Instructions for MB Ball Mill（1）

1. 磨機工作原理及用途PRINCIPLE OF OPERATION AND USES OF MILL

管磨機是水平的回轉圓筒，內裝研磨體（一般為鋼球、鋼鍛）。主要靠筒本回轉時將研磨體升舉落下的沖擊能量將物料磨碎。在工作過程中，反復進行的沖擊粉碎和滾動、滑動研磨，使塊狀物料逐漸變小，成為細粉。本機主要用于水泥生料及水泥熟料的粉磨。
Tube Mill is a horizontal rotary cylinder, load in abrasive mediums (general they are steel grinding balls, cylpebs). To crush the materials mainly by percussion energy of the abrasive bodies when the shell rotary to lift and fall them. And the material to be crushed. During the operational progress, by roll and slide repeatedly crushing. So massive material become powder.
This machine is mainly used in grinding for cement raw meals and cement clinkers.
2.結構概述SUMMARY  FOR  STRUCTURE
  2.1傳動系統Transmission system
  傳動系統包括電動機、減速器、傳動軸、大小齒輪(中心傳動無大小齒輪)和聯軸器等。電動機與減速機之間、減速器與小齒輪之間以彈性聯軸器聯接。此種聯軸器吸震性好，可以減少磨機沖擊震動對減速器的影響，可以提高設備使用壽命，且維修十分方便。大齒輪固定在筒體上。由電動機通過減速器、傳動軸、小齒輪、大齒圈帶動筒體回轉。為了增加傳動齒輪的使用壽命。磨機采用“大變位”齒輪。
  Transmission system is comprises of motor, reduction unit. Transmission shaft. Girth gear and pinion(central drive mill don’t use girth gear and pinion), coupling, etc. The reduction unit is connected to the motor by spring coupling, and the pinion is connected to the reduction unit by spring coupling which has a good damping capacity and may reduce the shock and vibration influence of mill shell on the reduction unit and increase the service life of the equipment and convenient to maintain. Girth gear is fixed on the flange of shell body, shell body is rotated by motor passing reducer transmission shaft pinion shaft pinion and girth grar rim. Inorder to increase service lift of transmission gears. The mill uses the “large modified” gear.
2.2進料裝置Feed device
   進料裝置主要包括進料斗支架、觀察門、進料斗等。進料斗內裝有襯板，同時利用物料本身作襯墊以減少物料對進料斗的磨損。進料斗與支架間有墊片，用增減墊片的方法來調節中心高度。
Feed device mainly consists of charging hopper supports, observation door.etc.liner is fixed in the charging hopper.But it also uses materials as liner to reduce its wearing for charging hopper. The spacers are used between the hopper and the supper by increasing or decreasing the spacer pieces.
2.3回轉部分Rotating part
回轉部分是由進出料螺旋筒、進出料中空軸、大齒輪（中心傳動無大齒輪）、筒體、襯板及隔倉板等部件組成。
筒體用鋼板卷制焊接而成，筒體兩端焊有同類鋼板的平端蓋。筒體上開有人孔，人孔用相同材料的加強板加強。磨體內分為粗磨倉、細磨倉。在粗磨倉中裝有ZGMn13（鑄造錳鋼）襯板用螺栓將其聯接在筒體上。為了減輕應力集中，襯板的螺栓孔采用橢圓形。細磨倉中亦有用螺栓固定的或鑲嵌的襯板，隔倉板為單層隔倉板，材質為ZGMn13（鑄造錳鋼）。整個回轉部分依靠兩個中空軸支承在兩個主軸承上。中空軸與平端蓋之間用螺栓聯接。
Rotating part has charging and discharging screw. Charging and discharging Trunnion shafts, girth gear, (central drive hasn’t girth gear)shell body,liners and compartment separators,etc.
Shell body is made of steel plates which are rolled up and welded .The plain-end covers of the same kind of steel plates are welded on the shell body ends. There are manholes on shell body with each one has a strengthen edge. The mill has a coarse grinding compartment and a fine grinding compartment. The circular liners of ZGMn13 manganese casting steel are bolted on the shell body in the coarse grinding compartment. The shape of boltholes is oval to prevent the stress concentration. Liners are uses in the fine grinding compartment by bolt . The compartment separators of ZGMn13 manganese casting steel are single layer. The two main bearings support the whole rotating part by two quill shafts. Quill shafts are connected with plain-end covers by bolts.
 2．4主軸承  Main bearing
主軸承由球面瓦、軸承座與上蓋等主要零部件組成。為保證中空軸軸線保持在一個軸線上，采用球面體的軸承瓦，以保證自動調心和主軸承正常油潤滑。
在中空軸上裝有固定油圈（即“帶油圈”），由固定油圈帶油潤滑。為了防止漏油，主軸承兩端裝小油刷，在靠近筒體一側裝有刮油板。（根據用戶亦可用稀油站潤滑）
為保證主軸承在正常溫度下進行工作，在主軸承和球面瓦之間通以冷卻水進行冷卻。由于粉磨產生大熱量傳出影響主軸承正常工作，在螺旋筒和中空軸之間的縫隙中填以隔熱材料。
Main bearings are comprised of globe bearings, bearing seats and upper covers, etc. The globe bearings are used for purposes of automatic alignment shaft lines of trunnion shafts each other, and make regular oil lubrication for main bearings.
The fixed oil rings (belt oil rings)are installed on the trunnion shafts for lubrication . To prevent oil leakage small oil brushes are installed on the both sides of main bearing and oil scrapers are installed on the side of near shell body. (thin oil station is used according to custom’s requirement)
Because the grinding produces a large amount of heat. The main bearings are cooled by water to keep the normal operation of the main bearings. Heat-insulating material is filled into the gap between the screw tube and trunnion shaft to prevent heat transfer.
2.5出料裝置 Discharging device
出料裝置是由出料罩、支架、出料篩子等零件組成。出料篩是用螺栓和出料螺旋筒聯接在一起的。經粉磨后的物料經過篩選后落入出料罩，其中雜質（如鐵塊、螺栓等）則從排渣口自動排出。在出料罩上部裝有管道收塵器聯接，為防止漏風，下部應裝鎖風裝置，再與輸送設備連接，否則會影響磨機的粉磨和產量。
Discharging device consists of discharging cover、 supports、discharging screen, etc. The discharging screen is connected with discharging screw tube by bolts. The ground material drops into discharging cover through the screen. Some objects (such as iron pieces,bolts,etc.) will be removed from exit. The pipeline connected with dust collector is installed on the discharging cover. Air lock device is installed on the lower part of discharging cover which is connected with conveying equipment in order to avoid air leak.
3．安裝   INSTALLATION
3．1 基礎 Foundation
3．1．1 基礎驗收 Foundation check and accept
（1）在磨機安裝之前，應對基礎進行清理和質理檢查，其強度應符合有關技術文件。
  Before installing the mill, the foundation should be cleared up and checked over for quality, its strength should conform to requirements of relevant communications.
 (2)地腳螺栓孔的布置與尺寸應當允許有可能把機器底板往任意一方偏移10～20mm。地腳螺栓與基礎孔壁的距離和螺栓下端到坑底的距離不小于15cm。地腳螺栓預留孔尺寸可參照表1。
  Arrangement and dimension of eyelet bolt holes of foundation should be appropriate to allow machinery base drift probably on arbitrary direction 10～20mm.Distance between eyelet bolts and foundational hole wall and between low end of eyelet bolt and hole bottom, must be not less than 15cm. Dimension of eyelet bolt reserve hole refer to table 1.
表1  地腳螺栓橫斷面尺寸
Table 1 Eyelet bolt hole dimension on cross section

