when the roller press is stopped for a long time
1.卸掉液壓系統(tǒng)壓力；
1. Remove the pressure of the hydraulic system;
2.將各潤滑點加好充足的潤滑油脂，防此設備零、部件生銹或有雜物進入設備密封腔內；
2. Add sufficient lubricating grease to each lubrication point to prevent rust or debris from entering the sealed cavity of the equipment;
3.將蓄能器的充氣壓力降至5×105 Pa;
3. Reduce the charging pressure of the accumulator to 5×105 Pa;
4.在設備重新啟動之前,必須按第六章和第七章的程序進行檢查、試車.
4. Before the equipment is restarted, it must be inspected and tested according to the procedures in Chapter 6 and Chapter 7.
四.設備運行的主要參數選擇及其調整
4. Selection and adjustment of main parameters of equipment operation
輥壓機在運行時，可供調節(jié)的參數主要有三個，即擠壓粉碎、磨輥轉速和被擠壓出的料餅厚度。一般來說，調節(jié)擠壓粉碎力，則可以改變被擠壓后的物料性能；而改變磨輥轉速（在本設備的范圍內），僅改變設備自身處理物料的能力，對物料性能無影響；調節(jié)被擠壓出的料餅厚度，可以改變設備自身的處理能力，同時對物料的性能稍有影響；
When the roller press is running, there are three main parameters that can be adjusted, namely, crushing, grinding roller speed and the thickness of the extruded cake. Generally speaking, adjusting the squeezing and crushing force can change the performance of the material after being squeezed; while changing the speed of the grinding roller (within the scope of this equipment) only changes the equipment's own ability to handle the material, and has no effect on the material performance; Adjusting the thickness of the extruded cake can change the processing capacity of the equipment itself, and at the same time have the slight impact on the performance of the material;
1、根據被擠壓物料的性質，選擇適當的粉碎力，以得到最佳的節(jié)能效果。本機的粉碎力與液壓系統(tǒng)壓力關系見下表：
1. According to the nature of the material to be extruded, select the appropriate crushing force to get the best energy saving effect. The relationship between the crushing force of this machine and the pressure of the hydraulic system is shown in the following table:
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液壓系統(tǒng)壓力×105Pa
Hydraulic system pressure ×105Pa
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總粉碎力kN
Hydraulic system pressure ×105Pa
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單位輥寬粉碎力kN/cm
Crushing force per unit roll width kN/cm
|
|
50
|
2512
|
38.6
|
|
60
|
3014
|
45.4
|
|
70
|
3516
|
54.1
|
|
75
|
3768
|
58.0
|
|
80
|
4019
|
61.8
|
|
90
|
4521
|
69.6
|
|
100
|
5024
|
77.3
|
在選擇了適當的液壓系統(tǒng)工作壓力后，可調節(jié)液壓系統(tǒng)閥臺上的電接點壓力表的上限與下限壓力指針，使壓力波動在一合適的范圍內（如1.2～2.0Mpa），并將其余各壓力控制閥表按“液壓系統(tǒng)試車”中所述進行調節(jié)。
After selecting the appropriate hydraulic system working pressure, the upper and lower pressure pointers of the electric contact pressure gauge on the valve table of the hydraulic system can be adjusted. Make the pressure fluctuate within the suitable range (such as 1.2～2.0Mpa), and adjust the other pressure control valve meters as described in “Hydraulic System Trial Run”.
