The dust ring of the hole is used to facilitate the entry of grease during lubrication.
4 Conclusion Through the small transformation of the passive sprocket, the lubrication problem of the bearing is solved, the unfavorable factors affecting the bearing life are eliminated, the service life of the component is prolonged, the effective utilization rate of the unit is improved, and the maintenance cost is saved. Overhaul labor intensity. Although the amount of transformation is small, it plays a big role.
Vibration Analysis of Y3.6mX8.5m Ball Mill Reducer Gear Early Failure Lu Fubao (Pingguo Aluminum Company Co., Ltd., Guangxi Pingguo 531400) Wheel Failure Signs and I丨I This paper analyzes the premature failure of the ball mill reducer gear. Vibration and spectrum characteristics, summarizing the countermeasures for the tooth mill of the ball mill reducer.
Reducer; fault symptom: vibration analysis; spectrum analysis 9TH132.41 I丨B article number 丨1刖目, first-phase engineering design An accidental gear tooth occurred in a Y3 year in September 1998, after the accident Tight: Repair, only one group during the period, continuous and stable. The hardness test of the equipment manufacturing believes that the speed reducer line is not parallel, resulting in the end of the tooth surface and the high surface roughness of the tooth root. Finally, the paper analyzes the gear of the reducer, and summarizes the two sets of ball mill and rod mill. The 6mX8. 5m ball mill in the production of 35 rounds of equipment accidents, because there is no emergency order, so that after a month and a half before the mill is running normally, serious Wei Association manufacturers for metallographic analysis of broken teeth and L in the installation and commissioning When the center of the large and small gears is in poor contact, the stress concentrates on one of the teeth, the cracks sprout here, and the early bending fatigue fracture occurs along the dangerous gear.
Vibration values ​​and spectrum symptoms before and after the tooth.
2 ball mill basic structure and parameters bookmark2 6mX8.5m ball mill transmission mechanism as shown, reducer model PT1000 1, reducer gear teeth: corpse 112 teeth, meshing frequency 347.2Hz, cylinder size gear teeth: corpse 21 teeth, Z2 = 224 teeth, meshing frequency 65.1Hz. The PM predictive maintenance software regularly monitors the state of the ball mill. The positions of each measuring point are as shown. Eight test sites are marked in the figure. The level of each part is collected (H) and vertical (V). ), axial (A) vibration data in three directions. Take the measuring point 4 (the axial direction of the input shaft of the reducer input shaft) and the measuring point 6 (the vertical direction of the output end of the reducer) as an example. The vibration values ​​between 1997 and 1998 are shown in Table 1: Table Date Measuring Point 4A Measuring Point 6A1997― From the data in the above table and the usual maintenance, the vibration of the reducer has the following characteristics: the vibration value has been relatively large, and the vibration value of the measuring point 4 (A) is the largest among all the measuring points, generally 5.0 ~ 7.0mm/s, compared with the international standard for rotational mechanical vibration diagnosis (ISO2372), is still much less than the limit of 11.2mm/s, which is within the allowable range.
(V) The vibration value is gradually increased, and the long-term rate is 53. The vibration value of the billiard mill reducer is significantly higher than that of another ball mill reducer of the same specification type, such as the same part and direction of the measuring point 4 (A), another The vibration value of the billiard mill (4) The inspection results show that when the bearing axial clearance of the measuring point 4 is adjusted to 0.16~0.40mm, the vibration value of the measuring point 4(A) can be reduced to below 4.5mm/s, but the bearing temperature Too high, up to 65 °C, in order to make the bearing temperature within the normal range (below 60 C), can only be adjusted to 0.7 ~ 1mm, thereby further increasing the eccentricity of the reducer gear.
In addition, there is a serious imbalance in the barrel of the ball mill, and the gears of the barrel are poorly meshed, causing serious wear on the tooth surface of the large gear of the cylinder. The vibration energy is transmitted to the reducer through the coupling, which is also a major factor causing the vibration of the reducer.
4 Spectrum analysis Taking the spectrum diagram of the output end of the output shaft of the reducer (measurement point 6) as an example, the variation of the spectrum before and after the repair of the teeth in September 1998 can be analyzed, and the fault sign of the gear reduction of the reducer can be obtained. . Before the end of May 1998, there was no obvious peak at the gear meshing frequency of the reducer gears at 1X and 2X, and the amplitudes were all below 0.5mm/s.
For the spectrum diagram of June 1998, the gear meshing frequency amplitude of the reducer has a peak at 0.78 mm/s2X but is not obvious, and it is estimated that there is slight pitting.
For the spectrum map of the gearbox in August 1998, the gear meshing frequency of the reducer reached 1.2mm/s, which is 53% longer than that of June. The amplitude of 2X is also larger than before, and the size of the cylinder is also the same. Gear meshing frequency (65. Significant peak value, at this time the gear of the reducer may have been severely pitting, and the gear meshing condition of the cylinder is gradually deteriorated.
For the spectrogram after the repair of the reducer in November 1998, there is no obvious peak at the meshing frequency of the reducer, but the peak of the 1X, 2X and 3X of the cylinder meshing frequency (65.1Hz) is still large, the size of the cylinder The case of poor gear meshing is not improved, so the vibration value of measuring point 4 (A) is still too large.