（3）地腳螺栓孔內不得有雜物和積水。在安裝前應加防塵蓋以防雜物掉入。
 There should be no sundry article and water in eyelet bolt holes. Before installing, should cover them to avert any sundry article fall in.
 (4)檢查基礎外形尺寸，以及標高相對于廠房和其它設備的尺寸是否符合設計要求。
 Foundation overall dimensions should be inspected, and its elevations relative to factory building and other equipments should fit design.
（5）基礎的平面標高應當比設備的下表面標高低30～50mm，以便在基礎與底板之間放置墊鐵進行調整。
 In order to adjust (height of equipment)by fitting spacers that between foundation and machinery base plate, therefore, foundation elevation should be lower 30～50mm than base surface of equipment.
 （6）為了保證二次澆灌時與原基礎結合緊密，必須把將要進行二次澆灌的表面鏟成麻面（凹坑直徑可為Φ30～50mm），各凹坑間的距離一般為150mm左右。在基礎的邊角處應鏟出缺口。
  In order to get integrative combination between second pour and former foundation therefore should shovel surface that will be to second pour and let them become pockmarks (pit diameter may be Φ30～50mm), distance between pits each other may usually be about 150mm.Shovel up notches on their borders of foundation.
 （7）基礎處理   Foundation treatment
（a）當標高過高時，用扁鏟鏟低；過低時，在原基礎上鏟出麻面，再補灌原標號混凝土。
 (a)Shovel it and cut down by flat shovel when elevation is too higher; shovel up pockmarks and patching pour by former grade of concrete when it is too lower.
 (b)若地腳螺栓位置偏移，可采用擴大預留孔的方法解決，或把地腳螺栓烤紅矯正到正確位置。
 If eyelet bolts drift, may extend reserve holes, or bake and manifest eyelet bolts as dull red and correct them.
3.1.2中心標板     Centre marking boards
   基礎經過檢查并符合要求后，就可根據按磨機實測尺寸修改的圖樣，在基礎上埋設中心標板。（注意應使用同一把量具）
   When  foundation  has been inspected and fit requirements, according to drawings which have been measured mill and have been altered, then may fix centre marking boards in foundation.(Note: using the same measuring tool).
  中心標板一般用鋼軌、工字鋼或槽鋼制成，其尺寸約為（150～200mm）×（30～60mm）。將其牢固地埋設在基礎表面里，然后標上中心標點。用沖子打出一個很小的沖眼（可使用經緯儀投點）作為安裝設時掛中心線找正設備位置的依據。
   Centre marking boards are usually made from steel rail. I-steel or channel beam (channel bar) their dimensions about(150～200mm)×(30～60mm). Fixed durably them in foundation,then mark out centre points, punch very small holes by puncher (ou by theodolite.) These holes are regarded as bases of obtaining the positions of equipment for installation.
3．1．3基準點   Datum points
   基準點是供作安裝機械時測量標高的標準依據，是根據廠區零點測出它的標高并示明。
   基準點一般用鉚釘制作，在鉚釘桿端焊上一塊50mm×50mm，厚10mm鋼板，或焊上兩根50mm長的已扳彎的螺蚊鋼。將其埋在預定的地方，也可將基準點點焊在相應的鋼筋上。
Datum points are regarded as standard bases of elevations for installation, to measure up their elevations against “zero point of plant district”, and make marks on them.
Datum points are usually made of rivets, and weld up a piece of 50mm×50mm,thickness 10mm of steel plates on the heads of rivets, or weld up two pieces of 50mm long , have been bent of screwy steel . They are buried in predetermined area. Also datum points may be spot welded on relevant reinforced steel bar .
3.1.4 基礎劃線索Drawing lines on base
    基礎劃線的質量要求如下：
The requirements of drawing lines on base should be as following:

