360型對輥式壓塊機設計【說明書+CAD】
360型對輥式壓塊機設計【說明書+CAD】,說明書+CAD,360型對輥式壓塊機設計【說明書+CAD】,對于,輥式壓塊機,設計,說明書,仿單,cad
黃河科技學院本科畢業(yè)設計（論文）任務書
工 學院 機械 系 機械設計制造及其自動化 專業(yè) 08 級 3 班
學 號 080105659 學生 張國輝 指導教師 康紅偉
畢業(yè)設計（論文）題目
360對輥式壓塊機設計
畢業(yè)設計（論文）工作內容與基本要求（目標、任務、途徑、方法，應掌握的原始資料（數(shù)據(jù)）、參考資料（文獻）以及設計技術要求、注意事項等）（紙張不夠可加頁）
一、設計技術要求、原始資料（數(shù)據(jù)）、參考資料（文獻）
通過實習調研搜集資料，運用所學知識，借助CAXA或AutoCAD軟件，對整機主體結構、傳動形式、壓輥結構、帶傳動、齒輪進行設計與計算；對電機、減速器、聯(lián)軸器和軸承進行計算與選擇等。
要求設備結構緊湊，成塊率及質量高。
主要參數(shù)
加工對象：X煤粉，密度： 0.8g/cm3；成球形狀：（詳見附圖）；
壓輥直徑：360mm；壓輥寬度：400mm；對輥徑向線壓比6t/cm；輥面切向線壓力：4.5kN/cm；主軸轉速：10 rpm。
通過該畢業(yè)設計，使學生對大學四年里學到和未學到的知識進行綜合強化訓練，為其走向工作崗位奠定良好基礎。
二、設計目標與任務
1.查閱文獻資料12種以上，外文資料不少于兩種。寫出3000字以上文獻綜述，單獨裝訂成冊。
2.翻譯外文科技資料，不少于3000漢字，單獨裝訂成冊。
3.完成總體方案設計。
4. 選擇并論證設計傳動方案、整機結構草圖，完成主要零部件的強度校核計算等。
5.繪制裝配圖、主要零部件圖，折合零號圖紙兩張以上。
6.編寫摘要，英中文完全對照，中文不少于300字。
7.編寫設計說明書，不少于8000字符。
三、時間安排
1---3周 完成文獻綜述及英文資料翻譯。完成畢業(yè)實習。
4---9周 總體結構設計、計算，用CAXA或AutoCAD等軟件繪制總裝圖、部裝圖、典型零件圖。
10--11周 編寫設計說明書，進一步修改完善畢業(yè)設計，準備并完成畢業(yè)答辯稿。
12周 畢業(yè)答辯。
畢業(yè)設計（論文）時間： 2012 年 02 月 13 日至 2012 年 05 月 15 日
計 劃 答 辯 時 間： 2012 年 05 月 19 日
專業(yè)（教研室）審批意見：
審批人簽名：
日 期：
黃河科技學院畢業(yè)設計（文獻翻譯）
畢業(yè)設計
文獻翻譯
院（系）名稱
工學院機械系
專業(yè)名稱
機械設計制造及其自動化
學生姓名
張國輝
指導教師
康宏偉
2012年 03 月 8 日
壓塊機的結構組成及其應用前景
Bergendahl
一臺對輥成型機可以分成以下幾個部件,安全聯(lián)軸器，壓輥、軸承、用于支承壓輥的系統(tǒng)、給料系統(tǒng)、承壓支架、傳動系統(tǒng)、潤滑系統(tǒng)及液壓施壓系統(tǒng),機架。
圖3 是一臺典型的對輥成型機的水平剖面圖。兩個壓輥支承在可自動調準的球面滾柱軸承上, 而該軸承安裝在機架上。傳動齒輪通過安全聯(lián)軸器與齒輪減速器的輸人軸相連。通過齒輪減速器 電機速度被降到高壓輥的速度。在齒輪加速器中，兩個斜齒輪與兩個輸出軸同步。壓輥與帶有牙嵌式齒輪聯(lián)軸器的雙輸出軸齒輪減速器相連。壓輥的上表面（圖3中看不到）安裝著給料系統(tǒng)。沒有表示出來的還有提供給主要齒輪的潤滑系統(tǒng)裝置，支架上的齒輪箱的滑斷面，聯(lián)軸器以及使壓輥在一起的液壓系統(tǒng)的施壓裝置。
圖3 一個典型的機器輥部分
意見與反饋 參加有道翻譯用戶滿意度調查！
1. 安全聯(lián)軸器
成型機工作時, 物料( 粉煤) 不可避免地帶有小件鐵器等堅硬物進入輥輪嚙合區(qū)而阻止輥輪的轉動。在這種情況下, 為了確保成型機輥輪安全正常工作, 活動對輥組件必須具有一定距離的平移退讓功能, 并能在嚴重過載情況下, 聯(lián)軸器能脫開傳動。所以設計的聯(lián)軸器應具有適應這種退讓和安全保護的功能。本設計采用雙摩擦滾子式安全聯(lián)軸器, 它兼有“滾子” 摩擦離合器”和“的功能, 即利用滾子鏈傳動, 滿足成型機活動對輥組件軸承座較大“可移式”的退讓要求; 利用摩擦片傳動, 設置過載保護。本安全聯(lián)軸器還具有安裝方便、調整和維護簡便、工作可靠、壽命長、不受環(huán)境因素影響等特點。
