中速磨主減速機說明書樣本

資料內(nèi)容僅供您學習參考，如有不當之處，請聯(lián)系改正或者刪除。Dateofissue:Jan.Versionnumber::05AML20verticalrollermillreducerManualinstructionExecutivestandard:Q/3201NGC009-·Drivingdevice&gearreducershouldbeoperatedbyskilledoperators.Pleasereadthisoperationmanualthroughbeforeusing.·Oilinthegearreducerhasbedrainedoutbeforedelivery.Therefore,pleaserefilloilintothereduceraccordingtotheoperationmanualbeforestartingup.·Pleaselettheoperatorholdsonecopyofthisoperationmanual.·PleasekeepthisOperationManual.NanjingHighSpeed&AccurateGear(Group)Co.,Ltd.

SafetyConsiderationduringoperatingBeforeusing(installation,running,maintenance,inspection,etc),operatorsmustreadthismanualanditsannexesthroughinordertooperatethisproductproperly.Theoperatormustreadupthewholeoperationmanualincludinggeneralknowledgeofthisproduct,pointsforsafeoperationandotherpointsneedtobenoticedbeforestartingupthisreducer.Afterfinishreading,theoperatorsshouldkeepthismanualatarm’slength.Handling,settingup,pipepreparing,machinerunning,operating,maintainingandinspectionmustbecarriedoutbyskilledpersonwhohasthiskindofprofessionalknowledge,orpeoplemaybeinjuredortheequipmentmaybebroken.Whenusingman-carryingdevice,thereshouldbesomeprotectiononsidesofthisdevice,sinceitmaycauseinjuryorequipmentbrokenbyspeedymovementofthisdevice.Whenusingliftingdevice,thereshouldbesomeprotectiononsidesofthisdevicetoavoidfallingofsomeparts,oritmaycauseinjuryorequipmentbrokenbythedroptofliftingdevice.Donotdisassemblethisreducerwhileit’srunning.Besides,eventhoughtheitstops,astheinput&outputshaftsofthereducerareconnectedtotheelectromotorandotherequipment,itisalsoforbiddentodisassemblethesepartsexceptoilinspectionpole,oilinlet,oiloutletandinspectioncover.Donotdrivethisreducerunderotherconditionsthatexceeditsspecification,oritmaycauseinjuryorequipmentbroken,etc.Keepfingersandthingsawayfromopenpartsofthereducer,asitmaycauseinjuryorequipmentbroken,etc.Donotusedamagedreducer,asitmaycauseinjuryorequipmentbroken,etc.Ourcompanywillnotguaranteethequalityofthisreducerifthecustomredevelopsit.Donotremovethenameplate.Pleasecheckthespecificationoftheoilstationifitisseparatefromthereducer.CONTENTSⅠ.GENERALINTRODUCTIONⅡ.CHARACTERISTICPARAMETERS1.OPERATINGENVIRONMENT2.CHARACTERISTICPARAMETERSFORTHISREDUCERⅢ.INSPECTIONUPONRECEIPTOFTHEREDUCER1.PRECAUTIONS2.INSPECTIONREQUIREMENTSⅣ.LIFTING,TRANSPORTATION&STORAGE1.LIFTING2.TRANSPORTATION3.STORAGEⅤ.INSTALLATION&ALIGNMENT1.POINTSNEEDTOBENOTEDDURINGINSTALLING2.FOUNDATION3.ALIGNMENTⅥ.RECORDSOFFIELDINSTALLATION,DEBUGGINGANDCOMMISSININGⅦ.OPERATIONANDMAINTENANCEOFTHEREDUCER1.Start-up2.SHUT-DOWN3.MaintenanceⅧ.REGULARINSPECTIONⅨ.Notesfordisassemblyandreassemblyofthereducer1.disassembly2.INSPECTION3.AssemblyⅩ．