1. 兩主軸承基礎上的橫向球心（可用注水法確定）中心距離，誤差不得超過磨機膨脹量的1/10，最大不得超過2mm；

Distance between two crosswise centre lines on base of two main bearings, its error should be not above 1/10 of mill expansion, moreover should be not above 2mm;

1. 中心標板上所示的縱向中心線與圖樣上縱向中心線的位移不得超過±3mm；

The position of lengthwise centre line that is indicated by centre marking board, as compared to drawings, their displacement should be not above ±3mm;

1. 磨體中心線與傳動軸中心線必須嚴格平行，其誤差不超過±0.5mm。

Mill centre line must parallel severely to centre line of transmission shaft , its error should be not avove ±0.5mm.

1. 對相鄰基礎必須測定對角線上等，以保證縱橫向中心線呈90o。

Diagonal lines of adjacent bases should be measured, and adjust them being equal each other, to obtain appearing 90o between crosswise centerline and lengthwise centerline each other.

1. 掛中心線      Hang centre line

掛中心線的目的是在安裝過程中檢查各部相互關系。
The purposes of hanging centerline are to check (positional) relations of every part each other in installing.

1. 借助標板檢查兩主軸承的底板所在基礎的實際中線距離及標板中心點的位置。

       To check the distance between two actual centerlines of main bearings on base plates, and the position of centre point of marking board by centre marking boards.

1. 借助標板檢查磨機筒體中心線與傳動軸中心線的垂直距離，及電動機中心線與傳動軸中心線的距離。

To check the vertical distance between mill shell centerline and transmission shaft centerline, and the vertical distance between the motor centerline and transmission shaft centerline by centre marking board