2、輥壓機處理量可以通過設置在進料裝置上的調節(jié)插板，改變被擠壓出的料餅厚度加以調節(jié)。輥壓機的工作輥縫原則是根據工藝要求的輥壓機處理量來確定，但它的下限受到原始輥縫和設備運行狀態(tài)的限制，當工作輥縫過小時，料餅太薄，缺乏彈性使設備震動加大，它的上限受到主電機額定負荷的限制；另外，如果新加入料的平均粒徑較大（在25～30mm以上）物料較硬，除如前所述加大回料量外，還應適當加大工作輥縫，這樣有利設備穩(wěn)定運轉，但料餅厚度調節(jié)范圍一般不能過大，料餅厚度過厚或過薄，對擠壓效果和設備本身都會產生不利的影響。一般調節(jié)范圍為：25-40㎜ 水泥。
The processing capacity of the roller press can be adjusted by changing the thickness of the squeezed cake by adjusting the plate on the feeding device. The working roll gap principle of the roller press is determined according to the processing capacity of the roller press required by the process, but its lower limit is limited by the original roll gap and the operating state of the equipment. When the work roll gap is too small, the material cake is too thin and the lack of elasticity increases the vibration of the equipment, and its upper limit is limited by the rated load of the main motor; In addition, if the average particle size of the newly added material is larger (above 25-30mm) and the material is harder, in addition to increasing the amount of recycled material as mentioned above, the work roll gap should also be appropriately increased, which is beneficial to the stable operation of the equipment. However, the adjustment range of the cake thickness is generally not too large. If the cake thickness is too thick or too thin, it will have an adverse effect on the extrusion effect and the equipment itself. The general adjustment range is: 25-40mm cement.
這里指的厚度為料餅的平均厚度
The thickness here refers to the average thickness of the cake
3、輥壓機系統(tǒng)工藝設備的連鎖
3. Interlocking of process equipment of roller press system
除鐵器、金屬探測器Iron remover, metal detector 出料輸送設備Discharge conveying equipment
集中潤滑系統(tǒng)Centralized Lubrication System
主軸承溫度檢測Main bearing temperature detection
主機啟動main machine start 稱量料倉控制Weighing Silo Control
輥縫檢測Roll gap inspection
液壓系統(tǒng)壓力檢測Hydraulic system pressure detection
喂料系統(tǒng)設備Feeding system equipment
五、輥壓機控制系統(tǒng)報警處理
5. Alarm processing of roller press control system
1、輥縫檢測報警
1. Roll gap detection alarm
1）當移動輥一側的軸承座或移動輥整體后退量過大，達到設定的最大輥縫時，系統(tǒng)控制柜報警，其特征是：報警鈴響，同時閃光報警器發(fā)出閃光指示，從其上可以知道輥縫過大的情況；
1) When the bearing seat on one side of the moving roller or the overall retreat of the moving roller is too large and reaches the set maximum roller gap, the system control cabinet will give an alarm. The characteristic is: the alarm bell sounds and the flashing alarm will give out flashing instructions. It can know that the roll gap is too large;
2）發(fā)生此種情況一般是因為輥縫中有較大很硬的異物，也有可能是由于進料插板調得過大，系統(tǒng)操作失誤也有可能造成報警；
2) This happens usually because there are large and hard foreign objects in the roll gap, or it may be because the feed plate is adjusted too large, and the system operation error may also cause an alarm;
3）當發(fā)生報警時，應及時處理。當查明因異物造成，則應立即停車，排除異物。若因操作失誤，液壓系統(tǒng)未加壓力，則應檢查、啟動液壓系統(tǒng)；若因輥縫過大，料餅過厚，則應將插板適當下調。
3) When an alarm occurs, it should be dealt with in time. When it is found that it is caused by the foreign body, the vehicle should be stopped immediately to remove the foreign body. If the hydraulic system is not pressurized due to operating errors, check and start the hydraulic system; if the roll gap is too large and the material cake is too thick, the insert plate should be appropriately lowered.
2、液壓系統(tǒng)壓力報警
2. Hydraulic system pressure alarm
1）當液壓系統(tǒng)超過設定工作壓力一定數值后，控制系統(tǒng)發(fā)出報警。特征是響鈴、閃光。當壓力達到規(guī)定的下限時，報警；當壓力達到規(guī)定的上限時，則控制系統(tǒng)自動關閉主電動機。
1) When the hydraulic system exceeds a certain value of the set working pressure, the control system issues an alarm. The characteristics are bells and flashes. When the pressure reaches the prescribed lower limit, an alarm is issued; when the pressure reaches the prescribed upper limit, the control system automatically shuts down the main motor.
3、液壓泵濾油器堵塞報警
3. Alarm for blockage of hydraulic pump oil filter
1）當液壓泵站的濾油器因雜質堵塞過濾網，造成濾油器進、出油壓差過大，控制系統(tǒng)發(fā)出報警。
1) When the oil filter of the hydraulic pump station blocks the filter screen due to impurities, causing the oil filter to enter and the oil outlet pressure difference is too large, the control system will issue an alarm.
