The use and maintenance of the trommel screen has a vital role in the life of the trommel screen, in the ordinary use of the process must pay attention to scientific and reasonable use of the trommel screen, the establishment of detailed maintenance measures, effectively ensure the use of the trommel screen cycle.This can not only lift the trommel screen for a long time, but also reduce the failure, reduce the downtime.Effectively ensure the continuity of product production, save enterprise costs.
Subject content and Scope of application:
Stable operation, no abnormal vibration, noise and other abnormal phenomena, stable current.
Bearing temperature is stable, its temperature rise does not exceed 35℃.
Good screening effect, in line with the technical requirements;
Bearing lubrication meets the specified requirements.
Operation performance:
The equipment is well lubricated, the lubrication system is unimpeded, and "Five-fixed" and "three-level filtration" are implemented;
Smooth operation, no noise;
Screen capacity to reach nameplate capacity or rated capacity
Equipment and Environment:
The machine is clean and tidy, free from oil, debris and leakage.
Safety protection device is complete and firm.
Technical information is complete and accurate, and shall include:
Equipment files, and in line with the company's equipment management system requirements;
Regular status monitoring and analysis records;
Equipment structure diagram and vulnerable parts diagram;
Operation rules of roller screen
Before the start of
Check whether the electrical equipment is in good condition.
Check whether there are other sundries in the roller screen. If there are, it must be cleaned before operation.
Check whether each bolt is loose or broken by turning the roller screen by hand.
Check whether the bearing housing and transmission are well lubricated, whether the oil level is moderate, and whether the protective cover is in good condition.
Check whether the transmission gear is well lubricated.
run
The drum screen must be started without load.
After starting, it is necessary to observe whether the discharge is normal.
The operator should inspect the equipment once an hour to check the particle size of the discharged material and whether there is any leakage and dust.
Check the temperature rise of the motor and transmission parts and see if there is abnormal sound.
Check whether the inlet and outlet are blocked and deal with it in time if any. Downtime
Before each stop, it must be confirmed that all the materials in the drum are screened before stopping.
Check the whole equipment after shutdown, and deal with any abnormity immediately.
Do well in equipment and environmental hygiene, fill in operating records, and do well in shift work.
4 drum screen maintenance procedures
Daily maintenance of equipment (operator responsible)
Routine inspection: check the equipment every two hours, and make operation records carefully.Content of patrol inspection:
A) Strictly implement the operating rules and prohibit overload operation;
B) It is advisable to check that the bearing temperature is generally 35℃ higher than the ambient temperature. The maximum temperature of rolling bearing and sliding bearing should not exceed 75℃ and 70℃ respectively, and check the motor temperature;
C) Check the oil level and temperature rise of the reducer (inside the upper and lower line of the oil standard);
D) Check the lubrication of transmission gear teeth;
E) Check whether the column pin of the elastic coupling has been extruded or damaged;
F) Check whether the rolling screen screen is normal and whether the screen body is leaking.
4.1.2 lubrication of equipment :(operators are responsible for it)
A) Check the lubricating position and lubricating oil level of the equipment on each shift, and lubricate the equipment according to the requirements of the lubrication table of the equipment;
B) The trommel screen lubricating grease must conform to the prescribed grades, and when the substitute oil is used, its performance shall not be lower than the technical performance of the prescribed grease, which shall be approved by the construction and maintenance center of the project;
C) Grease shall be kept clean and in special containers, and shall not be stored in open air.The temperature of the storage place shall not exceed the storage temperature stipulated by the lubricating oil.Do not use unqualified or deteriorated lubricating oil.
D) When oil leakage or oil leakage is found, the cause shall be found out in time, and the maintenance personnel shall be notified immediately for elimination. Leakage or oil leakage shall be prohibited;
E) Except for refueling, oil changing and cleaning of the bearing box, the bearing box shall be in a closed state to prevent dust, acid and water from falling into it;
F) The nozzle must be checked and cleaned before filling. If the oil hole is blocked, it shall be dealt with immediately. If it cannot be handled, a timely report shall be made.
