The roller skin of the ball press is a cylindrical shape member with a ball and socket dug on the surface layer of the roller core of the ball press. For ball presses and other equipment, the roller skin is a key component and plays an important role. The life of the roller skin determines the life of the ball press and also determines the shape of the ball press.

Roller skin material

The material of the roller skin of the ball press is divided into 65 manganese, 9 chromium 2 molybdenum, high chromium alloy and so on. When pressing different materials, different ball press roller skins should be selected: 65 manganese material is more popular, belongs to steel castings, and has a lower cost. It is generally used on small-volume ball presses, such as coal powder ball presses. Can crush coal powder, coke powder, charcoal powder and other materials: 9 Cr 2 Mo, high chrome alloy ball press roller is a forged part, mainly used in medium and large-scale coal briquette presses with high output. , Iron powder, magnesia powder, laterite nickel ore, etc.

Selection of ball and socket size for roller compactor

According to the needs of different users, the roller skin of the ball press is mainly divided into different shapes such as goose egg shape, trapezoid, cuboid, stadium type and so on.

The size of the roller ball and socket of the ball pressing machine cannot be too small. If it is too small, the pressure of the whole machine cannot be reached, and it is also a fixed problem when holding the ball, and the small ball and socket are being manufactured It is also quite troublesome, and the production cost is much higher than normal, so the size of the roller skin ball socket cannot be too small; if the size of the roller skin ball socket is too large, it is quite convenient for production For users, it is also very convenient, but it is also a problem to put into use afterwards. In large cases, the hardness will definitely decrease, and the strength may not meet the requirements for use. Therefore, the size is not too large.

The shape and size of the ball sockets of different types of ball presses will vary depending on the materials in order to meet various requirements. For example, for dry powder ball presses, you need to choose flat ball sockets, and the ball sockets are not large and shallow. The main reason is that dry powder ball presses do not allow any stickiness when pressing raw materials. Mixtures, if deep and large ball sockets are used, the ball formation rate is not high. It is even difficult to shape.

For briquette ball presses, large ball sockets should be used as much as possible, and the ball sockets should be set in the shape of balls, so as long as the moisture content of the materials and the amount of binder are controlled, the finished product rate of the pressed balls is as high as 95% , And the ball strength is very good. If it doesn’t work, you can try to press the ball twice to ensure the ball formation rate and strength. Therefore, the style design of the roller skin of the ball press equipment should also refer to and follow other aspects.

According to the current ball press production practice, the size of the current roller skin goose egg-shaped ball socket is generally 10mm-7mm. As for the size of the other shapes of the ball and socket, it needs to be customized according to different requirements. The output of the ball press is also determined based on the size of the ball socket.

Briquetting machine spare parts

The ball press roller skin installation

There are four installation methods, and everyone can compare their ball presses to install the appropriate method.

1. Bolt fastening method, that is, the roller sleeve and the hub are designed with bolt holes and tightened with refined high-strength bolts. This method is convenient for the field disassembly of the roller sleeve. Machine applications.

2. The cone sleeve assembly method, that is, the roll sleeve or the hub is designed with a taper, and it is tightened by the middle cone sleeve. This form is conducive to the disassembly of the roller sleeve and is used in the low and medium pressure ball press.

3. The tight fit hot-loading method, that is, the roller sleeve with ball socket is heated and installed on the wheel hub. This assembly form has high processing accuracy and strict processing temperature control. It must be useful when replacing, and it is generally used in high-pressure ball presses. Powerful ball press.

4. Key connection assembly method: The shaft and the sleeve have key grooves. The shaft and the sleeve are connected by keys. Because the shaft has key grooves and threads, the diameter of the main shaft of the ball press equipment is slightly larger than the shaft diameter of the keyless assembly. .

The ball press roller skin disassembly

1. The power must be turned off, and the main switch can be turned on.

2. After the power is cut off, put a warning “under repair” in a conspicuous position.

3. First perform pressure relief treatment on the lubricating pump, pull the switch for the supply belt of the mine belt, clean up the pumice on the belt head, remove and remove the four major parts, such as the cutout cover, the large pot, the cover plate, and the fixed cone dust cover. . The crane needs to be commanded by people during the lifting process, and strictly observe the lifting operation regulations.

