第七章 各系統(tǒng)單獨(dú)空載試車及其條件
Chapter 7 Each System Separate No-load Test Run and Its Conditions
輥壓機(jī)整機(jī)設(shè)備在完全裝好以后,必須在做好充分準(zhǔn)備的情況下,對各系統(tǒng)進(jìn)行單獨(dú)試車,及時(shí)準(zhǔn)確發(fā)現(xiàn)安裝中存在的隱患,檢查和調(diào)整內(nèi)部各結(jié)構(gòu)關(guān)系和參數(shù)關(guān)系。在確認(rèn)系統(tǒng)內(nèi)部均處于正常狀態(tài)后,方可進(jìn)入下一部程序。
After the complete equipment is fully installed, each system must be tested separately with sufficient preparations to find hidden dangers in the installation timely and accurately, and to check and adjust the internal structural relationships and parameter relationships. After confirming that the system is in the normal state, the next procedure can be entered.
一.主傳動(dòng)系統(tǒng)及電機(jī)空載試車及其條件
1. Main drive system and motor no-load test run and its conditions
1.準(zhǔn)備工作
1. Preparation
⑴用煤油清洗減速器。在減速器的箱體內(nèi)倒入適量的煤油先浸泡,待主電機(jī)可驅(qū)動(dòng)時(shí)空載轉(zhuǎn)動(dòng),清洗齒面;
⑴ Clean the reducer with kerosene. Pour the appropriate amount of kerosene into the box of the reducer and soak it first. When the main motor can drive, it will rotate without load and clean the tooth surface;
⑵接通主電機(jī)及冷卻風(fēng)機(jī)電源,并確認(rèn)主電動(dòng)機(jī)空載運(yùn)轉(zhuǎn)正常后,安裝并擰緊主電動(dòng)機(jī)與萬向節(jié)傳動(dòng)軸的法蘭盤聯(lián)接螺栓;
⑵Connect the main motor and cooling fan power supply, and confirm that the main motor is running normally without load, install and tighten the flange connecting bolts of the main motor and the universal joint drive shaft;
⑶擰下減速器箱體下側(cè)的兩螺塞,放出清洗用的煤油,再將螺塞擰緊。注意其密封圈是否完好,若已損壞應(yīng)及時(shí)更換,在用代用品時(shí),應(yīng)保證密封圈材料為耐油膠板。
(3) Unscrew the two screw plugs on the lower side of the reducer case, release kerosene for cleaning, and then tighten the screw plugs. Pay attention to whether the sealing ring is intact. If it is damaged, replace it in time. When using substitutes, ensure that the sealing ring material is oil-resistant rubber sheet.
⑷灌入所用的潤滑油,注意應(yīng)保證達(dá)到油標(biāo)指示的位置。
⑷Pour in the used lubricating oil, and pay attention to ensure that it reaches the position indicated by the oil mark.
2.潤滑油品的選用
2. Selection of lubricants
減速器應(yīng)根據(jù)不同的環(huán)境、不同的溫度或季度，選用不同的潤滑油。
Reducer should choose different lubricating oil according to different environment, different temperature or season.
⑴在正常的環(huán)境溫度中使用,即冬季溫度在-15℃以上,夏季在38℃以下,北方可選N220硫—磷型中極壓齒輪油;南方可選用N320硫--磷型中極壓齒輪油;若使用廠家根據(jù)本廠情況選用其它型號的潤滑油,應(yīng)與設(shè)備制造廠或研制單位協(xié)商確定;
⑴Use in normal ambient temperature, that is, the temperature is above -15℃ in winter and below 38℃ in summer. N220 sulfur-phosphorus type medium and extreme pressure gear oil can be selected in the north; N320 sulfur-phosphorus type medium and extreme pressure gear oil can be selected in the south. If the manufacturer chooses other types of lubricating oil according to the situation of the factory, it should be negotiated with the equipment manufacturer or research unit;
⑵若工作環(huán)境溫度高于40℃低于60℃時(shí),應(yīng)選用N460硫--磷型中極壓齒輪油;
⑵If the working environment temperature is higher than 40℃ and lower than 60℃, N460 sulfur-phosphorus type medium extreme pressure gear oil should be selected;
⑶當(dāng)工作環(huán)境溫度低于-15℃時(shí),應(yīng)于研制單位協(xié)商確定所有油品。
⑶ When the working environment temperature is lower than -15℃, all oil products should be negotiated with the research and development unit.
3.更換油品
3. Replace Oil
不同種類的油,不可混用。若需更換油的品種時(shí),應(yīng)先將減速器內(nèi)的油放盡,并清洗減速器,方可注入新潤滑油。
Different types of oils cannot be mixed. If you need to change the oil type, you should drain the oil in the reducer first, and clean the reducer before injecting new lubricating oil.