圖4凸緣聯(lián)軸器
2. 壓輥
對輥成型機的最主要部分是壓輥本身。不同的設計方案均是可以的。首先, 壓輥由具有堅工作表面的堅固的鍛造件制成。表面堅硬可使之適于選擇各種表面結構用于生產高強度的餅。另外一種方式是,壓輥的輥芯可能是可更換的。這樣, 對輥本身易于進行水冷。這種輥環(huán)的工作表面通常被加工成淺的球窩。最新設計的成型機采用了這種方式。因為, 通常由于給料的溫度較高, 為了避免在物料表面發(fā)生“ 熔融” , 或當傳導給壓輥的溫度必須降下來以確保軸承低溫工作時, 必須使輥環(huán)的表面得到冷卻。
堅硬的壓輥的優(yōu)點是它可以取代簡單的機器部件。當壓輥表面嚴重磨損后, 可以在外徑規(guī)的范圍內對表面進行重新焊接 這樣可使設備始終保持高效運行。當然, 使用經過預處理的部件可以確保由于人料傳給的熱而不致于使壓輥過熱。使用內表面具有冷卻系統(tǒng)的熱套套筒（ 圖4） 將更經濟, 并要求使用更清潔的冷卻水。為了避免與輥芯接觸的處理不當?shù)乃畬狠伒母g, 用一個冷卻裝置使冷卻水系統(tǒng)封閉起來是合適的。大多數(shù)設備采用的是淺的長方形的可以搖動的鐵箱, 以便于空氣的排出和確保料餅具有高而均勻的密度和強度。根據(jù)圖 , 設備中選用齒輪聯(lián)軸器的優(yōu)點是易于脫開。在左邊, 在壓輥中心線的上邊所示的是聯(lián)軸器的一半已被移到左邊, 而壓輥被很容易的脫開的情景（也可看支架的剖視圖）。
圖4 具有熱套筒和冷卻系統(tǒng)的壓塊機壓輥的剖面圖
3.軸承（壓輥的支撐裝置）
在現(xiàn)代大型的壓塊機中, 壓輥安裝在高效而體積小的、能自校準的球面滾柱軸承上。這樣, 尤其在采用寬的壓輥時, 可移動的壓輥能隨給料的不均勻程度和給料的厚度（ 多少）自由調整。
為確保壓塊機更安全地工作, 正確選用適當?shù)妮S承是至關重要的。最重要的考慮因素包括軸承的設計以及密封、冷卻和潤滑。在軸承套內軸承的受力及分布必須為最優(yōu)。這就要求進行精確的計算。就象Koppern公司提供的最新型的壓塊機中, 軸承套的實際變形是采用有限元方法進行了詳細計算后得出的。進行這些計算的目的是為了使軸承套的變形量與軸承負荷的理論分布相一致（圖5）。
圖5能自校準的球面滾柱軸承負載分布圖
如果需要的話, 冷卻系統(tǒng)將確保軸承低溫工作,并能改善潤滑效果, 潤滑脂低溫工作還能確保軸承在軸承套內具有良好的密封性能。較高的負荷、低速運轉的軸承要求采用特殊潤滑脂, 它具有大約高達10-3/m2的粘度, 并加了一定的添加劑。
4. 給料系統(tǒng)
給料系統(tǒng)位于壓塊機支架正對著壓輥輥隙的上邊。在給料為細粒和 或需要較大產量以及一些其它的特殊原因, 簡單的重力給料滑槽可能不被采用, 在這些情況下, 螺旋給料是必須的。由于螺旋給料的特征是在螺距的中心及邊緣的給料量是不一樣的及螺距的幾何尺寸與輥隙面積的尺寸不同, 所采用的螺距的直徑受到限制。
為使壓輥機沿輥寬得到均勻的給料分布, 采用了多螺旋給料機。例如, 一臺生產能力為80~100t/h的壓塊機, 要求其單輥的工作寬度在于1000~1200mm之間, 這樣就要求安裝多螺旋給料機。螺旋成一定角度安裝在給料中心的兩邊, 在重力的作用下,物料進人給料機, 通過螺旋的螺距向下輸送, 迫使物料直接進人壓輥間的輥隙（ 圖6）
圖6 螺旋給料機的示意圖
特別是在細粒物料壓實過程中, 物料中空氣的排出對于壓塊機的高效工作起著重要的作用,例如, 在鉀鹽的壓塊中, 散料的密度大約為1g/cm3，，而料餅的密度大約為2 g/cm3,，如果產量為100t/h，那么大約有50m3/h的空氣被排出, 這么大量的空氣必須能通過散料中的孔隙排出。由于散料中孔隙隨壓實過程而變小,因此, 這種物料的壓塊將變得更困難。
在壓輥輥隙間壓實成塊，由于物料緊緊地填滿了壓輥，向下移動的物料中的空氣必須逆著物流向上溢出，如果不是這樣, 機器的顫動將導致機器設備的損。因此, 在設計時必須實現(xiàn)（1）允許空氣從給料器低部和輥面間排出：（2） 保證兩邊和壓輥的肩角的縫隙（ 圖7 ）。
圖7 壓塊機中空氣的溢出