GUARANTEE Ⅰ.GENERALINTRODUCTIONML20verticalrollermillreducertransmitthroughthebevelgearscombinedwithplanetgears,apairofbevelgearswitharightangletransmissionareconnectedwithasetofplanettransmissionwhichinputshaftisperpendicularlyupwardthroughdouble-toothcoupling.Thesunwheelissupportedonthethrustdiscbythesphericalbearing,theaxialsupportoftheverticalmillisenduredbythetiltedthrustbearingwithfan-shapedoilfilm,andthistwofreedomofmotionmaketheinnerringandthreeplanetwheelsundertheequalstress.Internalgearisrigidlyfixedinthehousing,thedesignedcylindricalhousingprovidetheidealsupporttotheaxialthrustbearing.Inaddition,cylindricalhousingconfiguresymmetricalribsbothatinsideandoutside,whichletthehousehavestrongrigidity.Theoutputshaftweldedwiththeplanetcarrier,whichmaketheconfigurationsimpleandreasonable.BevelgearsareKlingelnberghelixgears,andthesungearandplanetgearsareinvolutespurgears.Thesegearsallapplytothecarburizedcarbonsteel,gearsfeaturehighaccuracyaftercarburizingandgrinding.Alltheblockbearingsaretherollingbearings.Axialthrustbearingsarethetiltedthrustbearingscomposedofseveralfan-shapedbearingbushing,whichcanstandtheaxialforceoftheverticalmill.Duringoperation,bearingbushingaredirectlysubmergedintotheoiltankandsuppliedfreshlubricationoilthroughthering-typenozzles,tokeepthetankalwaysinacertainoillevel,insuchamanner,themillcanworkforaperiodtimewhenthelubricationsystemsuddenlystoporothermechanicalerrorsoccur.Lubricationsystemisappliedtoseparateoilpumpstationwithpressureandself-protectivesystem,whichletthewholeunitworksafeandreliable.II.CharacteristicparameterOperatingenvironmentAmbienttemperature:-20oC－+40oCAmbienthumidity:below85%Environmentalconditions:nocorrosivegas,explosivegasorvapor.Nodustandatbetterairexchangeplace.·Ifhaveotherspecialrequirementsbesidestheaboveones,pleasecontactus.·Iftherearerequirementforanti-explosioninopenonthepurchaseorder,ourdesignerswillconsiderit.Itwillbesafetoinstallourproductsunderourspecification.·Thereducershouldbeinstalledatthiskindofplacewhereitisconvenienttocarryouttheinspectionandmaintenancework.·Thereducershouldbeinstalledonrigidsupport.CharacteristicparameterTypeML20InputpowerkW220Inputspeedn1rpm990Outputspeedn2rpm46.85Reductionratioi21.128WeightGkg6390OilproductIndustrialgearoilN320StaticloadDynamicloadOilmassL/min80InletoilpressureMpa0.15-0.25InletoiltemperatureoC25-50Ⅲ.Inspectionuponreceiptofreducer1.Precautions·Pleaseconfirmwhetherthepackingisstillingoodconditionbeforeopening.Pleasetakecarewhenopensthepacking.·Checkwhetherreceivedgoodsarecoordinatewithgoodslistedinthepurchasingorder.Ifimproperproductsareused,itmaycauseinjuryorequipmentbroken.·Donotremovethenameplate.2.InspectionrequirementsThefollowingshouldbeinspectedwhenthedrivingdeviceorgearreducerarrives.Iftherearesomeconfusionorproblems,pleasecontactoursalesdepartment.(1)Whetheritemsonthenameplateorthingsonthepackinglistarethesameastheminthepurchasingorder.(2)Whethertherearesomedamagecausedbytransportation.(3)Whetherboltsornutsareloose.Ⅳ.Lifting,transportation&storageLifting·Whenliftingthereducer,it’sforbiddentostandbelowthereducer,asthedroptreducermaycauseinjury.·Pleasenotetheliftingpositionshowninthedrawingandliftthereducerwithcare.·Pleasebecarefulwhenliftingthereducersinceitmaydropdownorturnover.Ifthereareliftingboltsorholes,onemustusethemwhenlifting.Whenliftingthewholesetofreducer,onemustuseliftingholesinthelowerhousing,whileitisforbiddentousethemintheupperhousing.However,afterthereducerisinstalledtotheequipment,donotuseliftingboltsorholestolifttheequipmentasitmaycauseinjuryormachinebroken.