4.傳動(dòng)系統(tǒng)空載試車必要條件：
4. Necessary conditions for no-load test run of the driving system:
（1）主電機(jī)接線轉(zhuǎn)向均正確，地腳螺栓已擰緊；
(1) The steering of the main motor wiring is correct, and the anchor bolts have been tightened;
（2）萬向節(jié)傳動(dòng)軸聯(lián)接法蘭螺栓及萬向節(jié)軸承座與底盤的螺栓均已按規(guī)定擰緊；
(2) The connecting flange bolts of the universal joint drive shaft and the bolts of the universal joint bearing seat and the base plate have been tightened as required;
（3）行星減速器手盤運(yùn)轉(zhuǎn)靈活，并且已加潤滑油；
(3) The hand plate of the planetary reducer operates flexibly and has been lubricated;
（4）縮套聯(lián)軸器已安裝完畢，縮緊螺栓已按規(guī)定擰緊；
(4) The shrink sleeve coupling has been installed and the shrink bolts have been tightened as required;
（5）扭矩支承中蝶形彈簧已做好調(diào)整和預(yù)緊，連桿機(jī)構(gòu)安裝符合要求，關(guān)節(jié)軸承中已注入了潤滑劑。（可選用2﹟或3﹟二硫化鉬基脂）；
(5) The butterfly spring in the torque support has been adjusted and preloaded, the connecting rod mechanism installation meets the requirements, and the joint bearing has been filled with lubricant. (2﹟ or 3﹟ molybdenum disulfide base grease can be used);
（6）檢查并確認(rèn)磨輥主軸軸系內(nèi)外無任何妨礙傳動(dòng)系統(tǒng)及磨輥轉(zhuǎn)動(dòng)的異物。尤其是輥隙中無鐵塊及其他雜物；
(6) Check and confirm that there is no foreign matter that hinders the rotation of the driving system and the rotation of the grinding roller. Especially there is no iron block and other debris in the nip;
（7）輥壓機(jī)處于無喂料狀態(tài)。
(7) The roller press is in the non-feeding state.
5、系統(tǒng)空載試車
5. No-load test run of the system
（1）仔細(xì)傾聽主軸承的運(yùn)轉(zhuǎn)聲音是否正常；
(1) Listen carefully to whether the running sound of the main bearing is normal;
（2）仔細(xì)傾聽行星減速器運(yùn)轉(zhuǎn)聲音是否正常；
(2) Listen carefully to see if the sound of the planetary reducer is normal;
（3）觀察萬向節(jié)傳動(dòng)軸在運(yùn)轉(zhuǎn)中的搖動(dòng)是否在允許的范圍內(nèi)；
(3) Observe whether the shaking of the universal joint drive shaft during operation is within the allowable range;
（4）仔細(xì)傾聽主電機(jī)運(yùn)轉(zhuǎn)聲音是否正常；檢查其冷卻風(fēng)機(jī)的轉(zhuǎn)向是否正確；
(4) Listen carefully to whether the running sound of the main motor is normal; check whether the direction of the cooling fan is correct;
（5）觀察電機(jī)的空載電流是否正常范圍之內(nèi)；
(5) Observe whether the no-load current of the motor is within the normal range;
（6）空載試運(yùn)轉(zhuǎn)應(yīng)保證連續(xù)4小時(shí)以上，并在運(yùn)轉(zhuǎn)過程中經(jīng)常觀察其各部分的溫升、運(yùn)轉(zhuǎn)聲音和電機(jī)電流及控制柜的工作狀況。
(6) No-load test operation should be guaranteed for more than 4 hours continuously, and the temperature rise, running sound and motor current of each part and the working condition of the control cabinet should be observed frequently during the operation.
