第十章  设备的检修

Chapter 10 Equipment Maintenance

一 、扭矩支承中零部件更换

1. Replacement of torque support parts

1 、蝶形弹簧的更换（若有蝶形弹簧装置）

1. Replacement of butterfly spring (if there is a butterfly spring device)

由于蝶形弹簧在工作中不断吸收传动系统中较大的冲击负荷 ，因而有可能使其因疲劳而产生塑性变形或断裂 。需要更换时 ，请按如下程序进行 。

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）拆下连杆机构下端的铰链 ；

1) Remove the hinge at the lower end of the linkage mechanism;

2）拆下蝶形弹簧导杆 ；

2) Remove the butterfly spring guide rod;

3）更换蝶形弹簧 ；

3) Replace the butterfly spring;

4）重新调整其预紧垫片 ；

4) Readjust its pre-tightening gasket;

5）装好两个下铰链 。

5) Install the two lower hinges.

2 、关节轴承及轴套的更换

2. Replacement of joint bearings and sleeves

1）拆下两个下铰链 ，抽出销轴 ，即可更换两个下铰链的关节轴承和轴套 ；

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）拆下蝶形弹簧的导杆 ；

2) Remove the guide rod of the butterfly spring;

3）拆卸两个上铰链 ，更换两个上铰链的关节轴承和轴套 。

3) Remove the two upper hinges and replace the joint bearings and sleeves of the two upper hinges.

二 、万向节传动轴及行星减速器零 、部件的维修与更换

2. Repair and replacement of universal joint drive shaft and planetary reducer parts and components

1、万向节传动轴的更换

1. Replacement of universal joint drive shaft

1）松开主电动机的地脚螺栓 ；

1) Loosen the anchor bolts of the main motor;

2）拆卸主电机与万向传动轴联接法兰的螺栓 ；

2) Remove the bolts of the connecting flange between the main motor and the universal joint shaft;

3）将主电动机沿轴线向后退15mm左右 ，使联接法兰的端面键脱开 ；

3) Move the main motor back about 15mm along the axis to disengage the end key of the connecting flange;

4）拆下万向节传动轴与减速器输入轴联接法兰的螺栓 ，即可拆下万向节传动轴 ；

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）安装新的万向节传动轴 。

5) Install a new universal joint drive shaft.

2 、行星减速器的检修

2. Overhaul of planetary reducer

1) 按上述程拆下万向节传动轴;

1) Remove the universal joint drive shaft according to the above procedure;

2) 松开缩套联轴器的缩紧螺栓;

2) Loosen the shrink bolts of the shrink sleeve coupling;

3) 按前述程序拆下扭矩支承装置 ；

3) Remove the torque support device according to the aforementioned procedure;

4）用吊车吊好减速器的吊钩 ，缓慢向外抽出减速器的输出空心轴 ；

4) Lift the hook of the reducer with a crane, and slowly pull out the output hollow shaft of the reducer;

5）在拆卸时应注意防此缩套联轴器滑落 ，以避免造成人员 ，设备损伤 ；

5) When disassembling, pay attention to prevent this shrinkable coupling from sliding down to avoid personnel and equipment damage;

6）重新安装检修好的减速器 。

6) Reinstall the repaired reducer.

三 、主轴承及“J”型密封圈更换

3. Replacement of main bearing and "J" seal ring

拆除轴承 ，必须首先拆除机架上横梁 ，然后才能吊出轴承 ，拆卸主轴承座及密封圈 。

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.

在拆卸旧轴承和更换新轴承时 ，要在干燥 、无灰尘的地方进行 ，必须防此灰尘和水气进入轴承密封腔内 。为了正确拆卸旧轴承和密封圈 ，更换新轴承和密封圈 ，必须按以下步骤进行 ：

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 、准备工作

1. Preparation

1）将液压系统卸压 ；

1) Relieve the pressure of the hydraulic system;

2）拆除传动系统 、进料系统 、辊罩及上横梁 ；

2) Remove the driving system, feeding system, roller cover and upper beam;

3）拆除润滑系统软管 、位移传感器及端面热电阻 ；

3) Remove the lubrication system hose, displacement sensor and end surface thermal resistance;

4）拆下液压缸与移动辊轴承座联接的球面座；

4) Remove the spherical seat connecting the hydraulic cylinder and the moving roller bearing seat;

5）轴系可由上部吊起放置检修位置 ，也可以水平吊起放置检修位置 ，但此时应先将无液压装置的立柱子拆掉 ，由此端水平吊出机架内腔 ；

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）拧松轴承座内外端盖的联接螺栓 。

6) Loosen the connecting bolts of the inner and outer end covers of the bearing seat.