4. If the old lining board cannot be removed, you can use gas welding to cut and clean the inner surface of the rack.

How to prevent roller skin damage during ball forming

The pressure roller is the core component of the ore powder ball press. It directly contacts the material and uses strong pressure to press the raw material into a ball. If the ball press material contains high hardness impurities such as metals, the roller skin will be damaged. Ball press machine manufacturers suggest to install iron remover to solve this problem, it can remove all kinds of impurities contained in raw materials to ensure that the ball press molding process will not adversely affect the pressure roller.

The common problem of the roller skin installation

Tooth roller

1. Misalignment of the roller skin of the ball press

If there is a “dislocation” in the circumferential direction, we can have an adjustment disk at the passive gear, and use the adjustment disk to make the following adjustments: first loosen the circumferential bolt, then use a manual wrench to tighten the top wire, and then press the direction of the displacement and how much To determine the direction of the top wire and the number of buckles, tighten the circumferential bolt on the adjustment disk, and then insert the test board to test the misalignment and adjust.

If there is an axial misalignment, we can first loosen the cover of the bearing seat that needs to be adjusted, and then add or subtract gaskets on the bearing cover according to the amount of displacement, and then tighten the gland bolts.

2.There is abnormal noise after installation

There is a strange noise behind the roller skin and it is intermittent. In fact, this problem is very simple, mainly caused by irrational assembly.

The link between the main shaft of the ball press and the reducer is a coupling. Most of the swash plate couplings are used. During the assembly process, it is necessary to ensure that the three parts of the swash plate, the output shaft of the reducer, and the main shaft of the ball press are the same. On the center line, the deviation should not exceed 3mm, because many customers do not have spreaders on the site, and the machinery and equipment are heavy, so the ideal result was not achieved during the assembly process.

It is found that such problems are not resolved in time. Light will cause damage to the coupling, and heavy ones will break the reducer casing. Therefore, it must be resolved in time to avoid serious consequences. Abnormal sound will also occur when the reducer is short of oil. It is necessary to check the oil level of the reducer in time to avoid dry grinding.

Major advantages of mosaic roller skin

1. Easy to replace

When the roller skin wears to a certain extent, it needs to be replaced, and it can be replaced in only four hours. After the overall roller skin wear, it needs to be returned to the factory for repair. The period will take 14 days. Longer time, the neck of the owner of the card, there is no way to worry. The manufacturer’s repair method is to cut off the roller skin by gas cutting and remove the two bearing seats and bearings. It is easy to hurt the shaft during the disassembly process. At this time, the shaft must be ground with holes. It’s gone.

2. Long life

Because under the premise of the same material, the service life of the inlaid roller skin is 1.5 times that of the whole set. After the heat treatment of the inlaid roller skin is no longer used to heat the assembly with a fire source, but bolts and keys are used to firmly attach the wheel segment, and the entire roller skin needs to be heated to 180-220 degrees Celsius before it can be opened. Sleeve on the shaft, the hardness will be reduced by 8-10HRC during this process, the hardness will be shortened and the life will be shortened.

3. Low cost

Manufacturers who use the overall roll skin must reserve two sets of spare parts, otherwise the turnover will not open, and the inlaid roll skin can be replaced flexibly, whichever can not be used, which can be exchanged.

Ball cleaning machine roller cleaning method

1. After each pressing production of the ball press, the roll skin must be cleaned in real time to ensure that there is no residue in the ball socket of the roll skin. This can avoid the problem of difficult to clean up the material residue after a long time . Moreover, it can also ensure that the subsequent production will not be deformed or derolled due to the residue.

2. If the rollers cannot be demolded or the pellets are produced irregularly, then a series of adjustments to the roller skins are needed, because long-term production runs may cause the roller skins to be misaligned or offset. After the adjustment, observe whether the ball is regular. If it is still irregular, check other parts.