二、液壓系統(tǒng)試車
2. Hydraulic system test run
1、蓄能器充氣
1. Charge the accumulator
（1）所充氣必須是氮?dú)�，�?yán)禁使用氧氣和空氣，否則有爆炸的危險(xiǎn)；
(1) The inflation must be nitrogen, oxygen and air are strictly prohibited, otherwise there is the danger of explosion;
（2）將充氣工具接到氮?dú)馄可稀２鹣滦钅芷鞒錃忾y門的安全罩和閥帽。將充氣工具另一端擰到蓄能器上。檢查蓄能器的放氣閥是否擰緊；
(2) Connect the inflation tool to the nitrogen bottle. Remove the safety cover and valve cap of the accumulator charging valve. Screw the other end of the inflation tool to the accumulator. Check whether the air release valve of the accumulator is tightened;
（3）首先打開蓄能器的閥門，檢查蓄能器內(nèi)的殘余壓力，關(guān)閉其閥門，在打開氮?dú)馄康拈y門，檢查氮?dú)馄績?nèi)的壓力；
(3) First, open the valve of the accumulator, check the residual pressure in the accumulator, close its valve, and open the valve of the nitrogen cylinder to check the pressure in the nitrogen cylinder;
（4）將氮?dú)馄康拈y門保持開啟狀態(tài)，緩慢擰開蓄能器充氣閥門，使皮囊慢慢脹開。注意觀察充氣工具上的壓力表，并經(jīng)常關(guān)閉氮?dú)馄康拈y門，以檢查蓄能器是否已達(dá)到預(yù)定的充氣壓力。
(4) Keep the valve of the nitrogen bottle open, slowly unscrew the accumulator inflation valve, so that the bladder slowly expands. Pay attention to the pressure gauge on the charging tool, and often close the valve of the nitrogen cylinder to check whether the accumulator has reached the predetermined charging pressure.
（5）蓄能器實(shí)際充氣壓力應(yīng)大于預(yù)充氣壓力5kg/c㎡左右，在充氣完畢后，略停留兩分鐘左右，等蓄能器內(nèi)氣體穩(wěn)定，溫度恢復(fù)正常后緩慢打開蓄能器的放氣閥門，將蓄能器內(nèi)壓力調(diào)至預(yù)定充氣壓力；
(5) The actual charging pressure of the accumulator should be greater than the pre-charging pressure by about 5kg/c㎡. After the charging is completed, stay for about two minutes. When the gas in the accumulator is stable and the temperature returns to normal, slowly open the discharge of the accumulator. The gas valve adjusts the pressure in the accumulator to the predetermined inflation pressure;
（6）關(guān)閉蓄能器充氣閥門和氮?dú)馄康拈y門，卸下蓄能器端的充氣工具，用肥皂水檢查確認(rèn)蓄能器充氣閥無泄漏后，方可擰緊閥帽和安全罩。
(6) Close the charging valve of the accumulator and the valve of the nitrogen bottle, remove the charging tool at the end of the accumulator, and check with soapy water to confirm that the charging valve of the accumulator does not leak before tightening the bonnet and safety cover.
2、液壓油的準(zhǔn)備
2. Preparation of hydraulic oil
（1）液壓系統(tǒng)必須是清潔干凈的，所有的閥門及管道均已安裝完畢，無任何暴露在外的管口和空腔；
(1) The hydraulic system must be clean, all valves and pipes have been installed, without any exposed nozzles and cavities;
（2）檢查準(zhǔn)備使用的液壓油質(zhì)量，可直接觀察其粘度、顏色、清潔度和透明度。防止取錯(cuò)、在灌入液壓油箱前必須經(jīng)過嚴(yán)格的過濾。
(2) Check the quality of the hydraulic oil to be used, and directly observe its viscosity, color, cleanliness and transparency. To prevent mistakes, it must be strictly filtered before filling the hydraulic oil tank.
3、液壓油品的選擇
3. Selection of hydraulic oil
為了保持液壓系統(tǒng)良好的工作狀態(tài)，穩(wěn)定的工作性能，防止液壓設(shè)備發(fā)生銹蝕和磨損過大等現(xiàn)象，以保證整機(jī)設(shè)備的使用壽命，提高運(yùn)轉(zhuǎn)率。必須使用所規(guī)定的液壓油。不允許使用普通機(jī)械油。
In order to keep the hydraulic system in good working condition and stable working performance, prevent the hydraulic equipment from rusting and excessive wear, so as to ensure the service life of the whole equipment and improve the operation rate. The specified hydraulic oil must be used. It is not allowed to use ordinary machine oil.
⑴在華北、華東及華南大部分地區(qū),環(huán)境溫度高于-20℃,低于40℃時(shí),北方可使用HL系列液壓油。一般選擇N32,南方選用N46;
⑴ In most areas of North China, East China and South China, when the ambient temperature is higher than -20℃ and lower than 40℃, HL series hydraulic oil can be used in the north. Generally choose N32, and the South chooses N46;
⑵在東北、西北等地區(qū),環(huán)境溫度低于-10℃高于-30℃,可選用低凝液壓油N32或N46。
⑵In Northeast, Northwest and other regions, the ambient temperature is lower than -10℃ and higher than -30℃, and low-condensing hydraulic oil N32 or N46 can be used.
⑶若用戶為了使工廠油品儲備管理方便而需改變液壓油品種時(shí),請與研制單位聯(lián)系確認(rèn)。
⑶ If the user needs to change the type of hydraulic oil in order to make the factory oil storage management convenient, please contact the research unit for confirmation.
