第十章 設備的檢修
Chapter 10 Equipment Maintenance
一、扭矩支承中零部件更換
1. Replacement of torque support parts
1、蝶形彈簧的更換（若有蝶形彈簧裝置）
1. Replacement of butterfly spring (if there is a butterfly spring device)
由于蝶形彈簧在工作中不斷吸收傳動系統(tǒng)中較大的沖擊負荷，因而有可能使其因疲勞而產(chǎn)生塑性變形或斷裂。需要更換時，請按如下程序進行。
Because the butterfly spring continuously absorbs the large impact load in the driving system during work, it may cause plastic deformation or fracture due to fatigue. When you need to replace it, please follow the procedure below.
1）拆下連桿機構(gòu)下端的鉸鏈；
1) Remove the hinge at the lower end of the linkage mechanism;
2）拆下蝶形彈簧導桿；
2) Remove the butterfly spring guide rod;
3）更換蝶形彈簧；
3) Replace the butterfly spring;
4）重新調(diào)整其預緊墊片；
4) Readjust its pre-tightening gasket;
5）裝好兩個下鉸鏈。
5) Install the two lower hinges.
2、關(guān)節(jié)軸承及軸套的更換
2. Replacement of joint bearings and sleeves
1）拆下兩個下鉸鏈，抽出銷軸，即可更換兩個下鉸鏈的關(guān)節(jié)軸承和軸套；
1) Remove the two lower hinges and pull out the pin shaft to replace the joint bearings and sleeves of the two lower hinges;
2）拆下蝶形彈簧的導桿；
2) Remove the guide rod of the butterfly spring;
3）拆卸兩個上鉸鏈，更換兩個上鉸鏈的關(guān)節(jié)軸承和軸套。
3) Remove the two upper hinges and replace the joint bearings and sleeves of the two upper hinges.
二、萬向節(jié)傳動軸及行星減速器零、部件的維修與更換
2. Repair and replacement of universal joint drive shaft and planetary reducer parts and components
1、萬向節(jié)傳動軸的更換
1. Replacement of universal joint drive shaft
1）松開主電動機的地腳螺栓；
1) Loosen the anchor bolts of the main motor;
2）拆卸主電機與萬向傳動軸聯(lián)接法蘭的螺栓；
2) Remove the bolts of the connecting flange between the main motor and the universal joint shaft;
3）將主電動機沿軸線向后退15mm左右，使聯(lián)接法蘭的端面鍵脫開；
3) Move the main motor back about 15mm along the axis to disengage the end key of the connecting flange;
4）拆下萬向節(jié)傳動軸與減速器輸入軸聯(lián)接法蘭的螺栓，即可拆下萬向節(jié)傳動軸；
4) Remove the bolts of the connecting flange between the universal joint drive shaft and the input shaft of the reducer, then the universal joint drive shaft can be removed;
5）安裝新的萬向節(jié)傳動軸。
5) Install a new universal joint drive shaft.
2、行星減速器的檢修
2. Overhaul of planetary reducer
1) 按上述程拆下萬向節(jié)傳動軸;
1) Remove the universal joint drive shaft according to the above procedure;
2) 松開縮套聯(lián)軸器的縮緊螺栓;
2) Loosen the shrink bolts of the shrink sleeve coupling;
3) 按前述程序拆下扭矩支承裝置；
3) Remove the torque support device according to the aforementioned procedure;
4）用吊車吊好減速器的吊鉤，緩慢向外抽出減速器的輸出空心軸；
4) Lift the hook of the reducer with a crane, and slowly pull out the output hollow shaft of the reducer;
5）在拆卸時應注意防此縮套聯(lián)軸器滑落，以避免造成人員，設備損傷；
5) When disassembling, pay attention to prevent this shrinkable coupling from sliding down to avoid personnel and equipment damage;
6）重新安裝檢修好的減速器。
6) Reinstall the repaired reducer.
三、主軸承及“J”型密封圈更換
3. Replacement of main bearing and "J" seal ring
拆除軸承，必須首先拆除機架上橫梁，然后才能吊出軸承，拆卸主軸承座及密封圈。
To remove the bearing, the beam on the frame must be removed first, and then the bearing can be lifted out, and the main bearing seat and seal ring can be removed.