·Pleaseclarifythereducer’sweightbeforeliftingfromthenameplate,package,outlinedrawingorsamplecopy.Ifitexceedsthemaximumliftcapacityoftheliftingdevice,pleasedonotliftthereducer,asitmaycauseinjuryormachinebroken.Note:Itisforbiddentoliftthereducerwiththeoutputflange.2.Transportation·Thelubricationoilmustbedrainedoutbeforetransportation.·Thereducermustbefastenedtightly.·Anti-wind,anti-rainandanti-moistprotectionmustbeadopted.·Itisforbiddentoplacethereducerdirectlyontheground.3.StorageIfthedrivingdeviceorreducerstopsforashortperiod,itshouldbestoredasfollows:1)Properplaceforstoring·Thereducershouldstayinacleananddryplace.Donotlayitoutdoororatthiskindofplacewheremaybehumid,dustyandthetemperatureischangefulorcontainscorrosivegas.·Rustpreventativeoilmustbepaintedtotheinputandoutputshafts.·Afterdismantlementthelubricationoilpipesshouldbepackedwithvinylresintopreventforeignsubstancesfromgettinginside.·Anti-wind,anti-rainandanti-moistprotectionmustbeadopted.·Itisforbiddentoplacethereducerdirectlyontheground.2)Storageperiod·Thisperiodshouldnotexceedtherustpreventingperiod.·Ifthestorageperiodislongerthanrustpreventingperiod,thespecialanticorrosivespecificationisneeded,pleasecontactus.·Ifthisreducerisanexportationproduct,theanticorrosivespecificationforexportproductsareneeded,pleasecontactus.·Standardrustprevention=1\*GB3①OutsidepreventionThereducerhasbeenpaintedwithrustpreventativeoilbeforedelivery.Theanti-ruststatusmustbeinspectedin6monthsafterdelivery,andifitisnecessary,itshouldbepaintedagain.=2\*GB3②InsiderustpreventionRustpreventionperiod6monthsStoringConditionThereshouldbenohumidity,nodust,lesstemperaturechange,nocorrosivegas.Normallyitshouldbelieindoorsorinthestoragearea.3)Usageafterstorage·Beingeffectedbytemperature,ultravioletradiationandotherfactors,sealsareeasilyagingandmetamorphosing.Thus,thesealsshouldbeinspectedbeforerestartupthereducerafteralongtimestorage,iftheabovementionedhappens,pleasereplacethemwithnewones.·Whenrestartingupthereducer,pleaseinspectwhetherthereareabnormalnoise,vibrationorheating.Ifabrakeisattached,pleasecheckwhetheritworkswell.Ifthereisanyabnormalphenomenon,pleasecontactourafter-saleservicedepartment.V.Installationandalignment1.Notesforinstalling·Donotrunningthereducerintheplacewheretherehasexplosivefactors,oritmaycauseexplosion,firebreakout,electricshock,injury,firehazardorequipmentbroken.Ifitisreallynecessarytorunthereducerunderthiskindofcondition,besuretouseananti-explosionmotor.·Whenchoosingananti-explosionmotor,besurethatit'sasuitabletypeforusingindangerousplaces(wherehasthedangerofgasorvaporeruption).·Itisforbiddentostayanycombustiblesnearthedrivingdevice,oritmayarisefirehazard.·Donotputanyarticlethatmayeffecttheventilationaroundthedrivingdeviceandgearreducer,asitmaycauseequipmentbrokenorfirehazardbecauseoflesscoolingorabnormalheat.