GOST认证对辊破Roller Crushe
2.Working Principle、Structure and Parameters of the Machine
2.1Working Principle
This machine crushed materials by two independent drive transfer roller extrude in the opposite direction. The materials was bitten by the roll surface, and then be forced to pass the two roll,and receive the power of extrusion,grinding and shearing,then begin to fracture after entering into the crushing chamber. The crushed particles throw to the bottom by the two roll in the direction of roller revolution's tangent. Usually,the feeding size is related with the crusher's model. The more wide of the roll's diameter,the more wide roll's gap,the bigger of the feeding size. The crushing result is the best when the crushing percentage is 5.
2.2 .Overview of the machine's Structure
Roll crusher is made up of frame、roll、transmission device(moving roller has a buffer device)、cover and dry oil lubrication system etc.
1.Transmission a 2.Transmission belt 3. Casing 4.buffer device 5.frame 6.Move roll 7.Fixed roll 8.Transmission Two 9.Dry oil lubrication pump
Schematic Diagram of Roll crusher
2.2.1 Frame
The frame is mainly consist of base、the word frame and pressure beam.It is connected by high-strength bolts and of pin positioning. To some extent,It is similar to roll mill.In addition,two set of rolls,cover,buffer device and the adjustment device were been installed above it, which also carry the static load and dynamic load of impact power during work.
2.2.2 Roll
Roll mainly consists of wear-resistant roller,main shaft,scroll bearing on both sides of the roller and bearing base etc.the two sets of rolls installed on the frame,one is fixed and the other is movable.The latter also called movable roll.According to various purposes, the position of the roll could be adjusted to change the size of the roll gap, thus changing the particle size.
The roll surface with hard wear-resistant materials and special welding process is very endurable and not easy to fall off, which is one of the unique advantages of this product, It not only improve the crushing effect, but also avoid the situation of frequent replacement of traditional crusher wear parts, the result of which is that it significantly save maintenance costs and downtime
2.2.3 Transmission device
Transmission device is made up of motor、reducer、coupling、belt conveyor and the base.
Motor connected by coupling and speed reducer, the slow axis of reducer connected by coupling or belt with the roller shaft. After the motor electrify,the slow rotation's speed of roll will be adjusted according to the actual needs of the user to broke the material.
In the design of the transmission, the phenomena of building up material has been effectively improved. This is the second unique excellence of this product.
2.2.4 Casing
Casing for protecting roll is consist of hood,down cover and the wear-resistant plates top tight device on both sides of the hood.The covering body is well sealed, so that the dust couldn’t filter in. The device, after tightening the wear-resistant plate, prevents the leakage on the side of roll, which is the third unique advantage of the product.
2.2.5 Dry oil lubricating device
Mini series are fueled by oil cup.
Lubrication device of φ1200 and the above equipment consists of dry oil pumps and the oil pipeline leading to different lubrication points. Supply point is the four bearing bits. The roller machine also includes the four mobile roller mechanical bearing at the sliding pair. The valve set in the glycerin pipeline could be used to close or open the appropriate valves, In this way, it makes the pumps concentrate their power on supplying oil to certain parts and improves the supply effect.
2.3 technical parameters
|
|
2PG600 |
2PG800 |
2PG1000 |
2PG1200 |
2PG1500 |
|
Diameter of roller（mm） |
ф600 |
ф800 |
ф1000 |
ф1200 |
ф1500 |
|
Feeding size （mm） |
＜40 |
＜60 |
＜80 |
＜90 |
＜100 |
|
Discharge size （mm） |
＜3~8 |
＜3~10 |
＜3~12 |
＜3~14 |
＜3~15 |
|
capacity (t/h) |
5~20 |
15~40 |
20~50 |
30~80 |
40~100 |
|
Size of feeding hole （length×width mm） |
370×400 |
600×500 |
700×600 |
800×600 |
800×800 |
|
Motor power （kw） |
11×2 |
22×2 |
30×2 |
45×2 |
75×2 |
|
Machine size （length×width×hight mm） |
2555×2490 ×1050 |
3490×2884 ×1035 |
4398×3354 ×1190 |
4547×3653×1478 |
4832×4037 ×1765 |
|
weight （kg） |
~4000 |
~7500 |
~12000 |
17000~19000 |
~28000 |
3. Installation and Ajustment of the Machine
The installation of roll can refer to the following steps.