Lubrication part Main drive reducer motor bearing grease Brand N220 medium load gear oil 3# Lithium base grease adding cycle Oil amount per shift oil tank timely refuelling 1/26 month of bearing box volume grease filling closed consumption According to oil standard oil changing cycle 6 month lubrication oil ring/splash
Main bearing size gear bearing wheel and wheel belt bearing pinion bearing cleaner bearing reducer
Machine # 3 Lithium base grease mechanical oil # 3 Lithium base grease # 3 Lithium base grease # N220 medium load gear
Oil for 3 consecutive months, 3 months, 3 months, 3 months, each shift of the fuel amount of oil tank timely refueling
Oil film formed on the surface of 1/2 of the bearing box volume 1/2 of the bearing box volume According to the oil standard 1/2
3. Cleaning contents :(responsible for the production team)
A) Clean up the motor, reducer and all platform materials in each shift;
B) The organism must be kept clean and tidy to eliminate running, leakage, dripping and leakage in a timely manner;
C) Clean the screen regularly for scaling and foreign matter;
D) Periodically clean the scaling on the box body and hopper.
Equipment cleaning :(chartering personnel)
A) Clean the equipment at least twice a week;
B) All parts of the equipment shall be cleaned to keep the appearance of the equipment clean, free from dust, oil and dirt;
C) It is strictly prohibited to wash the bearing box and all parts of the motor with water or coolant or directly wipe the electrical components and cabinets, and it is not allowed to blow the electrical components or cabinets directly with compressed air.
Regular maintenance :(maintenance personnel)
The shift shall check the equipment according to the circuit maintenance rules and make records.
Check the elastic coupling for extrusion or damage.
Check whether the motor is running normally.Check the running vibration and sound of the reducer.
Check the temperature rise of main bearing before and after.
Check whether the sound of rolling screen is normal and whether there is leakage of screen mesh.
Check whether the roller screen coupling and gear cover are in good condition and firm.
Replace and record the lubricating oil of the roller screen according to the lubrication requirements.
Check whether all kinds of safety protection equipment is reliable.
Check the motor winding, phase insulation and phase short circuit every month.
Stop the car immediately under any of the following circumstances
Reducer, oil leakage serious, lack of lubricating oil.
The temperature of motor and reducer rises sharply.
The load suddenly exceeded its normal value.
Mechanical noise is abnormal.
Abnormal in electric motor or electrical equipment.
The reason judgment and elimination method of common faults of roller screen are shown in Table 2.
Common faults of roller screen and abnormal current in dealing with faults
The cause of the problem
Gear wear bottom support bearing wear mesh scale uneven main bearing damage
Sound
Bad gear engagement
The bolts of the device are loose and the rotary support is deformed;
Processing method
Check gear replacement bearing cleaning scaling replacement bearing alignment or replacement stop repair
Supporting wheel bearing damage internal support falling off main bearing damage
The reducer has high temperature
There are large particle products in the finished products
Oil level too high or too low oil seal damage screen mesh damage
There is a gap between the feed box and the screen
Replacement inspection resumption replacement oil discharge or replacement oil disassembly replacement screen
Replace or thicken the seal strip
Maintenance rules for roller screen
The maintenance cycle can be adjusted appropriately according to the status test results and equipment operation status
Minor repair of maintenance contents:
A) Check and tighten bolts of transmission parts;
B) Repair and repair the leaking part of the screen mesh;
C) Inspect and repair the damage of fixing bolts of screen mesh;Check or replace the lubricating oil;
D) Check and dredge the feeding pipeline.
Repair:
A) Including minor repairs;
B) Check the main bearing and grease supplement;
C) Replace the screen mesh;
D) Check and replace the main bearing;
E) Adjust the clearance of large and small gears;
F) Check the wear condition of the screen vibrating belt, repair or replace it;
G) Check and replace pinion and roller bearing;
H) Check and replace the sieve shaker bearing;
I) Check and maintain or repair the motor and reducer, and correct the coaxiality.
Overhaul:
A) Including all the contents of the medium repair;
B) Calibration and welding of drum and sieve feeding end barrel;
C) Inspect and repair the sieve body support pipe rack;
D) Inspect, repair or replace gears;
E) Reducer disintegration inspection;
F) Inspection and treatment of equipment foundation;
G) Carry out electrical overhaul;
H) Equipment anticorrosive paint.