在拆卸舊軸承和更換新軸承時，要在干燥、無灰塵的地方進行，必須防此灰塵和水氣進入軸承密封腔內(nèi)。為了正確拆卸舊軸承和密封圈，更換新軸承和密封圈，必須按以下步驟進行：
When disassembling the old bearing and replacing the new bearing, it must be carried out in the dry and dust-free place, and dust and moisture must be prevented from entering the bearing seal cavity. In order to correctly disassemble the old bearing and sealing ring, and replace the new bearing and sealing ring, the following steps must be carried out:
1、準備工作
1. Preparation
1）將液壓系統(tǒng)卸壓；
1) Relieve the pressure of the hydraulic system;
2）拆除傳動系統(tǒng)、進料系統(tǒng)、輥罩及上橫梁；
2) Remove the driving system, feeding system, roller cover and upper beam;
3）拆除潤滑系統(tǒng)軟管、位移傳感器及端面熱電阻；
3) Remove the lubrication system hose, displacement sensor and end surface thermal resistance;
4）拆下液壓缸與移動輥軸承座聯(lián)接的球面座；
4) Remove the spherical seat connecting the hydraulic cylinder and the moving roller bearing seat;
5）軸系可由上部吊起放置檢修位置，也可以水平吊起放置檢修位置，但此時應先將無液壓裝置的立柱子拆掉，由此端水平吊出機架內(nèi)腔；
5) The shaft system can be hoisted from the upper part to place the inspection position, or it can be hoisted horizontally to place the inspection position, but at this time, the column without the hydraulic device should be removed first, and the end of the shaft should be hoisted out of the inner cavity of the frame horizontally;
6）擰松軸承座內(nèi)外端蓋的聯(lián)接螺栓。
6) Loosen the connecting bolts of the inner and outer end covers of the bearing seat.
2、拆卸舊軸承及“J”形密封圈
2. Remove the old bearing and "J"-shaped sealing ring
1）拆下軸承軸向定位環(huán)；
1) Remove the bearing axial positioning ring;
2）安裝好超高壓油泵接管和接頭；
2) install the ultra-high pressure oil pump connection pipe and joint;
3）搖動超高壓手柄，將油脂打入軸承內(nèi)圈與軸頸的結(jié)合面，用油膜來消除其金屬間的接觸，這樣不需另加力就可使軸承卸下來，對軸承進行檢修更換；
3) Shake the ultra-high pressure handle to drive grease into the joint surface of the inner ring of the bearing and the journal, and use the oil film to eliminate the contact between the metals, so that the bearing can be removed without additional force and the bearing can be repaired and replaced;
4）可將軸承座內(nèi)側(cè)的密封端蓋拆下，對其“J”型密封圈進行更換；
4) The sealing end cover on the inner side of the bearing seat can be removed, and its "J" type sealing ring can be replaced;
5）將軸承從軸承座中拆出，即可更換新軸承。
5) Remove the bearing from the bearing seat and replace it with the new bearing.
3、安裝新軸承及“J”形密封圈。
3. Install new bearings and "J"-shaped sealing rings.
四、進料裝置易損件更換
4. Replacement of vulnerable parts of the feeding device
進料裝置的易損件主要有調(diào)節(jié)閘板和襯板及耐磨塊。
The wearing parts of the feeding device mainly include the adjusting gate plate, the liner and the wear-resistant block.
1、調(diào)節(jié)閘板的維修更換
1. Maintenance and replacement of adjusting gate plate
1）拆下調(diào)節(jié)閘板與連接座的銷鏈接裝置；
1) Remove the pin link device between the adjusting gate plate and the connecting seat;
2）拆下調(diào)節(jié)閘板與進料筒的銷鏈接裝置；
2) remove the pin link device between the adjusting gate plate and the feed barrel;
3）抽出閘板，進行檢查更換；
3) Draw out the gate plate for inspection and replacement;
4）重新安裝調(diào)節(jié)閘板。
4) Reinstall the adjusting gate plate.
2、側(cè)擋板下端襯板的更換
2. Replacement of the bottom liner of the side baffle
1）拆掉進料裝置上方的軟聯(lián)接，將下一節(jié)進料管托起，并吊好；
1) Remove the soft connection above the feeding device, hold up the next section of the feeding pipe, and hang it;
2）松開側(cè)擋板彈性頂緊螺桿；
2) Loosen the elastic jacking screw of the side baffle;
3）抽出側(cè)擋板，更換其襯板；
3) Pull out the side baffle and replace its liner;
4）重新裝好側(cè)擋板，并調(diào)整其位置，按要求頂緊彈性頂緊螺桿。
4) Reinstall the side baffle, adjust its position, and tighten the elastic jack screw as required.