3. The maintenance work of the ball press roller skin should be cleaned and maintained every time and every day according to regulations. No matter what equipment, timely cleaning and maintenance are the prerequisites to ensure the normal operation of the equipment without failure. Only the maintenance of the guaranteed equipment can guarantee the life and operating quality of the equipment, and further progress to ensure the production of product failure.

The roller skin of the ball press is the core component of the ball press. The quality of the ball skin of the ball press determines the service life of the ball press directly. The hardness of the roller skin of the ball press is the most important parameter to measure the quality of the roller skin of the ball machine. The hardness of the roller skin depends on the alloy steel number selected and the final heat treatment process level.

The roller skin of the ball pressing machine is made into blanks according to the drawings of the roller skin, and then turned to make it clear on all sides. The next step is to sculpt the ball and socket on the circumference of the roller skin. Of course, the size and shape of the ball and socket need to be determined jointly according to the diameter of the roller skin and the material pressed. The last process is heat treatment, which is also the most critical one. In the case of the same raw material of the roll, the hardness of the roll is determined by the heat treatment.

Ball press roller type

Roller assembly

 

From the technical point of view, the roller skin can be divided into two types, casting and forging. The commonly used steel grade for casting roll skin is 65 manganese alloy, which has a relatively low cost, but the hardness of the roll skin is not too high, and it is not very wear-resistant. It is suitable for pressing delicate materials such as coal powder and clay. The commonly used steel number of forged roll skin is 92 Ming molybdenum, which has a high price and cost, but the hardness of the roll skin is relatively high, which can reach above HRC62, which is suitable for pressing rough materials such as iron powder and metal ore powder.

The shape of the material of the roller of the ball press machine is the significance of the purchase of the machine for the powder, and the roller skin will produce abraded parts in the production. For example, if the powder is doped with some high-hardness materials, it must be screened. If the roller skin is worn after pressing, it must be replaced.

The importance of the roller skin parts of the ball press is well known, and it is even more important. If problems occur in the production of the roller skin of the ball press, the results can be imagined. If the roller skin of the ball press takes a long time or is damaged, the customer must replace it in a timely manner to avoid that the products produced can not meet the predetermined conditions and cause waste of raw materials.

So from what aspects should the customer judge whether the roller skin is replaced?

(1) Use some professional testing instruments to carry out regular inspections, and the specific usage methods will have corresponding instructions.

(2) A comprehensive view based on personal experience.

(3) It is more direct to look at the effect of the ball.

Ball press roller replacement

The replacement of the roller skin of the ball press is mainly disassembly and installation, but in the replacement process, the corresponding removal and installation process must be mastered to achieve the safe and efficient replacement of the roller skin.

roller assembly

Disassembly

1. The power must be turned off, and the main switch can be turned on.

2. After the power is cut off, put a warning sign “under repair” in a conspicuous position.

3. First, perform pressure relief treatment on the lubricating pump, pull the switch for the supply belt of the mine belt, clean up the pumice on the belt head, and remove the four major parts, such as the guard of the feed port, the large pot, the cover plate, and the fixed cone dust cover. . During the hoisting process, the crane needs to be directed by a special person, and strictly observe the hoisting operation regulations.

4. If the old lining board cannot be removed, you can use gas welding to cut and clean the inner surface of the rack.

Installation

There are four installation methods, and everyone can compare their ball presses to install the appropriate method.

1. Bolt tightening method, that is, the roller sleeve and the hub are designed with bolt holes and tightened with refined high-strength bolts. This method is convenient for the on-site disassembly of the roller sleeve. Wet method, low-pressure ball press, kaolin ball Machine applications.

2. The cone sleeve assembly method, that is, the roll sleeve or the hub is designed with a taper, and it is tightened by the middle cone sleeve. This form is conducive to the disassembly of the roller sleeve and is used in the low and medium pressure ball press.

tooth roller

3. The tight fit hot-loading method, that is, the roller sleeve with ball socket is heated and installed on the wheel hub. This assembly form has high processing accuracy and strict processing temperature control. Special devices must be used when replacing, and it is generally used in high-pressure ball presses. Powerful ball press.