·Itisforbiddentostanduponthedrivingdeviceorreducer.Donothangingthereducer,oritmaycauseinjuryorequipmentbroken.FoundationThereducershallbemountedonthefoundationwithgoodrigidity,levelandwithoutvibration,e.g.thereducercanbemountedonframeworkoffoundationwhichsupportsurfaceismachined,thisframeworkoffoundationshallbemoldedwiththerollerfoundation.Afteraligning,firstfixthereducerbythelocatingpin,andthenconnectthefoundationwithbolts.AligningAligningbetweenthemainreducerandmainmotorTheoutputshaftwhichconnectsthereducerandthemainmotormustbeconcentricwiththemotorwhenoperation.Inordertomeetthisrequirement,thespecializedinstrumentmustmeasuretheaxialandradialrunout,moredetailsasthefollowingdrawing:CouplingtypeRadialrunoutAxialrunout(R=200)Rigiditycoupling0.030.02Flexibilitycoupling0.080.08IfR>200mmisneeded;theaxialrunoutmaybeincreasedaccordingly.Installationandaligningbetweenthereducerandthemill·Confirmtherotationdirectionbeforeconnectingtothemachineofotherside.Otherwise,thewrongrotationdirectionmaycauseinjuryormachinedamage.·Avoidimposingimpactforceortoomuchloadontheshaftwheninstallingthecoupling.Otherwise,itmaycausebrokenorfallenofftobearingorsealring.·Theinstallationofthereducerandthemillshouldbecarriedoutcorrectlyanddelicately.Cleanthediscmillandthrustpillowblock,withoutanyinclusion.Thefittingrabbetdimensionbetweenthediscmillandthrustpillowblockmustberecordedindetails.Tightentheconnectionboltsbetweenthediscmillandthrustpillowblock,andmakesurethethrustpillowblockisfreefromdeformationordistortion.Thetoleranceofaxialrunoutisnomorethan0.13mm.·Duringinstallingthereducer,ifnooilorlubricatesystemdoesn’twork,thereducermustn’trunslowly.VI.Therecordsoffieldinstallation,debuggingandcommissioning1.Thetypeofthereducer2.ThedeliverySerialNo.ofthereducer3.Thespecificationofmill4.Thespecification,type,power,revolution,pressure,currentofthemaindrivemotor5.Rotationdirection(frommotorend)6.DetailedrecordsduringinstallationandaligningTheresultofthealigningbetweenthereducerandthemotorTheresultofthealigningbetweenthereducerandthemill7.TestrunrecordThebeginningtime:MonthDayYearTheendingtime:MonthDayYearTheloadonthemil:MonthDayYearRunningtime:ItemBeginningtimeEndingtimeLoadonmainmotor(T)Voltageofelectricmachinestator(V)Start-upCurrentofelectricmachinestator(A)WorkcurrentofelectricmachinestatorTemperatureoCRemarkMax.Min.RoomtemperatureOiltanktemperatureBeforetestAftertestⅦ.OperationandMaintenance1.Start-up1)Preparationworkbeforestart-up·Lubricationoilhasbeendischargedfromthereducerbeforedelivery,sorecommendedlubemustbefilledinbeforeoperation.·Assembletheexternallubricationpipingcompletely.Thepipesshouldbecleanandfreeofanycottonorchipsinsidebeforefitting.·Makesurebyinspectionthatthesafetycontrollingandautomaticprotectionsystemsfunctionreliably.·Checkoillevelinthetank.·Checkwhetherallinstruments,gauges,apparatusandmetershavebeeninstalledcompletely;·Checktheoilleakageofthelubricationsystemafter1hrlubricating·Checktheoillevelofthethrustbearingandhousing,ifoilislessthanrequired,refilltonormallevel.·Heatuptheoiltemperatureover25℃bytheoilheater,whenthetemperatureofthebearingislowerthan25℃,2).Preparatoryworkbeforethestart-upofoilpump·Checkiftheoilpumpworkproperly·ChecktheoilpressureOutletpressureofthelow-pressurepump:0.25-0.4MpaInletpressureofthereducer:0.15-0.25Mpa3)Preparatoryworkbeforethestart-upofreducer·Inthecasethatthehighpressureisnotturnedon,thereducershouldbestartedupwithoutload.Itisforbiddentostartupthemotorwhenthehighpressureisinloading,whichisabletoprotectthethrustbearingfromdamagingundertheconditionsofnoneoil.