五、液壓系統(tǒng)零部件的更換
5. Replacement of hydraulic system components
液壓管道的泄露或設備出現(xiàn)故障都能引起液壓系統(tǒng)的損壞。損壞的閥門、泵、蓄能器及油管不能修復，只能更換。
Leakage of hydraulic pipelines or equipment failure can cause damage to the hydraulic system. Damaged valves, pumps, accumulators and oil pipes cannot be repaired and can only be replaced.
在液壓系統(tǒng)所有零部件的檢修更換前，必須首先清理周圍的現(xiàn)場，打掃灰塵及雜物。
Before overhauling and replacing all parts of the hydraulic system, the surrounding site must be cleaned up to remove dust and debris.
1、管接頭及連接法蘭處有明顯泄露，通過擰緊管接頭或連接螺栓不起作用時則應拆卸檢查其密封圈是否已經(jīng)損壞。若已損壞，則按下列程序更換。
1. There is obvious leakage at the pipe joints and connecting flanges. If the pipe joints or connecting bolts do not work by tightening the pipe joints or connecting bolts, they should be disassembled to check whether the sealing ring has been damaged. If it is damaged, replace it according to the following procedure.
1）卸掉油壓，拆下管接頭或法蘭螺栓；
1) Remove the oil pressure and remove the pipe joints or flange bolts;
2）取出密封圈；
2) Take out the sealing ring;
3）裝好新的密封圈，注意，必須檢查密封圈是否對位；
3) Install new sealing ring, pay attention, you must check whether the sealing ring is aligned;
4）安裝好管接頭或法蘭螺栓。
4) Install pipe joints or flange bolts.
2、液壓缸的拆卸與檢查
2. Disassembly and inspection of hydraulic cylinder
1）卸掉液壓系統(tǒng)的高壓；
1) Unload the high pressure of the hydraulic system;
2）拆下主機架上橫梁；
2) Remove the upper beam of the main frame;
3）松開球面座與主軸承座聯(lián)接的螺栓；
3) Loosen the bolts connecting the spherical seat and the main bearing seat;
4）緩慢擰松與立柱聯(lián)接的四只螺栓，將主油缸緩慢吊出至拆卸位置；
4) Slowly loosen the four bolts connected with the column, and slowly lift the main cylinder to the disassembly position;
5）液壓缸的拆卸與組裝必須在空氣干燥、無粉塵的地方進行；
5) The disassembly and assembly of the hydraulic cylinder must be carried out in the dry and dust-free place;
6）拆下球面壓頭及前端蓋；
6) Remove the spherical indenter and front end cover;
7）緩慢抽出活塞桿放置在干凈的棉布上進行拆卸、清洗、更換密封圈；
7) Slowly pull out the piston rod and place it on the clean cotton cloth for disassembly, cleaning and replacement of the sealing ring;
8）在安裝所有密封圈和對其進行組裝時，必須使所有的密封圈對位，安裝時應緩慢，避免將密封圈擠傷。
8) When installing all sealing rings and assembling them, all the sealing rings must be aligned, and the installation should be slow to avoid crushing the sealing rings.
六、磨輥表面耐磨層補焊
6. Repair welding of wear-resistant layer on the surface of grinding roller
當磨輥表面耐磨層發(fā)生破壞或過度磨損時需要進行補焊。針對破損或磨損的情況可分為兩種，其一是因為表面“一”字形花紋被打掉或磨輥局部磨損嚴重，則應進行局部補焊。其二是磨輥表面整體磨損達到規(guī)定的厚度，則需要進行整體補焊。
Repair welding is required when the wear-resistant layer on the surface of the grinding roller is damaged or excessively worn. There are two types of damage or wear. One is because the "one"-shaped pattern on the surface is knocked off or the grinding roller is locally worn, so local repair welding should be performed. The second is that the overall wear of the grinding roller surface reaches the specified thickness, and the overall repair welding is required.
1、磨輥輥面的局部補焊
1. Partial repair welding of roller surface
當在檢查磨輥輥面時，若發(fā)現(xiàn)某一處或幾處的硬層過度磨損或脫落，可用局部補焊的方法進行補焊。
When inspecting the surface of the grinding roll, if you find that the hard layer at one or several places is excessively worn or peeled off, you can use local repair welding to repair it.