3.1 Check and acceptance of the base. That is check the base's strength,size and appearance whether to meet the requirements level.
3.2 Equipments Inspection. That is, the user firstly should check the machine include size,appearance, spare parts after the plant to the site.If some of them will affect the installation. The user should contact the manufacturer as soon as possible.
3.2.1 Line the base
3.2.2 Parallels placed
3.2.3 Equipment placed, foundation bolt linked and alignment
3.2.4 The first time for filling slurry
3.2.5 Maintenance for base
3.2.6 The second time for precise alignment and the second time to filling slurry.
Host: Base and the portion above the base should be adjusted and well tighten before shipment. The user just need do alignment for the the machine by adjusting the parallels. The machine roughness is 0.2mm/m.
Two sets of transmission device. The body has been adjusted and well tightened at the factory before shipment. The gap of two half coupling connect by the coupling and roll shaft is 5~10( big model fits big numerical value).the radial tolerance is less than 0.2mm and the angular displacement is less than 0.5°.In addition ,the installation should pay attention to the following aspect: in the case of the belt tensioning device totally returned, you can make the belt work normally in the state of nervous by moving the base to adjust the gap of movable belt and in the following days, the belt tighten device will be more effective.
When you are sure the alignment and adjustment is correct,you can fill the slurry for the second time.
Motor and cabinet shell should have reasonable connection which comply with related rules.
4. Commissioning
Testing with load and non-load is needed after installation.
4.1 Running with no-load.
4.1.1 Before testing with no-load, the user should check the bolt whether loosed or not. The roll's gap exist iron debris or not. Besides, the user need to move the belt wheel by hand to make the roll turn around. Check the phenomenon of attrition exist or not. If there is something unmoral, the user should deal with it as soon as possible.
4.1.2 Testing with no-load
When everything goes well, the machine can test with no-load. Only there are normal after startup, can the machine continue testing with no-load.
Testing with no-load should not less than one hour. At the same time,the user should check the machine's balance condition.the motor's average electricity must less than 35% of the stated electricity. deviant vibration ,friction and abnormal voice should not appeared..Besides,each trundle bearing temperature must not exceed 70°Ｃ. The motor 's temperature shall not exceed 60°C. When all work in good condition, the machine can be test with load.
4.2 Running with load.
During testing with load, It is better for adding the feeding material gradually from 0% to 100% to view the change of electricity, vibration and voice.
4.2.1 In general, if the feeding material is continuos and average, the current average just has a minor fluctuation in 0%~50% of the stated current. But it is normal in a moment for the big fluctuation of current,vibration and voice when the big size material or much harder material enter into the roll gap. If other factors cause these phenomenon, the user should stop the machine as soon as possible and check it.
4.2.2 Testing with load should not less than four hours. During the time,the user should pay attention the the bearing and the motor's temperature.the temperature of bearing should not exceed ７５°C and the temperature should not exceed 70°C
4.2.3 Some parts of the machine will be loose as a result of that the vibration and shock more strong when it was tested with load than it was tested with no-load. So, check the whole machine carefully is necessary after testing. Especially the bolt and frame bolt on main machine's bearing base.all of them need to be tightened again.
4.2.4 If there are iron slab cross the machine during testing,the user should check whether the metal detector and de-ironing separator work normally or not. Or the user should deal with it timely. in general, the iron slab is forbidden into the machine.
5. Operation rule of machine
5.1 Before each startup
5.1.1 The user must check the bolts loose or not. if any loose exist, the user must tighten it timely.besides, check the roll gap is proper or not.