Maintenance methods and quality standards
Preparation before maintenance:
A) Check the operation and technical status of the equipment and test records, analyze the cause and location of the failure, and make the system
Formulate a detailed overhaul plan;
B) Familiar with assembly drawings and technical data;
C) Complete work, quantity, fixture and spreader required for overhaul;
D) Check the storage of appropriate spare parts, and review the size of spare parts as required;
E) After completing the processing of power cut, material discharge and replacement according to the regulations, the construction can only be carried out after the maintenance conditions are met and the maintenance work ticket and safety permit are obtained;
F) Conduct hazard identification and risk assessment, environmental factor identification and impact assessment during the maintenance process, and handle relevant tickets. Disassembly and inspection:
A) Remove the coupling and check the alignment of the coupling;
B) Remove the reduction gear and check the wear and lubrication condition of the gear;
C) Remove the bearing pedestal of the supporting wheel and check the wear and lubrication of the bearing;
D) Remove the pinion bearing and inspect the wear of pinion and bearing;
E) Remove the main bearing seat and inspect the wear of the main bearing and spindle;
F) Remove the screen and check whether the weld seams of the barrel and the supporting parts are cracked or detached.
G) Check the force and contact of the supporting wheel device to see if there is any wear of positive and negative s8;
H) Check whether the foundation stiffness is sufficient.
Safety precautions for maintenance:
A) Prior to equipment overhaul, the equipment must be handed over strictly (including cutting off power supply, cleaning materials, hanging warning boards, "ignition permit", etc.);
B) Maintenance tools and parts shall not be placed on the rotary parts, especially the supporting wheel;
C) When the maintenance personnel are working inside the equipment, they shall be supervised by a special person;
D) In case of hot work, procedures for hot work must be handled in accordance with regulations.5.2.4 Overhaul quality standard reducer:
The maintenance method and quality standard of reduction gear shall be implemented according to the Company's maintenance and maintenance Regulations for gear reduction Gear and Regulations for cycloid needle wheel reduction gear.5.2.4.2 shaft
A) The various dimensions, shape and position tolerances and surface roughness of the shaft can meet the technical requirements after repair. If there is bending, the mechanical pressure method can be straighter;
B) If the shaft neck part is too worn out, it can be repaired by setting, surfacing, electroplating and other methods.The thickness of insert sleeve is generally 10.00±2.00mm;Shaft deformation should be prevented during surfacing repair.The thickness of electroplating generally does not exceed 0.30mm;
C) Double-groove wear can be amplified to one level according to the actual situation, or the chain groove can be re-opened at 180° of the original chain groove.Big gear ring:
A) The tooth distance at the interface of large toothed ring shall not be greater than 0.5% (m is the module of toothed ring);
B) The roundness deviation of the large tooth ring shall not be greater than 0.04d (d is the dividing circle diameter of the tooth ring);
C) Adjust the tooth ring so that the deviation between the tooth ring and the lateral center line of the adjacent roller ring is no more than 3mm;
D) The circular runout tolerance of large tooth ring is 1.5mm;The runout tolerance of the end face circle is 1mm;
E) The thickness of the gear with large tooth ring is worn by 30%, or the flange has irreparable damage, it is necessary to replace the large tooth ring.The small gear:
A) The bevel of the pinion and transmission base shall be the same as that of the supporting wheel base;
B) With the large tooth ring as the reference, the position tolerance of the pinion is ±2mm, and the deviation of the slope should not be greater than 0.05mm/m;
C) The tooth surface contact spot of gears of both size and size shall be not less than 40% along the tooth height and not less than 50% along the tooth length;D) The coaxiality tolerance of the low-speed shaft and pinion shaft of the main reducer is 0.2mm. The allowable deviation of the horizontal and axial slope of the reducer shall not be greater than ±0.05mm;
E) Pinion has 30% wear in thickness or irreparable damage in flange, which shall be replaced.5.2.4.5 coupling
A) Alignment requirements for elastic bushing column elimination couplings
Coupling outer diameter 71-106130-190224-250315-400
End clearance
Radial clearance & LT;0.04 & lt;0.05 & lt;0.05 & lt;0.08
Axial clearance & LT;0.2/1000 & lt;0.2/1000 & lt;0.2/1000 & lt;0.2/1000
B) Allowable deviation of bolt hole center distance of adjacent quantity of coupling is ±1.0mm;C) The shaft hole of the coupling and the shaft journal shall be matched with H7/ JS6.5.2.4.6 cylinder:
A) The roundness of the cylinder (the difference between the maximum diameter and the minimum diameter on the same section) shall not be greater than 0.20%D;
B) Check the circumference of each cylinder segment. The circumference of the two butt joints should be the same, and the deviation should not be greater than 0.20%D and the maximum should not be greater than 6mm;
C) There shall be no local deformation of the cylinder, especially at the interface. Cold working method or heat addition can be adopted
.
The repair shall be carried out in the working method with no more than two heating times.