4. Key connection assembly method: The shaft and the sleeve have key grooves. The shaft and the sleeve are connected by keys. Because the shaft has key grooves and threads, the diameter of the main shaft of the ball press equipment is slightly larger than the shaft diameter of the keyless assembly. .

After all the operations are completed, the machine can be disconnected for trial operation. After the empty machine runs for a period of time, the materials can be added normally to start the operation. Remind everyone that the roll skin has been damaged for a long time or has to be replaced in a timely manner to avoid the production of products that do not meet the predetermined conditions, so as to cause waste of raw materials.

For various coal mine related industries and powder processing enterprises, the ball press can be said to be very familiar, and it should be very clear. The entire material forming production line can be collectively referred to as the ball press machine production line, because the core of the entire material forming the equipment is the ball press machine.

When using the ball press machine production line for material processing, the topic that cannot be avoided is the precautions for use, because correct use can ensure normal and efficient production. Below we summarize a few precautions for using the ball press production line for your reference.

Precautions for the use of ball press machine production line

Briquette machines

1.Familiar with the equipment and skilled use

Operators should be proficient in the structure, performance, and role of various components of the ball press equipment production line. Only by understanding the principle of the equipment, the structure and performance of various parts, can the ball press be used correctly and better, thereby avoiding unnecessary errors. , Resulting in dangerous situations such as equipment damage and safety accidents.

2.Ensure lubrication measures

For mechanical equipment, the interaction between components and parts, and parts to parts, is the basic principle of transmitting power to the equipment. If the transmission components such as bearings and gears cannot be properly lubricated, they may cause The transmission and work freezes, even if it is damaged during hard work, which affects the normal production. Therefore, it is necessary to lubricate according to the parts marked on the lubrication chart, while keeping the lubrication points clean.

3. Pay attention to check the production line and equipment

During the operation of the ball press equipment production line, pay attention to check that the bearing temperature of each part does not exceed 60 ° C, and check whether the bolts of each part are loose, whether there is abnormal noise in the transmission part, and whether there is any abnormal phenomenon in the equipment. If there are problems with equipment parts, you must stop work in time to maintain the equipment to prevent accidents.

4.Ensure cleanliness

A clean and tidy working environment is also one of the necessary environments to improve work efficiency. The ball press production line processes powdery materials, so it is normal to have dust at work, but after finishing the work, it is necessary to deal with the dust floating on the equipment in time. The dust prevents the inside of the equipment from entering the dust and wears out the equipment parts. In addition to the working area of ​​the ball press production line, it is also necessary to ensure the sanitation and cleanliness of other areas, so that employees have a good working environment.

5. Adhere to the “four determinations” principle

The operators of the ball press production line must abide by the “four set” principle, that is, set the project, set the personnel, set the time, and set the measures. The “four set” principle of safe production is the basic requirement for ensuring safe production and the basic management method. No matter how high the production output is, it is not as important as safe production.

The above are the precautions for the use of the ball press production line. In general, safe production is the basis of production. Not only the safety of equipment, but also the safety of personnel and product safety are very important.

As a molding equipment for pressing various materials, the ball press machine can meet the pressing needs of different industries. However, the selected roller skin does not match the material to be pressed, which can easily cause the wear of the ball skin of the ball press. The degree of wear caused by different hardness is also different, so the selection of the material of the roller skin of the ball press is very important. So what are the materials of roller skins on the market? Which one is more wear-resistant?

The materials of common roller skins are divided into cast spring steel, alloy steel, bearing steel, etc. For different materials, the roller skins are different, and they all have their own advantages.

Briquetting Machine Structure

Cast spring steel

Cast spring steel has high hardenability, surface decarburization tendency is smaller than silicon steel, and its comprehensive mechanical properties are better than carbon steel after heat treatment. It has very good fatigue strength, excellent elasticity, and good plasticity and hardness. At the same time, the low price makes it more popular, but it has overheat sensitivity and tempering brittleness, so it is usually used on small-volume ball presses, and can press soft materials such as coal powder, coke powder, and charcoal powder.

