立磨减速机使用说明书.doc

ZGM113型/ZGM123型中速辊式磨煤机使用和维护说明书 JLX61Z/JLX69Z型减速机使用和维护说明项目减速机用JLX61Z/JLX69Z型立磨减速机使用说明书Operation Manual of Gear Reducer for JLX61Z/JLX69Z Vertical Mill （最终定稿）重庆齿轮箱有限责任公司 Chongqing Gearbox Co., Ltd.1 型号含义和技术参数Definition of model and parameters 1.1 型号含义Definition of model JLX61Z/JLX69Z型号 JLX61Z/JLX69Z model J： 指减速机gear reducer；L： 指两级减速two-stage gear reduction； X： 指行星齿轮传动planetary gear drive；Z： 指铸造箱体cast casing； 61/69：指减速机名义功率nominal power of gear reducer1.2 技术参数Parameters 额定功率Rated power 570/700 kw 电动机功率Power of electric motor 570/632 kw 输入轴转速RPM of input shaft 991/991 r/min 输出轴转速RPM of output shaft 24.4/23.2 r/min 总传动比Total ratio of transmission 40.91/42.7 重量Weight 25900/28700 kg 容油量Oil capacity 250/342 L 润滑油牌号Name of lubricating oil N320硫磷型重负荷极压工业齿轮油N320sulfur/phosphorus industrial gear oil for high loading and extreme pressure 设计轴向载荷Designed axial loading 1600/2000 kN (静载荷static loading) 4800/8000 kN (动载荷dynamic loading)1.3工作参数Control parameters 油压正常值Normal value for input oil 0.2-04 Mpa（油温40） 油压报警值Alarm value for input oil 0.11MPa 油压停机值Shutdown value for input oil 0.08Mpa 润滑油工作油温最低值Min. value of operating oil temperature for lubricating oil 25 润滑油工作油温最高值Max. value of operating oil temperature for lubricating oil 60推力轴承油池油温报警值Alarm value of oil temperature in oil sump for thrust bearing 80 推力轴承油池油温停机值Shutdown value of oil temperature in oil sump for thrust bearing 83 2性能与结构特点Features on performance and mechanism 该减速机在传动上由一级螺旋伞齿轮和一级行星齿轮传动组成，与同样额定功率和传动比的三级普通螺伞圆柱齿轮减速机相比，不仅体积小、重量轻，而且传动平稳、噪音低、效率高等。所有这些主要是由于利用了行星齿轮传动的特点，同时又由于磨齿加工齿轮的数量占齿轮总数量的百分比提高，使得整个传动的各种性能大大提高所致。 The gear reducer is composed of one-stage spiral bevel gear and one-stage planetary gear in terms of drive. Compared with three-stage common spiral bevel gearcylindrical gear reducer, the gear reducer proper is featured by small volume, light weight, stable driving, low noise and high efficiency, etc. All these features are attributed to the utilization of planetary gear drive and increased ratio of no. of grinding teeth machining gears to the total no.s of gears, which result in remarkable improvement of all performances for the whole driving system. 该减速机主要由以下几部分组成。The gear reducer is structured as follows：2.1伞齿轮传动部分Driving part of bevel gear 减速机输入级为一对克林贝尔格螺旋伞齿轮。大小齿轮均采用渗碳淬火钢进行制造，并采用硬齿面加工方法加工而成，强度很高。小伞齿轮和大伞齿轮均通过轴承座装入下壳体中，两轴承座法兰下设有调整垫，用于调整齿轮副接触区的位置和齿侧间隙。 The input stage of the gear reducer is a couple of KLINGELNBERG extension epicycloidal spiral bevel gears hardened-steel and machined by means of hard tooth surface processing, which presents high strength. Bull gear and pinion gear are mounted in lower casing via bearing seat. There are adjusting spacers beneath flange of two bearing seats, which are designed to adjust the position of gears sub-contact area and the gap of flank of teeth. 2.2行星级齿轮传动部分Driving part of planetary-stage gear 行星级齿轮传动主要由太阳轮、行星轮、内齿圈等组成。Planetary-stage gear is mainly composed of sun wheel, planetary gear, internal ring gear, etc. 工作时太阳轮浮动，以便使其轮齿同时和三个行星轮均匀接触，达到均载目的；行星轮安装在行星架上，在绕自身轴线传动的同时，也随行星架一齐转动。内齿轮安装在壳体中固定不动。太阳轮，行星轮均为渗碳淬火后磨齿齿轮，内齿轮为调质齿轮。When in operation, the sun wheel is floating so as to allow its gears to uniformly contact 3 other planetary gears for uniform loading. Planetary gears are mounted on the planetary frame and is rotating with the planetary frame while driving around his own axis. Internal gear is mounted in the casing without movement. Sun wheel and planetary gear are made of post-carburized hardened grinding teeth gear while internal gear is of quenching and tempering gear.2.3齿轮联轴器Gear coupling 该减速机在两级齿轮传动之间设置了鼓形齿联轴器，其作用是连接两级齿轮之间的传动。