Supporting wheel bearing set:
A) The transverse center line of the rolling roller bearing group coincides with the transverse center line of the base, and the deviation shall not be greater than ±0.5mm;
B) The height difference between the two adjacent supporting wheels shall not be greater than 0.5mm;
C) All supporting wheels are located on the parallel inclined plane, and the deviation of the supporting wheels shall not be greater than 0.05mm/m;
D) The supporting wheel shaft journal diameter is reduced by 20%, or the thickness of the supporting wheel rim is reduced by 25%, the surface of the supporting wheel rim is worn into conical shape, polygonal, and partial through-through cracks occur, which need to be repaired and replaced.
Bearing:
A) Special tools shall be used to disassemble and install the rolling bearing, and direct tapping is strictly prohibited;
B) The rolling bearings shall be inspected and replaced if any of the following conditions are found:
1. Pitting, rust and crack on raceway, rolling body and cage of inner and outer rings of bearing;
2. There is noise when the bearing is rotating, or the roller is too loose.
C) After the bearing is mounted on the journal, the end face of the inner ring must be close to the shaft shoulder or positioning ring. It shall be inspected with a 0.05mm feeler and shall not pass;
D) The coordination between the bearing inner ring and the shaft and between the outer ring and the bearing seat shall be selected according to Table 5;
Table 5 Bearing fitting tolerances
Inner ring and shaft fit K6, JS6M6, K6
Coordination of outer ring and bearing seat J7, H7J7, H7
Centripetal ball bearing and centripetal thrust bearing thrust roller bearing
E) The surface roughness of the hole matched with the outer ring of the rolling bearing is Ra3.2;
F) Interference fit bearings can be assembled by heating in oil bath, and the oil temperature shall not exceed 120℃;
G) Tapered roller bearings shall be provided with sufficient clearance according to the axial clearance provided in the standard;
H) The rolling bearing shall be free from defects such as damage, rust, pitting and deformation.
The installation of the screen should start from the end of the feed, according to the installation requirements, the screws should be equally tight, not loose.
Base:
A) Use a ruler to check whether the upper machining surface of each base is flat and straight, and whether the four corners are warped. If there is any deformation, it must be eliminated;
B) The center distance and height of each base shall meet the requirements. The deviation of longitudinal center line shall not be greater than ±0.5mm, the deviation of transverse center distance of supporting device foundation at adjacent ends shall not be greater than ±1.5mm, the allowable deviation of elevation of two bases shall be 0.5mm, and the allowable deviation of machining surface slope of the base shall be 0.05mm/m.
Test and acceptance procedures for roller screen
Preparation before the test run
Confirm that all maintenance work has been completed, maintenance records are complete and maintenance quality is in accordance with regulations.
Clean and scrub the work site and equipment, and make and approve the test plan.6.1.3 Check whether all linkage, control, safety and other devices meet the technical requirements.6.1.4 Drive the slow speed device to turn the car, and the test run can be carried out only after there is no abnormal phenomenon in one rotation.
.
The lubricating oil of specified grade shall be filled at each lubricating position.
commissioning
1. First, the no-load test shall be conducted for 2 hours, and then, after passing the test, the load test shall be conducted for 4 hours.
2. Lotus Test:
A) Start each lubrication system first, and then start the main drive motor after all of them have been put into normal working condition;
B) Check that the cylinder runs smoothly without any friction, collision or violent vibration;
C) The roller ring is in good contact with the supporting wheel, and a lubricating film is formed;
D) The large gear ring is in good meshing condition with the pinion;
E) During operation, the temperature rise of the bearing and the oil tank shall not exceed 40℃ and 35℃;
F) The connecting parts shall be safe and firm, and the connecting bolts shall not become loose.
3 load test:
A) After confirming that there is no abnormal phenomenon in the empty load operation, the load test operation can be carried out, and the continuous load test operation shall not be less than 24 hours;
B) Check the feeding condition, and see if there is any phenomenon of material blocking or returning;
C) Check whether the cylinder is running smoothly;
D) Check the lubrication state between the roller and the supporting roller, the retaining roller, the big gear and the pinion to see whether an oil film is formed;
E) Check whether all fasteners are loose.
Acceptance and standards
The trommel screen After continuous load operation for 24h, all the indexes meet the design requirements or meet the production needs, then the handover procedures can be handled according to the prescribed procedures and delivered to production for use.
Maintenance records are complete and accurate.
The acceptance standard is for the equipment to be in good condition.