·Observetherisingofthebearingtemperaturewithoutload.Atallhours,itisnotallowedtoloadcontinuallyuntilthetemperatureriseofthebearingissteady.·Itisstrictlyprohibitedtoloadunevenly,andthetwoloadingcylindermustworkatthesametime.·Checkifanyabnormalnoiseorvibrationexistsinthereducer.·Checkthetemperatureofthethrustblockisnormal,anditmustbeshutdownwhenexceeding75℃.·Onecannotstartupthemainmotorwhenoutlettemperatureoftheoilcoolerisbelow25℃orabove50℃4)Preparatoryworkbeforethestartupofmainmotor·Onecancarryoutthetestrunaccordingtothetestprogramwithloadorwithoutload.·Checkifanyabnormalnoiseorvibrationexists.·Checkthetemperatureofthethrustblockisnormal,anditmustbeshutdownwhenexceeding75℃.·Onecannotstartupthemainmotorwhenoutlettemperatureoftheoilcoolerisbelow25℃orabove50℃2.Shut-downPrecautionsbeforeshut-downanditsprocess·Themilldiscmustbeunloadedbeforethemillstopworking;shutdownwithloadisstrictlyforbidden.UnloadofthemilldiscShutdownofthemainmotorStopfillingwatertotheoilcooler·Duringthefrozenwinter,donotshutoffthecoolingwatercompletely,ordrainthecoolingwatercompletely.Takenoticethatthemainmotorcanbestartedonlywhenthelubricationoilisinliquidstateinwinter,itisdifficulttoformoilfilmwiththestarchylubricationoil,foritiseasilytodamagethethrustbearing.4)Stoptheoilpump·Letthepumpworkforabout10minutesafterthemillstopworking.·Ifthemillonlystopforashorttime,itisnotnecessarytoshutofftheoilpumpinordertoletthemillcanstartupatanytime.·Aftershuttingofftheoilpump,ifoneneedstorestartthemill,hemustturnedontheoilpumpfirst,andtheninspecttheoillevelointhethrustbearingoiltank,whichshouldbehigherthantheprescribedscaleline,oritisnotallowedtostartthemill.3.MaintenanceInordertokeepthegoodoperatingsituation,regularlycheckthefollowingitemsduringthecontinuousoperation.1)Checkandrecordthedataofthepressure,temperatureandotherindicatedparameteratthestipulatedtimeeveryday.2)Comparetherecordeddatawiththefollowingtabledata,andfindoutthereasonfortheabnormalthings,ifnecessary,stopforinspection.ItemRatedvalueLimitedvalueRemarkInlettemperature25-50oCInletpressure0.15-0.25MpaOutletpressure0.25-0.4MPaOillevelofthetankAbove1/2Temperatureofthethrustbearingbushing70oC80oCThrustbearingbushingtemperatureinthehouse60oC75oC3)TakenoticeoftheoverloadtothereducerOilfiltering3–4hrsafterthefirstoperation,cleanthefilter.Normally,cleanthefilteronceafter200hours’work.Payattentiontothetypeandoriginoftheimpurityduringthecleaning.ChecktheconnectionboltsAfter20hours’initialoperationorsubsequent1000hours’running,carefullycheckthetighteningoftheboltsandnuts,whichconnectthehousingandframeworkofthefoundation.Ifnecessary,tightenit.Relativepositioninspectionbetweenthethrustpillowblockandhousing·Checktherelativepositiondimension”a”betweenthethrustpillowblockandhouseeveryhours.(seetheassemblydrawing).Comparethepresentdatawithformerdata,ifgreatchangehappen,stoptheoperationandcheckthereason.Frequentlycheckthenoiseandvibration,ifabnormalsituationoccur,analyzethereason,andsolveit.Frequentlycheckoilleakageineachpart,ifithappen,solveitFrequentlychecktheoillevel·Whentheoillevelisbelowthe1/3,refilltheoiltothestipulatedlevel.·Iftheoillevelisrising,maybethecoolingwaterdrainintotheoiltank,taketheoilsampleformtheoilplugpositionatthetankbottom.Ifnecessary,changetheoil.