1. 檢查地腳螺栓孔的位置等是否符合圖樣要求。

To check the positions of the eyelet bolt holes should fit drawing.
3.2地腳螺栓的安裝  Installing of eyelet bolts
3．2．1
地腳螺栓必須去除油質，銹垢及油漆，螺紋部分涂上油脂以防止生銹。在安裝前嚴防雜物掉入基礎孔內。
Eyelet bolts should have been cleaned down oil stains and rust, and smear grease on screw threads make antirust. Before installing, should avert strictly foreign matters fall in base holes.
3.2.2
地腳螺栓在基礎孔內應垂直，垂直度公差為5/1000。
Eyelet bolts should be perpendicular in the base holes, their perpendicularty  tolerances are 5/1000.
3.2.3
地腳螺栓的螺母下面應加墊圈，應有鎖緊裝置鎖緊。（鎖緊螺母或彈性墊圈）
Below the nut which is on the eyelet bolt, should add washer. Moreover. Check device should be used for locking them.(locking nut and spring washer)
3.2.4
擰緊地腳螺栓時，應從設備的中間部開始，然后往兩頭交錯進行，同時扭力要均勻。擰緊螺母后復查一次設備水平。
The order of tighten eyelet bolts, should beging at centre. Then toward staggeringly and successively moreover. Exert forcing even. After tighten. Check equipment level again.
3.2.5
減速機安裝應符合?減速機安裝使用說明書?的規定。
電動機安裝應符合?電動機安裝使用說明書?的規定。
Reducer is installed according to ?Operation instruction of reducer?.
Motor is installed according to ?Operation instruction of motor?.
4.操作、維修及檢修OPERATION, MAINTENANCE AND OVERHAUL
磨機安裝后必須經過空載、部分載荷和滿載，試運轉合格后才能正式投入生產。為保證磨機的長期正常運轉，必須注意磨機操作，維護和檢修，制定操作規程和維修制度。
The mill can be put into production after qualification of testrun of no-load, partial-load and full-load. The rules of operation and carried out to keep the normal operation of mill for long term.
4.1 磨機的操作         The operation of mill
磨機必須由經過專門訓練或熟悉磨機操作的人員操作。
The mill should be run by skilled  workers.
4.1.1
磨機運轉前的準備
磨機在起動前必須做好充分準備工作和檢查工作。
Preparations before operation
Full preparations and checkup of the mill should be made before mill start.

1. 磨機各零部件完整無缺，符合有關技術規定。所有的緊固螺栓和地腳螺栓、螺母均應緊固。

The every mill components and parts are complete and in conformity with technical regulations. Every fixed bolts and eyelet bolts should be screwed tightly.
（2）筒體內各零部件的安裝均應符合規定要求，各個篩板上的篩孔應暢通。
The installation of every components and parts should be up to the technical requirements. Every fixed screen openings should be unobetructed.
(3)各倉研磨體應符合要求。
The grinding compartments should meet the technical requirements.

1. 筒體上入孔蓋和進出產裝置檢查門等均應關嚴，牢固密閉。

Manhole cover of the mill shell and inspection door of charging and discharging devices should be closed and sealed.

1. 主軸承冷卻水道應暢通；主軸承不得有漏油、漏水、滲油滲水等現象；主軸承的潤滑油質量和油位高度均應符合規定要求；潤滑表面及存油處以及潤滑油本身應清潔；主軸承刮油板、刮油刷安裝方向應正確。

Cooling water circuit of main bearings should be passable and the water and oil leakage of the main bearings is not allowed. The lubrication oil quality and oil level of the main bearing should satisfy the technical requirements. The lubricated surfaces. Oil receiver and lubrication oil should be clean. The oil scraper and oil wiper should be installed in corrdct positions and directions.
(6)所有帶有密封裝置的地方要求將密封與磨擦面之間的壓力調節松緊適當，保證既能密封又不至于壓得過緊，造成密封很快磨損。
The pressure between the sealing elements and friction surface should be adjusted properly to avoid leakage or worn-off.
(7)儀表、照明、動力、信號、等系統應完整、靈活、可靠。
Instrumentation, illumination, power and signaling, etc, systems should be integrated, flexible and reliable.
(8)設備組裝應符合安裝技術和圖樣要求，電動機、減速器應符合說明書中和有關技術文件中的各項規定。
The assembly of motor and decelerator should be in keeping with drawing and regulations of operation instructions and relevant technical documents.
(9)輔助設備如輸送、提升、分級、收塵、風機等設備試運轉后均能保證正常生產，符合技術要求。
Auxiliary equipments such as conveying device. Lifting device and classifier, etc. can satisfy the technical reqirements for normal production after test-eun.
(10)磨機附近不得有防礙運轉的雜物。開車前必須認真檢查各運轉部件，設備危險點附近不得有人。
The objects which hamper the operation of mill must be removed from the places near the mill.every running components and parts should be checked before operation and the personnel should nlt appear in the dangerous places of equipment.