由于齿轮联轴器的内齿套也随行星级中的太阳轮一起浮动，所以联轴器齿轮也采用合金钢材料来制造。 There is a barrel-shaped gear coupling between two-stage gear drive for the gear reducer proper, the purpose of which is to link the drive for two-stage gear. Since the internal teeth sleeve for the gear coupling is floating with the sun gear in the planetary-stage, coupling gear is made of alloyed steel.2.4平面滑动推力轴承Plane sliding thrust bearing 为了承受磨煤机工作中的动静载荷，减速机上部设置了平面滑动推力轴承，靠推力盘旋转在推力盘和推力瓦之间产生动压润滑油膜进行工作。In order to sustain dynamic and static loading of coal mill in operation, the gear reducer is equipped with plane sliding thrust bearing at the upper part, which may generate dynamic pressure lubricating oil film between thrust disc and thrust bushing by means of rotation of thrust disc. 推力盘为钢制材料制成，推力轴承瓦面为塑料瓦材料制成。由于该轴承靠建立正常的润滑油膜而工作，轴承材料硬度又很低，所以不能在磨煤机加载而又无煤的情况下使用。在使用盘车装置时，要全部放松（对于变加载式磨煤机最好将磨辊抬起）磨煤机载荷来进行，以保证轴承的安全性。Thrust disc is made of steel and thrust bearing bushing surface is made of plastic bushing. Since the bearing is working by establishing proper lubricating oil film and there is low hardness of bearing material, it can not be used while loading coal mill and with no coal. When using barring gear, it is advisable to fully unload coal mill (regarding adjustable loading coal mill, preferably lift mill roller) so as to protect the safety of the bearing.2.5滚动轴承Roller bearing 本减速机均采用SKF和NSK轴承装配，和平面滑动轴承一样要求润滑油保证质量和清洁度。The gear reducer is equipped with SKF NSKbearing requiring assured quality and cleanliness for lubricant like plane sliding bearing.2.6壳体Casing 减速机采用上下箱分开式壳体，目的是为了方便下箱体中零部件损坏时的维修。上下箱体强度和刚度好。上箱体设有两个进油口和二个推力轴承回油观察孔，下箱体设有二个回油口，二个检修门和二个油位观察口。The gear reducer is assembled with upper and lower split-type casings, the purpose of which is to facilitate repair on damaged components in lower casing. Upper and lower casings good strength. In upper casing, there are two oil filling ports and two observation holes for oil return of thrust bearing. In lower casing, there are two oil return ports, two maintenance doors and two oil level observation holes.2.7润滑与冷却Lubrication and cooling 为了保证齿轮和轴承在运转中得到可靠地润滑与冷却，减速机选用了硫磷型极压工业齿轮油作为润滑与冷却介质，并采用过滤精度很高的润滑站对减速机提供合适温度的润滑油。减速机内部各润滑点的供油量是通过计算与试验确定下来的，可以充分满足所有存在相对运动零件的使用要求。同时进油管安装有溢流阀以控制低油温时（25）最高油压不超过允许值0.58MPa，在正常油温下（4060）溢流阀不工作。In order to make sure that gears and bearings are properly lubricated and cooled during operation, we utilize sulfur/phosphorous type extreme pressure industrial gear oil as lubricating and cooling media for the gear reducer and also choose lubricating station with fine filtering to provide lubricating oil of proper temperature for the gear reducer. The quantity of oil supply to each lubricating point inside the gear reducer is determined based on calculation and test, which can satisfy the requirement of operation for all parts with relative motion. whist the oil feeding pipes is equipped with overflow valves to control the maximum oil pressure not exceeding allowed valve at low oil temperature(25). The overflow valve can not work at normal oil temperature(40-60)3安装Installation 因为减速机既是磨煤机的驱动部件，又是磨煤机中主要转动部件（如磨辊、磨环等转动件）的最初安装基准，同时又是磨煤机碾磨加载力的支撑体，所以减速机的安装正确与否严重关系到磨煤机的工作性能问题。因此，在整个磨煤机安装过程中，必须有懂得减速机安装技术的工程师和技术工人（或者是经过专门技术培训的这些人员）一起进行。