Ⅷ.Regularinspection1.Theentireinspectionshouldbecarriedoutafterrunninghrsormore(generallynomorethan1year),andcanbeprocessedatstopperiodormaintenanceperiod.2.Theinspectionitems:InspectionpointsInspectionitemsNotesThrustbearingTherelativepositiondimension”a”betweenthethrustpillowblockandhousingComparetherecordeddatawiththedeliverydata.ChecktheconnectionofthethermalcouplingwhichmeasurethethrustbushingtemperatureDismountingtheobservationholecoveronthethrustbearinghousing.IfanydirtatthehousebottomofthethrustbearingBevelgearCheckteeththecontactpatternDismountingtheobservationholecoveronthelowerhousingIfnozzlesareblocked,orlooseoccurtoconnectionboltsHouseandpipingChecktighteningofthefollowingcomponents:BoltstighteningbetweenthethrustbearinghousingandthereducerBoltstighteningbetweenthelubricationpipingandhousingBoltstighteningbetweenthereducerandfoundationBoltstighteningbetweenthemillandthrustpillowblock.InputcouplingChecktheboltstighteningOilstationandauxiliarydeviceCleantheinternaltankIfnecessary,drainoldoilsformtankCheckthefollowingdevices:OilpumpCoolingdeviceHeaterRelayoftheoiltemperatureandpressureandotherinstrumentsCheckdeviceswhentheoilflowandpressureisnotenough.Checkdeviceswhenthecoolingabilitydeclineorwaterdrainintotheoiltank.Ensurethevalueshouldberight.3.Thefirstoilreplarollermustbeprocessedafterthehrsoperation,andlaterregularinspectionoftheoilshouldbecarriedoutfrequently.Iftheoilqualitydoesnotmeettherequirement,changetheoil,normallychangetheoilevery5000hrs,duringchangingtheoil,andcarefullycheckthenozzle,ifnozzlesareblocked,shouldimmediatelysolvethem.Thenewoilshouldcomplywiththerequirement.Ⅸ.AttentionfortheassemblyanddisassemblyItisnecessarytocheckandmaintainthewholereducerafteraperiodwork.InformtheNANJINGHIGHSPEED&ACCUATEGEARCO.,LTD.togethelpwhenthereducerneedstobemaintainedandremounted.Dismount1).Dismountshallcarryoutatspecialplacewheremustbecleanandwithoutothersundries.2)Wrapthebothendofthedismountedpipeswiththeplasticpapertopreventdirtyafterdismountingtheoutsidepipes.3)Duringthedismounting,takenoteoftheassemblyNo.,andpositionofthelocatingpinsoastorecoverthemtotheoriginalpositionwhenitisreassembled.4)Preventgearboxformanydirty,keepthehouseclean.5)Usethehydraulictooltodismountthethrustpillowblock,ifnecessary,contactthesupplier.InspectionAfterdisassemblingthedriveparts,checkandrecordthepartsindetail.·contactpatternofthetoothface·bearingworn·checkthewornsituationofthethrustpillowblock,thepermissibleheighttoleranceisnomorethanPAGE\#"'頁:'#'

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'"·Changetheworn-outpartsReassembly·Thereassemblyofthegearboxmustmeettherequirementofthedrawing,andcarryoutaccordingtothetechnologicalsituation.·Cleanallthepartsbeforethereassem