2 、拆卸旧轴承及“J”形密封圈

2. Remove the old bearing and "J"-shaped sealing ring

1）拆下轴承轴向定位环 ；

1) Remove the bearing axial positioning ring;

2）安装好超高压油泵接管和接头 ；

2) install the ultra-high pressure oil pump connection pipe and joint;

3）摇动超高压手柄 ，将油脂打入轴承内圈与轴颈的结合面 ，用油膜来消除其金属间的接触 ，这样不需另加力就可使轴承卸下来 ，对轴承进行检修更换 ；

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）可将轴承座内侧的密封端盖拆下 ，对其“J”型密封圈进行更换 ；

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）将轴承从轴承座中拆出 ，即可更换新轴承 。

5) Remove the bearing from the bearing seat and replace it with the new bearing.

3 、安装新轴承及“J”形密封圈 。

3. Install new bearings and "J"-shaped sealing rings.

四 、进料装置易损件更换

4. Replacement of vulnerable parts of the feeding device

进料装置的易损件主要有调节闸板和衬板及耐磨块 。

The wearing parts of the feeding device mainly include the adjusting gate plate, the liner and the wear-resistant block.

1 、调节闸板的维修更换

1. Maintenance and replacement of adjusting gate plate

1）拆下调节闸板与连接座的销链接装置 ；

1) Remove the pin link device between the adjusting gate plate and the connecting seat;

2）拆下调节闸板与进料筒的销链接装置 ；

2) remove the pin link device between the adjusting gate plate and the feed barrel;

3）抽出闸板 ，进行检查更换 ；

3) Draw out the gate plate for inspection and replacement;

4）重新安装调节闸板 。

4) Reinstall the adjusting gate plate.

2 、侧挡板下端衬板的更换

2. Replacement of the bottom liner of the side baffle

1）拆掉进料装置上方的软联接 ，将下一节进料管托起 ，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）松开侧挡板弹性顶紧螺杆 ；

2) Loosen the elastic jacking screw of the side baffle;

3）抽出侧挡板 ，更换其衬板 ；

3) Pull out the side baffle and replace its liner;

4）重新装好侧挡板 ，并调整其位置 ，按要求顶紧弹性顶紧螺杆 。

4) Reinstall the side baffle, adjust its position, and tighten the elastic jack screw as required.

五 、液压系统零部件的更换

5. Replacement of hydraulic system components

液压管道的泄露或设备出现故障都能引起液压系统的损坏 。损坏的阀门 、泵 、蓄能器及油管不能修复 ，只能更换 。

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.

在液压系统所有零部件的检修更换前 ，必须首先清理周围的现场 ，打扫灰尘及杂物 。

Before overhauling and replacing all parts of the hydraulic system, the surrounding site must be cleaned up to remove dust and debris.

1 、管接头及连接法兰处有明显泄露 ，通过拧紧管接头或连接螺栓不起作用时则应拆卸检查其密封圈是否已经损坏 。若已损坏 ，则按下列程序更换 。

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）卸掉油压 ，拆下管接头或法兰螺栓 ；

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）装好新的密封圈 ，注意 ，必须检查密封圈是否对位 ；

3) Install new sealing ring, pay attention, you must check whether the sealing ring is aligned;

4）安装好管接头或法兰螺栓 。

4) Install pipe joints or flange bolts.

2 、液压缸的拆卸与检查

2. Disassembly and inspection of hydraulic cylinder

1）卸掉液压系统的高压 ；

1) Unload the high pressure of the hydraulic system;

2）拆下主机架上横梁 ；

2) Remove the upper beam of the main frame;

3）松开球面座与主轴承座联接的螺栓 ；

3) Loosen the bolts connecting the spherical seat and the main bearing seat;

4）缓慢拧松与立柱联接的四只螺栓 ，将主油缸缓慢吊出至拆卸位置 ；

4) Slowly loosen the four bolts connected with the column, and slowly lift the main cylinder to the disassembly position;

5）液压缸的拆卸与组装必须在空气干燥 、无粉尘的地方进行 ；

5) The disassembly and assembly of the hydraulic cylinder must be carried out in the dry and dust-free place;

6）拆下球面压头及前端盖 ；

6) Remove the spherical indenter and front end cover;

7）缓慢抽出活塞杆放置在干净的棉布上进行拆卸 、清洗、更换密封圈 ；

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）在安装所有密封圈和对其进行组装时 ，必须使所有的密封圈对位，安装时应缓慢 ，避免将密封圈挤伤 。

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 、磨辊表面耐磨层补焊

6. Repair welding of wear-resistant layer on the surface of grinding roller

当磨辊表面耐磨层发生破坏或过度磨损时需要进行补焊 。针对破损或磨损的情况可分为两种 ，其一是因为表面“一”字形花纹被打掉或磨辊局部磨损严重 ，则应进行局部补焊 。其二是磨辊表面整体磨损达到规定的厚度 ，则需要进行整体补焊。

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 、磨辊辊面的局部补焊

1. Partial repair welding of roller surface

当在检查磨辊辊面时 ，若发现某一处或几处的硬层过度磨损或脱落 ，可用局部补焊的方法进行补焊 。

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）先停机 ，将所需补焊部位转至观察门处 ；

1) Stop the machine first, and transfer the required repair welding part to the observation door;