研究表明, 如果輥寬不超過500 一600mm , 空氣僅僅能有效地從兩邊溢出, 這樣輥寬的極限也總是取決于散料的顆粒粒度分布或散料的透氣性。隨著輥寬的增大, 空氣可能被迫夾在輥隙間的物料中不能逸出而導致壓塊機負荷的進一步增加。為避免出現(xiàn)這一問題,對總寬度1000 一1200mm 的壓塊機, 其總的工作寬度將被分成2個500 一600mm 的兩部分,每一部分設置兩個螺旋。為了使空氣能夠溢出, 所有 臺螺旋是相同的( 見圖4 ) , 為了滿足各種不同給料速度和設備生產能力的要求, 螺旋的速度必須能被分別調整。
5.承壓支架
在設計壓塊機的承壓支架時, 必須使之能夠承受壓輥傳來的高壓和支承給料系統(tǒng), 通常采用雙支架。所謂的標準支架要求維修方便, 比如, 由于磨損或者檢修時必須將壓輥移開。不僅如此, 像Koppern公司又發(fā)展了一種“ 鉸接” 支架( 圖8 ) , 這種支架易于移開或更換壓輥。支架垂直部分的底端與水平部分的上面相連, 而垂直支架可以通過鉸接處放下, 在移開一部分壓輥附件和浮輥端的液壓箱, 以及斷開齒輪連軸器、潤滑脂的管路、冷卻水的連接系統(tǒng)之后, 壓輥可以被拉出到一個易于用橋式吊車吊起的地方。如果使用標準的支架, 更換一次壓輥可能化費一周的時間,而使用鉸接式支架, 可能只需要1 一2 個班即可。為了使維修工作更方便, 設計中采用了一個壓輥移開裝置和一個提升橫桿, 二者均與壓輥的軸承箱相連。
圖8 鉸鏈式支架的示意圖
6.驅動齒輪系
壓輥機的驅動齒輪系由兩個大型齒輪聯(lián)軸器, 包括同步斜齒輪在內的減速器齒輪, 和在電機與齒輪箱輸人軸間的一個安全聯(lián)軸器組成。通常, 安全聯(lián)軸器是一個能自動復位的機構, 它可以在通常工作時驅動轉矩的1.7~1.9倍范圍內調整。減速齒輪包括兩部分：減速器和同步轉矩分配齒輪, 一般情況下, 減速器的安全系數(shù)為 , 而同步轉矩分配齒輪的安全系數(shù)為2。大型齒輪減速器裝有油冷卻和過濾裝置, 以確保設備能連續(xù)運轉。
最主要的是, 同步齒輪和齒輪聯(lián)軸器的連接保證了提供給壓輥完全均勻的線速度。僅僅在沒有剪切力作用的情況下設備才能獲得較高的產量。
7. 潤滑
一個連續(xù)潤滑系統(tǒng)能提供給主要齒輪和浮輥的滑面一種連續(xù)的、可靠的特殊潤滑脂。為確保有效地工作, 潤滑系統(tǒng)被監(jiān)控。大型機器往往也總是具有對齒輪聯(lián)軸器的自動潤滑系統(tǒng), 這樣可使設備長期連續(xù)運轉而不必停車進行潤滑維修。
8. 液壓施壓系統(tǒng)
液壓施壓系統(tǒng)用于提供給液壓箱壓力，改壓力迫使輥向被壓實的物料和固定輥靠近。為滿足特殊的工作需要，壓力的高低和大小可自由調整。壓力的梯度隨間距的變化而升高, 通過改變液壓儲能器中氮的分壓可以在很大范圍內調整壓力的梯度。在物料被壓人壓輥的間隙時液壓系統(tǒng)也用作安全裝置。一臺電控系統(tǒng)監(jiān)控它的功能。
9. 機架
為了改進老式對輥成型機低速重載、剛性不足的毛病, 本設計采用分別由左、 上、右、 下四個端架組成的機架結構, 各端架間用銷軸連接,使機架制作簡便、拆裝方便, 而且機架的承載能力強, 滿足了大型對輥成型機的工作要求。
10. 應用前景
GXM 600/ 45 型對輥式工業(yè)型煤成型機的研制成功, 為工業(yè)型煤走向規(guī)模生產提供了可靠的設備, 本機可面向年產 10 萬 t 的工業(yè)型煤廠, 可作為加工鍋爐型煤和氣化型煤的主機。在我國利用粉煤生產型煤具有較高的節(jié)能、環(huán)保和社會效益, 并越來越受到人們的重視, 其產量也將不斷增加。由此可見, GXM 600/ 45 型對輥式工業(yè)型煤成型機也將具有廣闊的應用前景。為了改進老式對輥成型機低速重載、剛性不足的毛病, 本設計采用分別由左、 上、右、 下四個端架組成的機架結構, 各端架間用銷軸連接,使機架制作簡便、拆裝方便, 而且機架的承載能力強, 滿足了大型對輥成型機的工作要求。
Press block machine structure and its application prospect
Bergendahl
A roll forming machine can be divided into several parts, safe coupling ，pressure roller, bearings, used to support pressure roller system, feeding system, the pressure bracket, the transmission system, lubrication system and hydraulic put pressure on the system，frame.