⑷一旦已選定并使用了某種液壓油,一般不宜更換油品,只需定期檢查,補(bǔ)充液壓油。
⑷Once a certain hydraulic oil has been selected and used, it is generally not suitable to change the oil, and only need to check regularly and replenish the hydraulic oil.
4.液壓系統(tǒng)試車前的準(zhǔn)備
4. Preparation before hydraulic system test run
⑴檢查所有管道接頭及法蘭是否已連接就位好;
⑴Check whether all pipe joints and flanges are connected in place;
⑵檢查所有方向閥是否與所需要?jiǎng)幼鞯姆较蛞恢?/span>;
⑵Check whether all the directional valves are consistent with the required direction of action;
⑶將所有的溢流閥調(diào)到最小壓力上;
(3) Adjust all the relief valves to the minimum pressure;
⑷將液壓系統(tǒng)的排氣閥打開;
⑷Open the exhaust valve of the hydraulic system;
⑸檢查液壓油箱內(nèi)液壓油的油位是否在規(guī)定的高度內(nèi);
⑸ Check whether the oil level of the hydraulic oil in the hydraulic oil tank is within the specified height;
⑹用機(jī)旁開關(guān)點(diǎn)動(dòng)液壓油泵,觀察其轉(zhuǎn)向是否正確;
⑹ Use the switch on the side of the machine to jog the hydraulic oil pump to observe whether the steering is correct;
⑺檢查移動(dòng)輥軸系做水平移動(dòng)時(shí),有無阻礙其運(yùn)轉(zhuǎn)的雜物,與其他設(shè)備有無可能發(fā)生干涉,特別是兩磨輥間的和四只軸承座之間有無異物或鐵塊妨礙移動(dòng)輥運(yùn)動(dòng);
⑺Check whether there is any debris that hinders its operation when the moving roller shaft system moves horizontally, and whether it may interfere with other equipment, especially whether there are foreign objects or iron blocks between the two grinding rollers and the four bearing seats that hinder the movement of the moving roller;
⑻主機(jī)架各聯(lián)接部分安裝就位,聯(lián)接螺栓組均已按規(guī)定擰緊力矩均勻擰緊;
⑻The connecting parts of the main frame are installed in place, and the connecting bolt groups have been evenly tightened according to the specified tightening torque;
5.液壓系統(tǒng)中各壓力控制閥和壓力表參數(shù)的設(shè)定關(guān)系(參照液壓系統(tǒng)圖).
5.The setting relationship of the pressure control valve and pressure gauge parameters in the hydraulic system (refer to the hydraulic system drawing).
設(shè):⑴電接點(diǎn)壓力表上限壓力為PD上;
Set: ⑴The upper limit pressure of the electric contact pressure gauge is PD;
⑵電接點(diǎn)壓力表下限壓力為PD下;
⑵The lower limit pressure of the electric contact pressure gauge is PD;
⑶蓄能器充氣壓力為Px;
⑶The charging pressure of the accumulator is Px;
⑷電磁液流閥調(diào)定壓力為Pv1;
⑷The set pressure of the electromagnetic liquid flow valve is Pv1;
⑸泵站溢流閥調(diào)定壓力為Pv2;
⑸The setting pressure of the overflow valve of the pumping station is Pv2;
⑹壓力傳感器調(diào)定壓力為PcY;
⑹The set pressure of the pressure sensor is PcY;
⑺低壓腔溢流閥調(diào)定壓力為Pv3;
⑺ The setting pressure of the relief valve in the low pressure chamber is Pv3;
則:⑴PD上-PD下=1.2～2.0Mpa;
Then: ⑴PD up-PD down=1.2～2.0Mpa;
⑵PD下-Px≥0.6～1.5Mpa;
⑵ PD under -Px≥0.6～1.5Mpa;
⑶Px≥0.6PD上;
⑶Px≥0.6PD;
⑷PcY-PD上=2.0～2.2Mpa;
⑷PcY-PD upper=2.0～2.2Mpa;
⑸Pv1-PD上=1.5～2.0Mpa;
⑸Pv1-PD upper=1.5～2.0Mpa;
⑹Pv2-PD上=1.5Mpa;
⑹Pv2-PD upper=1.5Mpa;
⑺Pv3=3.5～4.0Mpa;
⑺Pv3=3.5～4.0Mpa;
設(shè)定依據(jù):電接點(diǎn)壓力表上,下限壓力差值越小,擠壓出的物料物理性能一致性越好,但液壓系統(tǒng)工作時(shí)有壓力波動(dòng),因而一般差值大小按三倍于波動(dòng)壓力調(diào)定。
Setting basis: On the electric contact pressure gauge, the smaller the lower limit pressure difference, the better the consistency of the physical properties of the extruded material. However, the hydraulic system has pressure fluctuations when it is working, so the difference is generally set at three times the fluctuation pressure.