Since the gear reducer is not only the driving part for coal mill, but the original erection benchmark for the main rotating part (such as mill roller, mill ring, etc.) for coal mill and the support for loading force of grinding of coal mill as well, the correct erection of the gear reducer has a close relation with its performance. Therefore, the erection of the gear reducer must be carried out by experienced engineers and technicians (or people subject to particular training). 安装减速机前，必须仔细审阅减速机外形图和润滑站外形图，了解上述设备后进行下述工作。Prior to installation, dimensional drawing of the gear reducer and lubricating station and lubricating station must be carefully reviewed to have a good understanding of follow-up works.齿轮箱基础底板的检验Inspection of sole plate for gearbox： 由于磨机粉磨装置的重量和粉磨压力都将通过齿轮箱传到基础底座上,所以整个齿轮箱必须放置在基础底板的整个平面上.将齿轮箱安装在基础底板上时,整个基础底板必须经过严格的水平检验,基础底板的水平误差不能超过0.05mm/M,并且要仔细地清洗齿轮箱和基础底板的结合面,然后用润滑脂涂抹基础底板,以便在安装齿轮箱时能够移动之.Since the weight and pulverizing pressure of mills pulverizing unit are traveling to soleplate via gearbox, the whole gearbox has to be laid across the plane of soleplate. When installing the gearbox onto the soleplate, the whole soleplate must be carefully inspected horizontally with horizontal error not more than 0.05mm/M. Meanwhile, thoroughly clean the joint surface between gearbox and soleplate before applying grease to the soleplate so as to move it when installing the gearbox.在基础底板上安装齿轮箱Install gearbox onto soleplate首先确定基础底板上磨机中心线的位置,然后利用齿轮箱下部的起吊孔将其起吊到预定位置,仔细调整减速机位置，使减速机底板上中心刻线对准基础底板上磨机中心线，然后通过箱体底板上的8个螺栓孔用螺栓将齿轮箱紧固在基础底板上。First of all, determine the position of mills central line on the soleplate and then lift the soleplate to the expected position by means of 4 lifting eyes on the lower part of gearbox. Carefully adjust the position of gear reducer to allow its central line on the base plate to align with mills central line on the soleplate. And then tighten the gearbox to the soleplate with 8 bolts on casing base plate.3.1 清理与检查Clean and check 安装前用煤油擦洗掉减速机底面，输入轴颈，输出传动法兰端面上的防锈漆和其它杂质污物等。检查并排放干净减速机内部的残留润滑防锈油。Get rid of corrosion and other impurity with kerosene oil from gear reducers bottom, neck of input shaft and output drive flange end surface. Check and empty residual rust-preventative oil inside the gear reducer. 为保证减速机精确定位，修磨因不慎而造成的减速机底面上和基础台板表面上的凸痕等。为防止安装后并且在长期使用情况下，减速机底面与台板表面锈蚀在一起，应在台板表面上均匀涂以一层薄薄的MoS2润滑脂。In order to ensure the accurate alignment of the gear reducer, grind and remove the imprint marks unintentionally left on the gear reducer surface and foundation bedplate surface. In order to prevent corrosion of gear reducer surface and bedplate surface occurring during operation after installation, apply a uniform thin film of MoS2 lubricating grease to bedplate surface.注意！减速机输入轴迷宫防锈包装密封，输出传动法兰迷宫防锈包装密封，呼吸器上的防锈包装胶带最好在减速机启动前拆除，以免安装周期过长，内部零件发生锈蚀。Caution：It is advisable to remove the labyrinth seal for input shaft and output drive flange, rubber tape on respirator before startup of the gear reducer so that internal parts can be free of corrosion due to long-term erection.3.2安装减速机Installation of gear reducer 安装减速机的基准精度要求为：减速机台板的水平度误差不大于0.1mm/m，平面度误差不大于0.1mm。The benchmarking accuracy of installing gear reducer is defined as follows： Horizontal error for bedplate of gear reducer not more than 0.1mm/m,Flatness error not more than 0.1mm, 减速机以底面法兰侧面的四条刻线对准台板划线进行找正。The gear reducer is aligned based on 4 mark lines on sides of bottom flange and bedplate marks. 地脚螺栓应采用液压预紧设备进行拧紧，并进行防松处理。Anchor bolts are tightened with hydraulic pretightening equipment and locking measures are employed. 为了防止减速机在工作中因磨煤机振动而产生位移，减速机底部方法兰四边必须用螺栓顶住定位，定位螺栓要进行防松。