Fig 2 Horizontal profile of a typical roll forming machine. Two pressure rollers supported on the automatic alignment of the spherical roller bearings, the bearings installed in the rack. The drive gear through the safety coupling with gear reducer input shaft. By the gear reducer motor speed is reduced to the speed of the pressure roller. Gear accelerator, the synchronization of the two helical gear and output shaft. Pressure roller and connected to double output shaft gear reducer with a the Jaw gear couplings. The pressure roller surface (Figure 3 can not see) the feeding system is installed. Did not indicate there to the main gear lubrication system device, the sliding section of bracket on the gearbox, coupling, and the pressure roller with hydraulic pressure from the device.
Fig3 Atypical of the machines to roller section
1. Safe coupling
Molding machine work, material (adding) do not avoid zone ，A small iron and hard thing into the roller gear area and prevent roller the rotation of the wheels. In this case, in order to ensure that the molding machine the roller security work, the activities of the component must have a certain distance .The concessions from the translation of the function, and in serious cases can overload, united the open transmission shaft can take off. So the coupling design should have comfortable should this concession and safety protection function. This design USES the double friction roller type safe coupling, it with "roller" friction clutch "and" function, namely, use rolling the son chain, meet the molding machine activities on roller bearing a component big "will move a type" concession request; Use of friction transmission, setting overload protection. This safe coupling also has easy installation, adjustment and convenient maintenance, reliable working, long service life, not affected by environmental factors influence characteristics.