蓄能器的充氣壓力與電接點(diǎn)壓力表下限越接近,系統(tǒng)加壓的時(shí)間就越短,但它們的差值不應(yīng)小于波動(dòng)壓力的1.5～2倍,充氣壓力同時(shí)不應(yīng)小于電接點(diǎn)壓力表上限壓力的60%,否則蓄能器內(nèi)的皮囊易損壞。
The closer the charging pressure of the accumulator is to the lower limit of the electric contact pressure gauge, the shorter the time for the system to pressurize. But their difference should not be less than 1.5 to 2 times of the fluctuating pressure, and the inflation pressure should not be less than 60% of the upper limit pressure of the electric contact pressure gauge, otherwise the bladder in the accumulator is easily damaged.
從以上各參數(shù)的設(shè)定關(guān)系還可看出PY1、PY2、PCY的大小關(guān)系為PCY＞PV1＞PV2,這亦反映出系統(tǒng)的三重保護(hù)措施:1.當(dāng)系統(tǒng)壓力超過泵站溢流閥設(shè)定壓力PV2時(shí),則通過該溢流閥卸壓,對系統(tǒng)起保護(hù)作用;2.若泵站溢流閥失靈,則通過電磁溢流閥對系統(tǒng)卸壓,同樣起到保護(hù)作用;3.若以上兩溢流閥都失靈,則通過壓力傳感器將系統(tǒng)壓力傳給控制系統(tǒng),由控制系統(tǒng)實(shí)行聯(lián)鎖停機(jī)。
From the setting relationship of the above parameters, it can be seen that the size relationship of PY1, PY2, and PCY is PCY>PV1>PV2, which also reflects the system's triple protection measures: 1. When the system pressure exceeds the set pressure PV2 of the overflow valve of the pumping station, the pressure is relieved through the overflow valve to protect the system; 2. If the overflow valve of the pumping station fails, the electromagnetic overflow valve is used to relieve the pressure of the system, which also plays a protective role; 3. If the above two overflow valves fail, the system pressure is transmitted to the control system through the pressure sensor, and the control system implements interlocking shutdown.
根據(jù)原理圖可看出,系統(tǒng)的最高壓力為16.0Mpa,工作壓力依據(jù)具體情況而定,一般為7～9Mpa。
It can be seen from the schematic diagram that the maximum pressure of the system is 16.0Mpa, and the working pressure depends on the specific conditions, generally 7-9Mpa.
7.液壓系統(tǒng)試車
7. Hydraulic system commissioning
液壓系統(tǒng)主要可劃分為以下三個(gè)回路:加壓回路,退輥回路,壓力保護(hù)回路,在進(jìn)行試車時(shí),可按以下步驟進(jìn)行:
The hydraulic system can be divided into the following three circuits: pressurization circuit, roll back circuit, pressure protection circuit, during the test run, the following steps can be carried out:
⑴調(diào)試泵站壓力,檢驗(yàn)齒輪泵和油泵電機(jī)的工作性能
⑴ Debug the pressure of the pump station, check the working performance of the gear pump and oil pump motor
①將泵站溢流閥(件6)手柄調(diào)于最松狀態(tài);
① Adjust the handle of the pump station relief valve (part 6) to the most loose state;
②三位四通換向閥(件7)處于失電狀態(tài);
②The three-position four-way reversing valve (part 7) is in the power-off state;
③啟動(dòng)油泵電機(jī);
③Start the oil pump motor;
④確認(rèn)電機(jī)及油泵運(yùn)轉(zhuǎn)正常平衡后,緩慢擰緊溢流閥手柄,以1Mpa為一遞升速度,使油泵壓力為逐步上升至10Mpa,在此期間注意其調(diào)節(jié)是否靈活。
④ After confirming that the motor and the oil pump are running normally and balanced, slowly tighten the relief valve handle, and use 1Mpa as the step-up speed to gradually increase the oil pump pressure to 10Mpa. During this period, pay attention to whether its adjustment is flexible.
注:在調(diào)試過程中,若出現(xiàn)齒輪泵密封圈處往外冒油,則可考慮是否油泵電機(jī)反接。
Note: During the debugging process, if oil is leaking from the gear pump seal ring, you can consider whether the oil pump motor is reversed.