1）先停機，將所需補焊部位轉(zhuǎn)至觀察門處；
1) Stop the machine first, and transfer the required repair welding part to the observation door;
2）用鋼絲刷清除表面的物料和雜物，拖刷不掉，可用手砂輪進行打磨，直至補焊表面光滑為止；
2) Use the steel wire brush to remove materials and sundries on the surface. If the brush cannot be removed, it can be polished with hand wheel until the repair welding surface is smooth;
3）按規(guī)定的補焊工藝，用特定的補焊焊條（由設備制造廠或設計單位提供）進行補焊。
3) According to the specified repair welding process, use the specific repair welding electrode (provided by the equipment manufacturer or design unit) for repair welding.
2、磨輥輥面的整體補焊
2. Integral repair welding of grinding roller surface
當磨輥輥面的“一”字形花紋已基本磨光，而局部區(qū)域（占總面積50%）的耐磨層磨損高度達到7㎜時，應對整個磨輥輥面進行修復、補焊。
When the "one"-shaped pattern on the surface of the grinding roller has been basically polished, and the wear height of the wear-resistant layer in the local area (50% of the total area) has reached 7 mm, the entire surface of the roller should be repaired and welded.
1）先停車，緩慢驅(qū)動磨輥，將其整個表面清洗干凈；
1) Stop first, drive the grinding roller slowly, and clean its entire surface;
2）盡可能將其上的裂紋打磨掉；
2) Grind away the cracks as much as possible;
3）用加熱工具對整個磨輥進行預熱，注意加熱要均勻，以30℃/h的溫升速度加熱至80～100℃。
3) Preheat the entire grinding roll with heating tool. Pay attention to the uniform heating, and heat it to 80-100°C at the temperature rise rate of 30°C/h.
4）在補焊前，用來進行補焊的焊條必須在250℃的溫度下烘干約2小時；
4) Before repair welding, the welding rod used for repair welding must be dried at the temperature of 250°C for about 2 hours;
5）補焊時電焊機的地線必須直接搭在磨輥上，否則可能燒壞主軸承，另外焊機電流不宜過大；
5) During repair welding, the ground wire of the electric welding machine must be directly placed on the grinding roller, otherwise the main bearing may be burned, and the welding machine current should not be too large;
6）按規(guī)定的補焊工藝，用特定的補焊焊條對耐磨層進行堆焊，直至要求的厚度；
6) According to the specified repair welding process, use the specific repair welding electrode to build up the wear-resistant layer to the required thickness;
7）按規(guī)定的工藝，用特定的焊條對“一”字形花紋進行重新堆焊；
7) Re-surfacing the "one" pattern with the specific welding rod according to the prescribed process;
8）若輥面局部區(qū)域耐磨層高度超過10㎜以上，過渡層因磨損需要補焊時,應與設備廠家聯(lián)系,進行修復;
8) If the height of the wear-resistant layer in the local area of the roll surface exceeds 10 mm, and the transition layer needs to be repaired due to wear, contact the equipment manufacturer for repair;
9)所有補焊材料及工藝均應由設備廠家提供和指導。
9) All repair welding materials and processes should be provided and guided by the equipment manufacturer.
七、磨輥輥面耐磨層厚度檢測方法
7. Detection method of the thickness of the wear-resistant layer of the roller surface
輥壓機磨輥由軸身,過渡層,耐磨層及“一”字形花紋所組成，其材料、化學成份及金相組織均不相同。其中軸身為中碳鋼鍛件，其余各層均是堆焊上的。耐磨層及“一”字形花紋構(gòu)成磨輥面強度的抗磨損層，直接與物料接觸，過渡層的作用是用以聯(lián)接軸身與耐磨層，解決軸身的可焊性，它與軸身同樣不具備耐磨性能。
The grinding roller of the roller press is composed of shaft body, transition layer, wear-resistant layer and "one"-shaped pattern. The material, chemical composition and metallographic structure are all different. The shaft body is medium carbon steel forging, and the remaining layers are all overlaid. The wear-resistant layer and the "one"-shaped pattern constitute the wear-resistant layer of the surface strength of the grinding roller, which is in direct contact with the material. The function of the transition layer is to connect the shaft body and the wear-resistant layer to solve the weldability of the shaft body. The body also does not have wear resistance.