In order to prevent displacement of the gear reducer due to vibration of coal mill during operation, four sides of square flange at the gear reducers bottom must be jacked in place and locking measures are employed for locking bolts.注意 ！减速机底面不允许加垫片。Caution：no shimming on the bottom of gear reducer.3.3安装润滑站： 按稀油润滑站说明书执行。Installation of lubricating station：to be carried out against Instructions on Thin Oil Lubricating Station. 3.4加油Oil feeding在加工作油之前，应先放净系统内的残油，清除包装用盲法兰、丝堵、胶带并且恢复呼吸器的安装。再加入牌号正确、质量和清洁度合格的工作油。 Caution：The residual oil in the gear reducer delivered to customers is SRC Particular Sealing Anti-rust Oil developed by Beijing Sanlian Fine Chemical Plant for our special duty. Prior to filling working oil, empty the residual oil in the system, remove blind flange, pipe plug and tape for package and restore the installation of respirator. Feed working oil with correct type, quality and cleanliness. In case of working oil to be used from other Co.s, more attention shall be paid to the above steps. 减速机的加油应该在稀油润滑站和减速机与润滑站之间的管路全部安装完毕之后进行。当这些部分安装完毕后，可以卸下减速机进出油口法兰和上下箱体上的测温座螺塞，安装测温元件等。注意：应该先安装好. Feeding oil to the gear reducer shall be carried out when the pipelines between thin oil lubricating station the gear reducer and lubricating station as well are fully installed in place. When these parts are installed, disassemble input/output oil port flange and plug screw of temperature-measuring base at the upper and lower casings and then install components for measuring temperature. Caution：installation in place first. 因减速机采用滑动推力轴承来承受磨煤机的工作载荷，所以对润滑油的粘度和加油过滤精度有严格的要求，用户必须注意。Since sliding thrust bearing of the gear reducer is used to sustain the operation loading of coal mill, there are strict requirements on lubricants viscosity and filtering accuracy for oil filling, to which users shall pay attention. 加油工作应该在润滑站安装完毕并且与减速机之间连接好润滑管路之后进行。在启动润滑站之前，系统各种仪表、开关和线路等必须接好。Oil filling shall be carried out when the lubricating station is installed and lubricating pipelines linking the gear reducer are installed. Before startup of the lubricating station, all instruments, switches and wirings must be in place. 在向减速机加油之前，认真审定所购油品是否为减速机规定用油，生产厂家是否为国家承认的正式单位，油品有无检验报告和合格证等。严禁使用伪劣油品和与本说明书规定牌号不一致的油品。Before feeding oil to the gear reducer, review the procured oil against the oil specification for the gear reducer, such as whether the manufacturer is the nationally approved unit, whether there are examination report and certificate, etc. Oil of poor quality or those different with the specification are not allowed to be used. 本减速机推荐的国内油品生产厂商为北京三联精细化工厂生产的N320硫磷型重极压工业齿轮油。国外用油应使用性能相同的润滑油。The recommended oil manufacturer for the gear reducer proper is N320 sulfur/phosphorous type extreme pressure industrial gear oil made by Beijing Shanlian Fine Chemical Plant. Lube oil with same properties shall be used if not made in China.表3-1. 北京三联精细化工厂生产的N320硫磷型重极压工业齿轮油性能指标Table 3-1 Performance Index of N320 sulfur/phosphorous type extreme pressure industrial gear oil made by Beijing Shanlian Fine Chemical Plant. 比 重Density,g/cm3凝 点Freezing point（最小）闪 点Flashing point（最小）粘 度Viscosity 40（100） cst粘度指数Viscosity （最低）符合标准Standard to be employed-1520028835290Q/SH018.3215-89润滑油应采用过滤精度不低于0.025mm的滤油机注入减速机。较为方便的方法是拆除减速机箱体中分面法兰上的呼吸器（整个拆下），利用其安装孔对减速机下箱体进行加油，当减速机下箱中的油位到达后油窗中间刻线时（不停止滤油机对减速机的加油），可以启动润滑站油泵对减速机上箱体进行加油。油位到达后油窗中间刻线时，说明上箱体油已加满。这时请不要立即关闭润滑站油泵，因为启动润滑站油泵对减速机上箱体进行加油过程中致使下箱体油位下降，应待减速机下箱中的油位再次到达后油窗中间刻线时停止用滤油机对减速机的加油。在加油完毕后，如果下箱体中油位低于油窗中间刻线，应对减速机补油，若油位高于中间刻线，应进行适当放油。此油位均以减速机运行状态为准。