⑵用進(jìn)輥油路給系統(tǒng)排氣
⑵Using the roller inlet oil circuit to exhaust the system
①根據(jù)設(shè)定的充氣壓力給蓄能器充氣;
① Inflate the accumulator according to the set inflation pressure;
②將各元件調(diào)至使移動(dòng)輥推進(jìn)的狀態(tài);
② Adjust the components to the state where the moving roller is pushed forward;
③起動(dòng)油泵電機(jī),以設(shè)定的壓力給系統(tǒng)充油排氣。注意觀察兩側(cè)排氣閥處(或壓力表開關(guān)安裝處)是否有油冒出。若兩側(cè)都沒冒油或只有一側(cè)冒油,都應(yīng)繼續(xù)往系統(tǒng)中充油,直到出油為止。待系統(tǒng)中氣體都排出后,方可擰緊排氣閥(或裝好壓力表)。
③Start the oil pump motor and fill the system with oil and exhaust at the set pressure. Pay attention to whether there is oil coming out of the exhaust valve on both sides (or at the pressure gauge switch installation place). If there is no oil on both sides or only one side, you should continue to fill the system with oil until the oil comes out. Tighten the exhaust valve (or install the pressure gauge) after the gas in the system is exhausted.
注:在只有一側(cè)冒油的情況下,可將該側(cè)的排氣閥擰緊關(guān)閉,再往系統(tǒng)中充油。
Note: When only one side is emitting oil, the exhaust valve on that side can be tightened and closed, and then the system can be filled with oil.
⑶調(diào)試各油路,檢驗(yàn)系統(tǒng)各元器件的可靠性和靈敏度。
⑶ Debug each oil circuit, check the reliability and sensitivity of each component of the system.
設(shè)定系統(tǒng)壓力為P
Set the system pressure to P
1.調(diào)試進(jìn)輥油路
1. Debugging the oil circuit of roller inlet
a.將蓄能器的充氣壓力調(diào)至(0.65～0.85)P;
a. Adjust the charging pressure of the accumulator to (0.65～0.85)P;
b.將電接點(diǎn)壓力表上、下限壓力至:
b. Set the upper and lower limit pressure of the electric contact pressure gauge to:
上限PD上=(P＋0.70)Mpa;
Upper limit PD=(P＋0.70)Mpa;
下限PD下=(P-0.70)Mpa;
Lower limit PD lower=(P-0.70)Mpa;
c.將各方向閥調(diào)至左進(jìn)輥狀態(tài);
c. Adjust the directional valves to the left roll state;
d.啟動(dòng)油泵電機(jī),調(diào)節(jié)泵站溢流閥的壓力至(P+0.5)Mpa(可從泵站壓力表上讀取);
d.Start the oil pump motor and adjust the pressure of the pump station relief valve to (P+0.5)Mpa (can be read from the pump station pressure gauge);
e.調(diào)節(jié)組合閥中電磁溢流閥手柄,使電接點(diǎn)壓力表顯示壓力與泵站壓力表相同,并在此基礎(chǔ)上,稍稍再擰緊一點(diǎn)電磁溢流閥手柄;
e. Adjust the handle of the electromagnetic overflow valve in the combination valve so that the electric contact pressure gauge shows the same pressure as the pressure gauge of the pump station, and on this basis, slightly tighten the electromagnetic overflow valve handle;
f.觀察左輥推進(jìn)是否靈活,因是單邊進(jìn)輥,所以推進(jìn)距離不宜過長,以移動(dòng)輥與導(dǎo)軌不發(fā)生干涉為宜;
f. Observe whether the left roller is advancing flexibly. Because it is the single-side roller, the advancing distance should not be too long, and it is advisable to avoid interference between the moving roller and the guide rail;
g.擰松電磁溢流閥手柄,給系統(tǒng)卸壓;
g. Loosen the electromagnetic relief valve handle to relieve the pressure of the system;
h.將各方向閥調(diào)至右進(jìn)輥狀態(tài);
h. Adjust the directional valves to the right roller state;
i.起動(dòng)油泵電機(jī);
i. Start the oil pump motor;
j.同b;
j. Same as b;
k.觀察右輥推進(jìn)是否靈活。同樣推進(jìn)距離不宜過長;
k. Observe whether the right roller advances flexibly. Similarly, the advance distance should not be too long;
l.擰松電磁溢流閥手柄,給系統(tǒng)卸壓;
l. Loosen the handle of the electromagnetic overflow valve to relieve the pressure of the system;
m.將各方向閥調(diào)至左、右同時(shí)進(jìn)輥狀態(tài);
m. Adjust the directional valves to the left and right at the same time to enter the roller state;
n.起動(dòng)油泵電機(jī);
n. Start the oil pump motor;
o.同d;
o. Same as d;
p.觀察兩輥水平移動(dòng)是否靈活。
p. Observe whether the horizontal movement of the two rollers is flexible.