Fig4 Flange coupling
2. Pressure roller
The most important part of the roll forming machine is the pressure roller itself. The different designs are possible. First of all, the pressure roller has Caine work the surface of solid forgings made??. The hard surface allows suitable to choose a variety of surface structures for the production of high strength of the cake. Another way, the pressure roller of the roller core may be replaced. In this way, the roll itself is easy to be water cooled. The work surface of the roll ring is usually processed into a shallow ball and socket. The latest design of the molding machine used in this way. Conduction to the pressure roller temperature must be down to ensure that the bearings at low temperatures the surface of the roller ring must be cooled, usually due to higher feed temperature, in order to avoid the occurrence in the material surface "melt".
Fig 3 Profile of a typical roll forming machine
The hard pressure roller advantage is that it can replace the simple machine parts. When the severe wear of the pressure roller surface, within the scope of the regulations in the outer diameter surface of the re-to welding . This will enable the device is always to maintain efficient operation. Of course, the use of pre-processed components can ensure that the people expected to pass the hot and would not make the pressure roller overheating. The inner surface of the heat of the cooling system sleeve (Figure 4) will be more economic use, and require the use of cleaner cooling water. In order to avoid improper handling of water in contact with the roller core corrosion, pressure roller and a cooling device cooling water system closure is appropriate. Most of the equipment used can shake a shallow rectangular metal box, with high and uniform density and strength in order to facilitate the discharge of air and ensure that the material bread. Advantages the figure, equipment selection of gear coupling is easy to disengage. Shown on the left, the upper pressure roller centerline is half of the coupling has been moved to the left, the pressure roller is easily torn off and the scene (to see cutaway view of stent).
Fig 4 Briquetting machine with thermal sleeve and the cooling system pressure roller profile
3. Bearings (pressure roller support device)
In modern large-scale briquetting machine, the pressure roller in the efficient and small size, self-calibrated spherical roller bearings. In this way, free to adjust especially in the wide pressure roller, pressure roller with removable feeding uneven and to the material thickness (how much).
To ensure that the briquetting machine work more safely, it is crucial to the correct selection of the appropriate bearing. The most important considerations include the design of bearings and seals, cooling and lubrication. Bearing comprising a bearing force and distribution must be optimal. This requires a precise calculation. Come like Koppern latest briquetting machine, the actual deformation of the bearing is carried out detailed calculations using finite element method. The purpose of these calculations is consistent with the deformation of the bearing sleeve and the theoretical distribution of bearing loads (Figure 5).
Fig 5 Self-calibration of spherical roller bearing load distribution map
If necessary, cooling systems will ensure that the bearings at low temperatures, and can improve lubrication grease at low temperatures but also to ensure that the bearings in the bearing kit has a good sealing performance. High load, low speed bearing using a special grease, it has about as high as 10-3/m2 viscosity, and the addition of certain additives.
4. Feeding system
Top of the feeding system in the bracket is facing the pressure briquetting machine roll gap. Feed fine and of or require large production, and some other special reason, a simple gravity feed chute may not be adopted in these cases, the screw feeder is a must. The diameter of the pitch characteristics of the screw feeder is in the center of the pitch and the edge of the feeding is not the same and the pitch of different geometric dimensions and the size of the roll gap area is restricted.
To make the pressure roller machine uniform feed distribution along the roll width, using a multi-screw feeder. For example, a production capacity of 80 100t / h briquetting machine, single roller width is between 1000 ~ 1200mm, this requires the installation of multi-screw feeder. Spiral into a certain angle installed on both sides of the feeding center, under the action of gravity, the material into the feeder, conveying spiral pitch down, forcing the material directly into the pressure nip between the roll (Figure 6)
Fig 6 Spiral to the schematic of the feeder
In particular, fine-grained material in the compaction process, the materials in the air discharge plays an important role for the efficient work of the briquetting machine, for example, in the briquetting of the potassium salt, the density of the bulk material is about as 1g/cm3material the density of the cake is about 2 g/cm3, if the output of 100t / h, then approximately 50m3 / h air is discharged, so a lot of air through the pores of the bulk compound excreted. As the bulk compound pores become smaller with the compaction process, therefore, a tablet of this material will become more difficult.