2）當濾油器堵塞報警發(fā)生后，不必馬上停車，可以讓其繼續(xù)工作一定時間，待主機停止工作時，拆卸濾油器，清洗濾網。但時間不可過長，否則將會損壞過濾網。
2) When the oil filter blockage alarm occurs, it is not necessary to stop the machine immediately, and it can continue to work for a certain period of time. When the main engine stops working, remove the oil filter and clean the filter screen. But the time should not be too long; otherwise the filter screen will be damaged.
4、潤滑泵貯油筒空油報警
4. Alarm for empty oil in lubrication pump oil tank
1）當潤滑泵貯油筒內油脂達到規(guī)定的下限位時，控制系統(tǒng)發(fā)出報警。特點是響鈴、閃光；
1) When the grease in the oil tank of the lubrication pump reaches the specified lower limit, the control system will issue an alarm. The characteristic is ringing and flashing;
2）當發(fā)出貯油筒空油報警時，不必停主機，而應當立即取油，用充填泵向貯油筒內打油。一般加油應小于30L。
2) When the oil storage tank empty alarm is issued, it is not necessary to stop the main engine, but should immediately take oil, and use the filling pump to pump oil into the storage tank. Generally, the fuel should be less than 30L.
5.潤滑油路阻塞報警
5. Alarm for blockage of lubricating oil circuit
1）當潤滑油路中某一路或幾路堵塞,控制系統(tǒng)均能發(fā)出報警信號。其特征是，當潤滑油泵工作時，即控制柜模擬板上油泵電機工作指示燈亮時，分油器接近開關發(fā)出信號；
1) When one or several of the lubricating oil circuits are blocked, the control system can send out an alarm signal. Its characteristic is that when the lubricating oil pump is working, that is, when the oil pump motor working indicator on the analog board of the control cabinet is on, the oil separator proximity switch sends one signal;
2）當發(fā)現這一異常情況時，主機可不用停車，應仔細檢查各分油器的出口，確定被堵塞油路的位置加以檢修。若因檢修時間較長，則應停機。
2) When this abnormal situation is found, the main engine does not need to be stopped, and the outlet of each oil separator should be carefully checked to determine the position of the blocked oil circuit for maintenance. If the maintenance time is long, the machine should be shut down.
六、設備正常檢查表
6. Equipment normal checklist
為了保證設備能正常運轉，提高運轉率，及時發(fā)現設備故障及隱患，延長設備使用壽命，必須按下表對設備進行經常的檢查；
In order to ensure the normal operation of the equipment, improve the operation rate, discover equipment failures and hidden dangers in time, and prolong the service life of the equipment, the equipment must be checked frequently according to the following table;
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序號項目No. Item
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檢查系統(tǒng)Inspection system
|
檢查內容Inspection content
|
檢查周期Inspection cycle
|
處理方法Processing method
|
|
1
|
電氣控制系統(tǒng)Electrical control system
|
a.主電控柜各儀器儀表工作發(fā)熱
a. Heating of the instruments and meters of the main electric control cabinet
b.主機控制柜各儀表工作狀況
b. The working status of each instrument in the main machine control cabinet
|
每天
everyday
|
更換元器件或導線;重新擰緊接頭
Replace components or wires; re-tighten the connectors
增加冷卻設備
Increase cooling equipment
|
|
2
|
主電機及傳動系統(tǒng)Main motor and driving system
|
a.主電機發(fā)熱正常，工作電源正常
a. The main motor is heating normally and the working power supply is normal
b.萬向節(jié)傳動軸軸承座與底座的聯(lián)接螺栓
b. Connecting bolts between bearing seat of universal joint drive shaft and base
c.行星減速器潤滑油位