2.調(diào)試退輥油路
2. Debug the retreating oil circuit
a.給系統(tǒng)卸壓;
a. Relieve pressure on the system;
b.將各方向閥調(diào)至左退輥狀態(tài);
b. Adjust the directional valves to the left retraction state;
c.起動(dòng)油泵電機(jī),調(diào)節(jié)回路溢流閥,使其壓力調(diào)至4Mpa(從泵站壓力表讀取);
c. Start the oil pump motor and adjust the loop relief valve to adjust the pressure to 4Mpa (read from the pump station pressure gauge);
d.觀察退輥是否靈活。
d. Observe whether the roll back is flexible.
3.用進(jìn)輥油路進(jìn)行保壓試驗(yàn)
3. Use the roller inlet oil circuit to carry out the pressure holding test
a.將各方向閥調(diào)至進(jìn)輥狀態(tài);
a. Adjust the directional valves to the roll-in state;
b.蓄能器充氣壓力為8Mpa;
b. The charging pressure of the accumulator is 8Mpa;
c.電接點(diǎn)壓力表上、下限設(shè)定為PD上=11Mpa,PD下=9Mpa;
c. The upper and lower limits of the electric contact pressure gauge are set to PD upper=11Mpa, PD lower=9Mpa;
d.調(diào)整液壓泵站的溢流閥,使其壓力為10Mpa;
d. Adjust the overflow valve of the hydraulic pump station to make its pressure 10Mpa;
e.調(diào)整組合閥中電磁閥壓力,使其在10Mpa的基礎(chǔ)上再稍稍超過一點(diǎn);
e. Adjust the solenoid valve pressure in the combined valve to make it slightly more than 10Mpa;
f.在上述設(shè)定參數(shù)下,系統(tǒng)壓力約為10Mpa,在此壓力下保壓2小時(shí),檢查各接頭和法蘭等有無明顯的外泄漏。
f. Under the above setting parameters, the system pressure is about 10Mpa. Keep the pressure at this pressure for 2 hours. Check the joints and flanges for obvious external leakage.
三.潤滑系統(tǒng)試車
3. Lubrication system commissioning
將潤滑系統(tǒng)安裝好，注意各個(gè)潤滑點(diǎn)的管接頭處暫時(shí)脫開不裝。
Install the lubrication system, and pay attention to the temporary disconnection of the pipe joints of each lubrication point.
該潤滑系統(tǒng)共有14個(gè)潤滑點(diǎn),這14個(gè)潤滑點(diǎn)的分布是:四個(gè)軸承座,每個(gè)軸承座上三個(gè)潤滑點(diǎn)共有十二個(gè)潤滑點(diǎn),兩個(gè)下導(dǎo)軌,每個(gè)導(dǎo)軌上一個(gè)潤滑點(diǎn)共有兩個(gè)個(gè)潤滑點(diǎn),各潤滑點(diǎn)所需油量的多少是根據(jù)設(shè)備的運(yùn)轉(zhuǎn)特點(diǎn)，按時(shí)間、次數(shù)來由系統(tǒng)分點(diǎn)供油。
The lubrication system has a total of 14 lubrication points. The distribution of these 14 lubrication points is: four bearing seats, three lubrication points on each bearing seat, a total of twelve lubrication points, two lower guide rails, one on each guide. There are two lubrication points in total, and the amount of oil required for each lubrication point is based on the operating characteristics of the equipment, and the system will supply oil at points according to time and frequency.
具體操作如下：
The specific operations are as follows:
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在安裝完畢后,往潤滑泵內(nèi)充入適量的潤滑油(約30L);
⑴ After installation, fill the lubrication pump with an appropriate amount of lubricating oil (about 30L);
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起動(dòng)電機(jī),注意電機(jī)的正反接,觀察各個(gè)潤滑點(diǎn)的管接頭是否出油;
⑵ Start the motor, pay attention to the positive and negative connection of the motor, and observe whether the pipe joints of each lubrication point are oily;
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由于各個(gè)潤滑油路的長度不一致，當(dāng)各個(gè)潤滑點(diǎn)的管接頭出油后，應(yīng)立即關(guān)閉此油路的供油開關(guān)，并與各個(gè)潤滑點(diǎn)依次連接好，避免浪費(fèi)潤滑油。
⑶ Since the length of each lubricating circuit is inconsistent, when the pipe joints of each lubricating point are out of oil, the oil supply switch of this oil circuit should be turned off immediately and connected to each lubricating point in order to avoid wasting lubricating oil.
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在潤滑電機(jī)不發(fā)熱的前提下,將導(dǎo)軌,端蓋處充滿油脂,直到看到有潤滑油溢出來為止。
⑷ On the premise that the lubricating motor does not generate heat, fill the guide rail and end cover with grease until you see the lubricating oil overflow.