During the accident repair process, it was found that the output shaft gear of the reducer has two gear teeth broken, and all the teeth have 1/3 of the tooth surface pitting corrosion along the tooth length direction. It is proved that the gear center line of the reducer is not parallel, and there is obvious eccentric load phenomenon. The thickness of the tooth surface of the cylinder gear is about. 5mm. The output shaft gear of the reducer was replaced, and the large gear of the cylinder was not replaced. Therefore, the spectrum diagram before and after the repair does reflect the technical status and maintenance of the various stages of the reducer.
5 Conclusion Although the gear of the reducer has been eccentric since the start of production, the occurrence of gear fatigue fracture accident is a gradual development process, and there are obvious signs: (1) the vibration value of the reducer has been in operation for 3 years. More than 100% larger than the other billiard mill reducer, indicating that its technical condition is not good, and failed to find out the cause and deal with it, laying a hidden danger for the accident.
To this end, the following lessons should be learned: First, in the case of poor technical conditions of the reducer, try to find out the cause and eliminate hidden dangers in time; second, strengthen the analysis of the monitoring data, when the speed of the gearbox meshing frequency is 2 When the width is more than 50% within the month, the gear should be stopped to check the wear of the gears, so as to find the problem in time, order the corresponding spare parts, and avoid delaying the repair time of the equipment due to lack of spare parts. Third, when judging the technical condition of the mill, the vibration of the rotating machinery The international standard for diagnosis (ISO2372) can only be used as a standard. The comparison between devices of the same model and the same working condition should be selected as the basis for judgment.
The 4th China Nonferrous Metals Society Metallurgical Equipment Academic Committee Amusement Machinery Professional Committee Amusement Machine Design Work Symposium was held in Chengdu from April 24 to 26, 2000. The conference was jointly organized by the Amusement Park Professional Committee and the China Amusement Park Amusement Park Association. The purpose is to strengthen the exchanges and cooperation between designers in the amusement industry and promote the healthy and rapid development of the industry.
The meeting was presided over by Zhang Tao, director of the amusement machine professional committee. The vice presidents of the association, Lu Bing, Ma Jiewu, and Chen Chucai made important speeches. The committee members had a full discussion and extensive exchanges at the meeting, confirming the importance of design work. .
Looking back at the development of China's amusement industry, we are decades behind some developed countries. As far as the current situation is concerned, both the design level and the manufacturing level have a certain gap with others. Although some projects have approached or reached the international level of similar products, they still cannot be compared with the whole. Therefore, the task of the design worker is a long way to go, glory and arduous. In order to narrow and catch up with the world's advanced level, designers should take up their own responsibilities, because design is the leader, there is no design, and nothing else can be talked about. First of all, designers should continue to learn, improve their own quality, master the open ideas of advanced technology, and have an innovative spirit. The current design concept is not a single mechanical drawing in the past, but a whole design, including rich content, structural design and art design, etc., is a systematic project. The biggest requirement for the design of amusement machines is safety first. This is also the most basic requirement. It is necessary to establish safety awareness at all times. In terms of design methods, due to the development of computers, most of them have used computational calculations to design work, thereby reducing labor intensity and increasing productivity. Second, designers must expand their horizons, absorb advanced foreign technology, and rapidly improve their design level and quality of their work. Designers must work together to improve the overall design level. It is necessary to work with the production personnel to create high-quality products that meet the needs of society.
Huludao zinc plant equipment management is always unremitting. Huludao zinc plant is an old factory built during the Japanese-Puppet period. A large number of equipment has been old and aging, and serious leakage. If you do not strengthen equipment basic management, consciously maintain and maintain equipment, many equipment will Retirement, resulting in the loss of state-owned assets. Therefore, the factory put forward the slogan "equipment is quality, equipment is benefit". On this basis, they focused on the equipment management, on-site maintenance, lubrication management, red flag equipment competition, etc. of major smelters and workshops, and strengthened the assessment, training and job-based training activities for employees. The revised rules and assessment contents of the equipment evaluation have been revised three times, so that the operation has procedures, the movements are standardized, and the operation is guaranteed. In order to improve the integrity rate of equipment, the factory has firmly grasped the main line of equipment evaluation in the past year, insisted on upgrading the equipment evaluation of 10~15 days per month, and found 482 basic management problems to rectify hidden dangers on site. More than 1,200 cases, to avoid equipment accidents 6 times, and based on the equipment evaluation and evaluation criteria, 35 first-class units, 31 third-class units, the cumulative award amount of nearly 400,000 yuan. Equipment maintenance is a necessary means to maintain simple reproduction, and reducing maintenance costs is an important means to improve the economic efficiency of enterprises. In the year, 18 major overhaul projects were completed, with an overhaul cost of 24.95 million yuan; 60 intermediate repair projects with an overhaul cost of 44.49 million yuan; 404 minor repair projects with an overhaul cost of 7.5 million yuan. A total of 358 sets of equipment and spare parts were repaired throughout the year, which reduced the cost of the plant by 9.8 million yuan.
Huludao Zinc Factory adheres to the equipment maintenance and management focus on equipment management, and strengthens the equipment maintenance and management work with emphasis on upgrading equipment evaluation. It provides reliable guarantee for the factory to fully complete the production tasks in 1999, and has achieved good economic and social benefits. The equipment integrity rate was 98.2%, an increase of 1 percentage point over the previous year; the Grade A maintenance rate was 98.5%, an increase of 1.2 percentage points over the previous year; the control equipment red flag rate was 59%, an increase of 1.5 percentage points over the previous year; The furnace is 700 days, and the distillation tower is 652 days, which is to ensure stable production and improve economic efficiency.
(Zhao Shiquan)
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