2）用钢丝刷清除表面的物料和杂物 ，拖刷不掉 ，可用手砂轮进行打磨 ，直至补焊表面光滑为止 ；

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）按规定的补焊工艺 ，用特定的补焊焊条（由设备制造厂或设计单位提供）进行补焊 。

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 、磨辊辊面的整体补焊

2. Integral repair welding of grinding roller surface

当磨辊辊面的“一”字形花纹已基本磨光 ，而局部区域（占总面积50%）的耐磨层磨损高度达到7㎜时 ，应对整个磨辊辊面进行修复 、补焊 。

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）先停车 ，缓慢驱动磨辊 ，将其整个表面清洗干净 ；

1) Stop first, drive the grinding roller slowly, and clean its entire surface;

2）尽可能将其上的裂纹打磨掉 ；

2) Grind away the cracks as much as possible;

3）用加热工具对整个磨辊进行预热 ，注意加热要均匀 ，以30℃/h的温升速度加热至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）在补焊前 ，用来进行补焊的焊条必须在250℃的温度下烘干约2小时 ；

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）补焊时电焊机的地线必须直接搭在磨辊上，否则可能烧坏主轴承 ，另外焊机电流不宜过大 ；

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）按规定的补焊工艺 ，用特定的补焊焊条对耐磨层进行堆焊 ，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）按规定的工艺，用特定的焊条对“一”字形花纹进行重新堆焊 ；

7) Re-surfacing the "one" pattern with the specific welding rod according to the prescribed process;

8）若辊面局部区域耐磨层高度超过10㎜以上 ，过渡层因磨损需要补焊时,应与设备厂家联系,进行修复;

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)所有补焊材料及工艺均应由设备厂家提供和指导 。

9) All repair welding materials and processes should be provided and guided by the equipment manufacturer.

七 、磨辊辊面耐磨层厚度检测方法

7. Detection method of the thickness of the wear-resistant layer of the roller surface

辊压机磨辊由轴身,过渡层,耐磨层及“一”字形花纹所组成 ，其材料 、化学成份及金相组织均不相同。其中轴身为中碳钢锻件 ，其余各层均是堆焊上的 。耐磨层及“一”字形花纹构成磨辊面强度的抗磨损层 ，直接与物料接触 ，过渡层的作用是用以联接轴身与耐磨层 ，解决轴身的可焊性 ，它与轴身同样不具备耐磨性能 。

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.

在磨辊工作中 ，只能“一”字形花纹及耐磨层可以参与磨损 ，而过滤层及磨辊身是绝对不能让其直接与高压下的物料相接触 ，否则将会使这些材料及零件发生极度磨损而失效 。因此 ，在磨辊整个工作周期中必须定期 、严格检查耐磨层的实际高度 ，防此因耐磨层过渡磨损损伤过渡层及轴身 。

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.

磨辊辊面的磨损可分为两种情况 ：其一是整个耐磨层均匀磨损 ，各个方向上磨损量相差不大 ，其二是因为磨辊耐磨层上某一点或一块堆焊合金剥落 ，造成局部磨损 。两种形式均可使耐磨层失效 。为防此其发生 ，必须在对耐磨层作定期厚度检测的同时 ，还应经常观察耐磨层有无剥落 ，并及时检测其深度 ，以便修复 。

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.

对磨辊耐磨层所作的定期检测 ，称为标准检测 。在新辊层开始使用的前三个月中 ，每15天检测一次 ；在三个月后每星期检测一次 。

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.

对磨辊剥落点或剥落块的检测 。称为特殊检测 ，从磨辊开始工作之日起就应保证每天对辊面进行一次观察（可不必停机） ，发现剥落点或块 ，应立即停机车检测其深度 ，确定是否立即修复 。

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.

具体耐磨层高度检测方法如下 ：

The specific method for detecting the height of the wear layer is as follows:

1）停机 ，将辊罩上观察门打开 ；

1) Stop the machine and open the observation door on the roller cover;

2）将辊压机检测圆柱段圆周Ф1400mm表面清洗干净 ；

2) Clean the surface of the cylindrical section of the roller press with circumference of 1400mm;

3）以Ф1400mm 辊段的圆弧表面为基准 ，将检测仪的：“V”形块卡于其上 ，前后滑动几次 ，确信在其接触面上无异物 ；

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）用深度尺以检测仪的基准梁（下侧）为基准 ，检测磨辊耐磨层距基准梁的高度 ，并作记录 ；

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）标准检测时 ，深度尺应在基准梁上所刻位置上依次测量 。沿圆方向每30°检测一组 ，并将每次每组的数据记录在记录表上 ；

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）特殊检测时 ，必须准确测出耐磨层上最深点至基准梁的高度 。

6) During special inspection, the height from the deepest point on the wear-resistant layer to the reference beam must be accurately measured.