Lubricating oil shall be fed to the gear reducer through filter press with filtering accuracy not less than 0.025mm. A easy method is to fully disassemble the respirator at the split flange in the casing and feed oil to the lower casing through the erection hole. When the oil level in the lower casing reaches the intermediate mark in the oil window (not stop feeding oil to the gear reducer from filter press), startup oil pump in the lubricating station to feed oil to lower casing. In order to assess the oil level in the upper casing, it is allowed to remove the plug screw of observation hole at thrust bearing oil sump in the upper casing. When lubricating oil is found to overflow from oil sump, indicating that the upper casing is full, please do not stop oil pump immediately. Since oil level in the lower casing drops in the process of oil feeding to the upper casing from startup of oil pump, do not stop oil feeding to the gear reducer from the filter press until the oil level in the lower casing reaches the intermediate mark in the oil window again. After the completion of oil filling, if the oil level in the lower casing is below the intermediate mark in the oil window, add more oil to the gear reducer. If the oil level is beyond the intermediate mark, drain the oil slightly. The oil level shall be dependant on the operation status of the gear reducer. 运行后观察油窗中的油位在油窗中间刻线处为宜，略高或略底均不会影响减速机的正常运行。当减速机中油位下降到油窗“下边缘”处时，应进行补油。After operation, observe the oil level in the oil window, preferably at the intermediate mark. Slightly below or beyond the mark will not affect the normal operation of the gear reducer. When the oil level in the gear reducer drops to “lower limit” in the oil window, exercise oil addition. 注意！严禁将油位加至过高，以免造成减速机输入轴漏油。Caution：It is prohibited to fill oil too high to prevent input shaft of gear reducer from leaking.注意！必须及时补油，以免减速机中油位过低发生事故。Caution：Exercise timely oil addition to prevent any accident due to too low oil level in the gear reducer. 注意！严禁打开减速机下箱体上的检修门对减速机进行加油和观看，以免发生漏油现象。Caution：It is prohibited to open the maintenance door at the lower casing to add oil and take a look to prevent oil leak. 注意！技术参数中提到的减速机容油量，不包括润滑站内部的存油量。Caution：Oil capacity as mentioned in the specification does not include the oil storing in the lubricating station. 4启动Startup 启动前应除去减速机输入轴迷宫密封端面和输出传动法兰迷宫密封外圆表面，以及呼吸器上的防锈包装及胶带。Prior to startup, get rid of tape from labyrinth seal end of input shaft, labyrinth seal outer surface of output drive flange and respirator. 减速机和润滑站以及控制系统安装完毕后应进行试运转工作。减速机的试运转工作对于变加载式磨煤机，可以采用抬起磨辊或者是减少磨辊加载力的方式来进行；对于非变加载式磨煤机，只能和磨煤机试运转同步进行。一旦启动减速机，必须首先启动润滑站。润滑站的试运转工作应安排在减速机试运行转之前进行。该项工作必须在调试工程师的指导下进行，控制技术参数按1.3条的要求进行。 After the completion of installation of the gear reducer, lubricating station and control system, start commissioning. For the variable loading coal mill, the gear reducer is commissioned by lifting roller or reducing roller loading force. For non variable loading coal mill, the commissioning of gear reducer can only be carried out together with coal mill. Once startup gear reducer, you have to start lubricating station first. Lubricating station shall be commissioned before gear reducer under the guidance of commissioning engineer. Refer to 1.3 for control technical parameters. 试运转中主要开展如下工作Main works to be done during commissioning： 一是检查运行参数是否满足设计规定；二是检查系统零部件运转是否正常。Check operation parameters for compliance with design. Check each part is working properly. 检查运行参数是指各处的油温，油压是否符合规定。检查系统零部件运转是否正常是指密切注意油泵，过滤器，冷却器，加热器，减速机运