在磨輥工作中，只能“一”字形花紋及耐磨層可以參與磨損，而過濾層及磨輥身是絕對不能讓其直接與高壓下的物料相接觸，否則將會使這些材料及零件發(fā)生極度磨損而失效。因此，在磨輥整個工作周期中必須定期、嚴格檢查耐磨層的實際高度，防此因耐磨層過渡磨損損傷過渡層及軸身。
In the work of the roller, only the "one" pattern and the wear-resistant layer can participate in the wear, and the filter layer and the roller body must not be directly contacted with the materials under high pressure, otherwise these materials and parts will undergo extreme wear and fail. Therefore, the actual height of the wear layer must be checked regularly and strictly during the entire work cycle of the grinding roller to prevent the transition layer and shaft from being damaged due to the transition wear of the wear layer.
磨輥輥面的磨損可分為兩種情況：其一是整個耐磨層均勻磨損，各個方向上磨損量相差不大，其二是因為磨輥耐磨層上某一點或一塊堆焊合金剝落，造成局部磨損。兩種形式均可使耐磨層失效。為防此其發(fā)生，必須在對耐磨層作定期厚度檢測的同時，還應經(jīng)常觀察耐磨層有無剝落，并及時檢測其深度，以便修復。
The wear of the roller surface of the grinding roller can be divided into two situations: one is that the entire wear-resistant layer is uniformly worn, and the amount of wear in all directions is not much different, and the other is because a certain point on the wear-resistant layer of the grinding roller or a piece of surfacing alloy peels off, and causing local wear. Both forms can make the wear-resistant layer ineffective. In order to prevent this from happening, it is necessary to regularly inspect the thickness of the wear-resistant layer and at the same time check whether the wear-resistant layer is peeling off, and detect its depth in time for repair.
對磨輥耐磨層所作的定期檢測，稱為標準檢測。在新輥層開始使用的前三個月中，每15天檢測一次；在三個月后每星期檢測一次。
The regular inspection of the wear-resistant layer of the grinding roller is called standard inspection. During the first three months of using the new roll layer, it will be tested every 15 days; after three months, it will be tested every week.
對磨輥剝落點或剝落塊的檢測。稱為特殊檢測，從磨輥開始工作之日起就應保證每天對輥面進行一次觀察（可不必停機），發(fā)現(xiàn)剝落點或塊，應立即停機車檢測其深度，確定是否立即修復。
Detect the peeling points or pieces of grinding rollers. It is called special inspection. It is necessary to observe the roller surface once a day from the day when the roller starts to work (without stopping the machine). If the peeling point or block is found, the car should be stopped immediately to check its depth and determine whether to repair it immediately.
具體耐磨層高度檢測方法如下：
The specific method for detecting the height of the wear layer is as follows:
1）停機，將輥罩上觀察門打開；
1) Stop the machine and open the observation door on the roller cover;
2）將輥壓機檢測圓柱段圓周Ф1400mm表面清洗干凈；
2) Clean the surface of the cylindrical section of the roller press with circumference of 1400mm;
3）以Ф1400mm 輥段的圓弧表面為基準，將檢測儀的：“V”形塊卡于其上，前后滑動幾次，確信在其接觸面上無異物；
3) Using the arc surface of the Ф1400mm roller section as a reference, clamp the "V"-shaped block of the detector on it and slide it back and forth several times to make sure that there is no foreign matter on the contact surface;
4）用深度尺以檢測儀的基準梁（下側(cè)）為基準，檢測磨輥耐磨層距基準梁的高度，并作記錄；
4) Use the depth gauge to measure the height of the wear-resistant layer of the grinding roller from the reference beam based on the reference beam (lower side) of the detector, and make a record;
5）標準檢測時，深度尺應在基準梁上所刻位置上依次測量。沿圓方向每30°檢測一組，并將每次每組的數(shù)據(jù)記錄在記錄表上；
5) During standard testing, the depth gauge should be measured sequentially at the positions engraved on the reference beam. Detect one group every 30° along the circular direction, and record the data of each group each time on the record sheet;
6）特殊檢測時，必須準確測出耐磨層上最深點至基準梁的高度。
6) During special inspection, the height from the deepest point on the wear-resistant layer to the reference beam must be accurately measured.