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然后根據(jù)設(shè)備各個(gè)潤滑點(diǎn)的使用情況，在潤滑系統(tǒng)的控制柜中，依次設(shè)置好各個(gè)潤滑點(diǎn)的加油次數(shù)，加油時(shí)間。
⑸ Then according to the usage of each lubrication point of the equipment, in the control cabinet of the lubrication system, set the refueling times and refueling time of each lubrication point in sequence.
四.檢測系統(tǒng)試車
4. Testing system commissioning
1.輥縫檢測調(diào)試
1. Roll gap inspection and debugging
⑴檢查確認(rèn)感應(yīng)式位移傳感器的一次儀表和二次儀表接線是否正確;
⑴Check whether the wiring of the primary instrument and the secondary instrument of the inductive displacement sensor is correct;
⑵將移動(dòng)輥推到頭,檢測原始輥縫并作記錄;
⑵Push the moving roller to the end, detect the original roller gap and make a record;
⑶抽動(dòng)位移傳感器的活動(dòng)桿于不同位移量時(shí),檢測二次儀表顯示的線性度;
⑶ The movable rod of the twitch displacement sensor detects the linearity displayed by the secondary meter when the displacement is different;
⑷找出感應(yīng)式位移傳感器的線性工作段，將傳感器的外殼安裝于適合的位置上；
⑷ Find out the linear working section of the inductive displacement sensor, and install the housing of the sensor in a suitable position;
⑸以所檢測的原始輥縫為初始量，將位移傳感器的活動(dòng)桿固定于移動(dòng)輥軸承座上。并注意其安裝是否牢固。
⑸ Fix the movable rod of the displacement sensor on the bearing seat of the movable roller with the detected original roller gap as the initial quantity. And pay attention to whether its installation is firm.
2、軸承溫度檢測
2. Bearing temperature detection
⑴檢查端面熱電阻的接線和二次儀表接線是否正確；
⑴Check whether the wiring of the end surface thermal resistance and the secondary instrument wiring are correct;
⑵用標(biāo)準(zhǔn)溫度計(jì)檢驗(yàn)端面熱電阻在0℃～80℃內(nèi)的溫度誤差值是否在產(chǎn)品規(guī)定的范圍內(nèi)；
⑵Use the standard thermometer to check whether the temperature error value of the end face thermal resistance within 0℃～80℃ is within the specified range of the product;
⑶將校驗(yàn)后的端面熱電阻裝于主軸承外端蓋上。注意熱電阻元件端面應(yīng)與主軸承外圈保持良好的接觸。而熱電阻上的彈簧又不可壓得過緊，以防損壞元件。
(3) Install the calibrated thermal resistance on the outer end cover of the main bearing. Note that the end face of the thermal resistance element should keep good contact with the outer ring of the main bearing. The spring on the thermal resistance should not be too tight to prevent damage to the components.
3、液壓系統(tǒng)壓力檢測
3. Hydraulic system pressure detection
⑴檢查確認(rèn)壓力傳感器及顯示儀表的接線是否正確；
⑴Check whether the wiring of the pressure sensor and display instrument is correct;
⑵將液壓系統(tǒng)調(diào)節(jié)至不同的壓力。調(diào)整顯示儀表上的指示數(shù)值。在2～12.0Mpa的范圍內(nèi)其壓力顯示誤差不大于±0.3Mpa在7～11Mpa的范圍內(nèi)其誤差不大于±0.1Mpa。
⑵Adjust the hydraulic system to different pressures. Adjust the indicated value on the display instrument. In the range of 2～12.0Mpa, the pressure display error is not more than ±0.3Mpa, and the error in the range of 7～11Mpa is not more than ±0.1Mpa.
4、潤滑系統(tǒng)正常工作檢測
4. Detection of normal operation of lubrication system
⑴檢查確認(rèn)接近開關(guān)和指示燈的接線是否正確；
⑴Check whether the wiring of proximity switch and indicator light is correct;
⑵將接近開關(guān)裝于遞進(jìn)式分配器的接近開關(guān)安裝座上。調(diào)整好接近開關(guān)頭部與分油器滑桿間的距離，使其在規(guī)定的范圍內(nèi)；
(2) Install the proximity switch on the proximity switch mounting seat of the progressive distributor. Adjust the distance between the head of the proximity switch and the sliding rod of the oil separator to make it within the specified range;
⑶啟動(dòng)油泵電機(jī)，觀察當(dāng)分油器滑桿移動(dòng)時(shí)，接近開關(guān)的指示燈是否隨之有規(guī)律地閃動(dòng)。
(3) Start the oil pump motor and observe whether the indicator light of the proximity switch flashes regularly when the oil separator slide rod moves.