Pressure roll roll band to band compacted into blocks, because the material tightly fill the pressure roller, moving down the material in the air must be going against the logistics up the overflow, if not the quiver of the machine will result in the loss of machinery and equipment. Therefore, the design must implement (1) allow air discharged from the lower part of the feeder between the roll surface: (2) to ensure that the gap on both sides and the pressure roller shoulder angle (Figure 7).
Fig 7 The escape of air in the briquetting machine
Studies have shown that if roller width 600mm, over 500 air only from both sides of the overflow, this roller width limit always depends on the particle size distribution of bulk materials or the permeability of the bulk material. With the roll width increases, the air may be forced to clip roll band to band's material can not escape, resulting in a further increase in the briquetting machine load. To avoid this problem, briquetting machine of 1000 a total width of 1200mm, the total working width will be divided into two 500 a 600mm two parts, each part of the set up two spiral. In order to allow the air to overflow, all spiral is the same (see Figure 4), in order to meet the requirements of various feed speed and equipment production capacity, the speed of the screw must be adjusted separately.
5. Pressure stent
Pressure stent in the design of briquetting machine, you must make it able to withstand the pressure of the high-pressure roller coming and supporting feeding system, usually with double stent. The so-called standard stents require easy maintenance, for example, due to wear or maintenance must be the pressure roller is removed. Not only that, like knock Koppern company and the development of a "hinge" bracket (Figure 8), this bracket is easy to remove or replace pressure roller. Bracket connected to the bottom of the vertical part of the horizontal portion of the above, the vertical bracket can be hinged at the down, remove part of the pressure roller attachment and floating roller side of the hydraulic tank, and disconnect the gear couplings grease piping, after connection of the cooling water system, the pressure roller can be pulled out to an easy overhead crane to lift. If using a standard bracket, replacement of a pressure roller of the fee may a week, while the articulated bracket may only need two classes can be. In order to make maintenance work more convenient, the design of a pressure roller to remove the device and a lifting bar, both connected with the pressure roller bearing box.
Fig 8 Schematic of the articulated bracket
6. Drive gear
The pressure roller drive gear of the machine by two large gear couplings, including synchronized helical gears, gear reducer, and a secure coupling between the people axis in the motor and gearbox input. Typically, the safety coupling is an automatic reset of the institutions, it can drive torque range of 1.7 to 1.9 times usual hours of work adjustment. Reduction gear consists of two parts :: Reducers and synchronous torque distribution gear, under normal circumstances, the safety factor of the reducer for synchronous torque distribution gear safety factor of 2. The large gear reducer is equipped with oil cooling and filtering devices to ensure that the equipment of continuous operation.
The most important is the connection of the synchronization gears and gear couplings guarantee provided to the uniform linear velocity of the pressure roller. Equipment in order to obtain higher yields only in the case of no shear stress.
7. Lubricating
A continuous lubrication system provides continuous to the main gear and a sliding surface of the floating roller, reliable special grease. To ensure effective work, the lubrication system is monitored. Large machines tend to always have the automatic lubrication of the gear coupling system, it will give the device long-term continuous operation without having to stop for lubrication maintenance.
8.Hydraulic put pressure on the system
The hydraulic put pressure on the system used to provide to the hydraulic tank pressure to change the pressure on roller closer to the compaction of materials and fixed roller. To meet special needs, the level and size of the pressure can be adjusted freely. Pressure gradient with the change of the pitch increased, the pressure gradient can be adjusted in a wide range by changing the sub-nitrogen in the hydraulic accumulator pressure. Also used as safety devices in the hydraulic system when the material is pressure pressure roller gap. An electric control system to monitor its function.
9．Frame
In order to improve the speed of the old machine overloaded, and rigid he shortage problem, this design USES the from both left, up, right, with four The frame of a frame structure, each end frame with pin shaft link between, Make the convenient in assembling and disassembling, make simple, and the bearing can frame .Force is powerful, meet the large to roller machine work requirements.
17
收藏