5.1.2 The machine should start with no-load. It can be add materials when the crusher running normally.
5.2 during working
5.2.1 In order to extend the life of the machine, You’d better feeding well-distributed, and do your best to avoid the frequency impact on the machine
5.2.2 Make sure no any kind of metal in the materiels. Please pick it up in time if you catch.
5.2.3 Please pay attention to the change about electric current, temperature, vibration, and voice. If the problem existing, please deal with it in time.
5.2.4 during the mahine is working , it’s dangerous to do some cleanning and adding the lubricating oil
5.3 Service order for the first stop for material and the standby all the material is broken and clear and then, after stops the host to the next time when on the roll up, can be unloaded to start.
6. Machine breakdowns and maintenance ：
6.1With the approach usually
|
The problem in operation |
Cause |
Approach |
|
|
host |
The gap between the rollers was getting wide |
1 ． especially new use of the iron pole, have been compacted. 2 ． longer using the rollers wearing too much. |
1 ． through readjustment, and wast naked from the roll to move the provisions of the clearance between the rolls, stuffed with thick pads iron of suitable. 2 ．Welding the sphere of rollers according to the instruction |
|
Rollers jammed by materiels |
Found in the old product （ has now improved ）. |
Empty the materials among the rollers |
|
|
The vibration of host so much |
Feeding materiels large in size, especially in large piece of plastic materials, such as a plaster |
Strictly controls the size of such materials |
|
|
transmission |
The heating motor tripped off or broken or the pin for coupling broken or the belt skided |
1 ． have a piece of iron and other metal objects in the seam of the two rolls among 2． Feeding too much |
1 ．clear out the metal things . 2 ．hold the feeding quantity |
|
Fever of Bearings |
1 ． the longer using of bearings and wearing too much 2．lubricating oil shortage or poor in quality. |
1.review and replace the bearings 2.oil changes, and keep in large quantities. |
|
6.2 Machine maintenance
The maintenance for this machine can be devided in to two parts: daily maintenance and period maintenance
6.2.1 Daily maintenance ：
6.2.1.1Please use a manual pump to adding the lubricating grease to the bearings everyday （ zl -3 lithium lubricating grease ）, and the quantity should not less than 60ml a day. Be remember to open and close all the manual ball valves.
6.2.1.2 Often check the bolts for every parts. if loosed , please tightening it in time.
6.2.1.3Ready to do the running record, note the current , temperature, vibration and the voice changing. If some thing abnormal, please deal with it in time.
6.2.2 Period maintenance
6.2.2.1Reducer, which should adding the N46 machinery oil. You should change the oil after working 300-6000 hour, and then you must chang it every 1500-5000 hour. The changing of the oil depends on the working environment, but the maximum shoudn’t surpass 12 months.
6.2.2.2 In general , the bearings of motors can change the lubricating grease more than 5000 for a time （zl -3 lithium lubricating grease ）, to the bearing-closed motor which needn’t changing any grease.
6.2.2.3 the surface of roller for welding normally10 ~ 12 months.
a.To clean the materiels on the surface with the electric wire brush, if you can not brush off, please use the hand emery wheel or horns to polishing it till smooth.
b. please use the acetylene air gun to heating part of the roller to 300℃.
c. Please roasting the welding electrode under 200 ℃ for an hour.
d.Use the DC and alternating current electric welder and the current is 140-160A to repair and welding .to be ensure the wear resistance layer 8 ～ 10mm
6.2.2.4 In general, you should check the bearings of master machine every two years , according to its wearing to decide whether to replace. If the seals are good for sealing or exchanged very often and no any dust in, the bearings needn’t change for years.
6.2.2.5 The carrying stress for spring devise is very important which deciding the crushing effect for certain hardness and feeding size. the stress of spring will getting weak for longer using if the spring come and forth so frequency. In this situation, you can cut down the board and adjusted it in aid of pressure machine.