c. Lubricating oil level of planetary reducer
d.行星減速器法蘭螺栓
d. Planetary reducer flange bolts
e.縮套聯(lián)軸器縮緊螺栓
e. Shrink sleeve coupling shrink bolts
f.扭矩支承蝶形彈簧
f. Torque support butterfly spring
g.扭矩支承鉸鏈座螺栓
g. Torque support hinge seat bolt
|
每天
everyday
每周
weekly
每周
weekly
每月
Every month
每半月
Every half month
每天
everyday
每周
weekly
|
檢查電氣控制；檢查、更換主電動機
Check the electrical control; check and replace the main motor
按規(guī)定擰緊力矩重新擰緊
Re-tighten according to the specified tightening torque
補充潤滑油
Replenish lubricating oil
重新擰緊Re-tighten
按規(guī)定力矩擰緊
Tighten according to the specified torque
更換碟形彈簧
Replace disc spring
重新擰緊Re-tighten
|
|
3
|
主軸軸系main shaft system
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a.主軸承溫度
a. Main bearing temperature
b.磨輥輥面耐磨堆焊層厚度
b. Thickness of wear-resistant surfacing layer on roller surface
c.磨輥輥面“菱”形花紋
c. “Diamond” pattern on the surface of the grinding roller
d.端蓋密度圈
d. End cover density ring
|
每天
everyday
每半月
Every half month
每天
everyday
每天
everyday
|
若需要則更換軸承
Replace bearing if necessary
重新補焊修復
Re-welding repair
局部補焊
Partial repair welding
多加潤滑脂,更換密度圈
Add more grease and replace the density ring
|
|
4
|
液壓系統(tǒng)
Hydraulic system
|
a.所有管接頭、法蘭聯(lián)接
a. All pipe joints and flange connections
b.系統(tǒng)保壓性能
b. System pressure holding performance
c.各壓力保護閥的功能
c. The function of each pressure protection valve
d.液壓油油位高度
d. Hydraulic oil level
e.液壓油質
e. Hydraulic oil quality
f.泵站濾油器濾網
f. Pump station oil filter screen
g.蓄能器充氣壓力
f. Pump station oil filter screen
|
每天
everyday
每周
weekly
每半月
Every half month
每周
Weekly
每半月
Every half month
每月
Every month
每月
Every month
|
重新擰緊, 更換密度圈
Retighten and replace the density ring
更換檢修有關元器件
Replace and repair related components
重新調節(jié)或更換元件
Readjust or replace components
補充液壓油(同型號)
Replenish hydraulic oil (same model)
更換新液壓油
Replace with new hydraulic oil
更換濾網或濾油器
Replace the filter screen or oil filter
補充氮氣
Nitrogen supplement
|
|
5
|
潤滑系統(tǒng)lubrication system
|
a.潤滑脂油位高度
a. Grease oil level height
b.泵站安全片
b. Pump station safety piece
c.分油器工作狀況
c. Working condition of oil separator
d.泵站出油口網
d. Pump station outlet network
|
每月
Every month
每天
everyday
每天
everyday
每月
Every month
|
檢修、更換空油報警裝置
Repair and replace the empty oil alarm device
更換安全片
Replace the safety piece
檢修各潤滑管路
Overhaul each lubrication pipeline
清洗濾網
Clean the filter
|
|
6
|
進料裝置feeding device
|
a.進料擋板、側擋板
a. Feed baffle, side baffle
b.調節(jié)閘板的端部
b. Adjust the end of the gate
c.側擋板下端襯板
c. Side baffle bottom liner
|
每二月
Every two month
每月
Every month
每周
Weekly
|
更換擋板、側擋板
Replace baffle, side baffle
修復或更換閘板
Repair or replace the gate
修復、更換襯板
Repair and replace the liner
|
|
7
|
檢測系統(tǒng)Detection Systems
|
a.各一次儀表工作狀況
a. The working status of each instrument
b.標定檢測儀表
b. Calibration detection instrument
|
每天
everyday
每半年
Every half year
|
更換一次儀表
Replace the meter once
重新調試
Re-debug
|
|
8
|
主機架main frame
|
a.上、下橫梁與立柱的連接
a. Connection between upper and lower beams and columns
b.地腳螺栓
b. Anchor bolts
|
每天
everyday
每天
everyday
|
按規(guī)定擰緊機架聯(lián)接螺栓
Tighten the frame connecting bolts as required
重新擰緊
Re-tighten
|