Alloy steel

This alloy steel undergoes strict processing, and its hardness can reach HRC58-62. It has high strength and abrasion resistance, at the same time has certain corrosion resistance, and is easy to detach the ball. This alloy steel roll skin is forged Hitting parts are mainly used on medium and large-scale coal briquette presses, which can compact ore powder, iron fine powder, magnesium oxide, laterite nickel ore, etc.

metal briquette machine

Bearing steel

Compared with alloy steel, bearing steel has higher hardness and wear resistance, but also has uniform hardness, high elastic limit, high contact fatigue strength, necessary toughness, certain hardenability, Corrosion resistance. And as a ball press forging roller skin, it is more wear-resistant than the casting type.

It is not difficult to see that although the cost of the cast roller skin is low and can be replaced frequently after wear, this non-wearable roller skin is only increasing the price of the ball press in disguise. The cost paid by the operator will only change with the use of time. It is gradually improved, and the forged rolls of chromium-molybdenum alloys are more wear-resistant. You only need to pay for one return. The forged rolls of bearing steel have higher performance than chrome-molybdenum alloys, which can meet the long-term Usage requirements.

High-pressure roller mills are widely used in major mines and related material crushing industries. They have the characteristics of large production capacity, fine output granularity, low unit energy consumption and low steel consumption. After years of research, it is found that the particle size of the high-pressure roller mill is not only related to the nature of the original ore, but also related to the operation and other factors.

First, roll surface pressure

It was found through experiments that by increasing the pressure on the roll surface of the high-pressure roller mill, the output particle size of the middle and side materials became finer, the particle size distribution of the middle material was more concentrated, and the particle size distribution of the side material was more uniform. The crushing effect of high-pressure roller mills on materials mainly depends on the pressure on the materials near the small distance between the two rollers. Usually, the specific pressure (the ratio of the total pressure provided by the hydraulic system to the diameter and width of the rollers) is used as a measure of the working pressure. Job parameters.

With the increase of the pressure on the roll surface, the uniformity coefficient of the middle material increases, the particle size distribution is more concentrated, the crushing ratio increases, the output particle size becomes finer, and the fine-grained part of the middle material after the crushing accounts for the majority; As the pressure increases, the uniformity coefficient of the edge material decreases, the particle size distribution becomes wider, the crushing ratio increases, and the discharge particle size becomes finer. The high-pressure roller mill edge material is closer to the conventional crushed product.

Use of roller mill

The fine-grained part of the crushed media is the majority. This is because the “size effect” of the mineral particles (the mechanical strength of the ore particles increases significantly with the decrease of the ore size) during the pulverization process. The fine-grained materials are more difficult to pulverize than the coarse-grained materials under the pressure of the roll surface, so that the fine-grained materials account for the majority.

The high-pressure roller mill side material is closer to the conventional crushed product, which is caused by the “edge effect” of the pressure roller during the crushing process. The lower roller surface pressure on the baffles at both ends of the pressure roller and the edge of the pressure roller makes the material easily slide relative to the edge of the pressure roller, reducing the crushing effect of the material layer, so that the crushing method of the material by the edge of the roller is closer to the conventional crushing method .

Second, the speed of the roller surface

Under the same roll surface pressure, when the roll surface speed is increased to a certain amount, the uniformity coefficient of the intermediate material increases, the particle size distribution is more concentrated, the crushing ratio increases, and the product particle size becomes finer, but it affects the uniformity coefficient of the side material and The change of the crushing ratio is not obvious; but when the speed of the roller surface is continuously increased, the change of the crushing ratio of the intermediate material is no longer obvious.

The appropriate speed is related to the surface characteristics of the roll, the hardness of the material, and the size of the ore feed. The speed of the roll surface directly affects the crushing capacity and the degree of wear on the roll surface, and it will affect the particle size characteristics of the product. Increasing the speed of the roller surface has little effect on the particle size characteristics of the discharge, and the unit energy consumption of the high-pressure roller mill has not changed significantly, but its processing capacity has been greatly enhanced. However, higher roller surface speed will wear the roller surface and bearings, which will affect the service life of the equipment.

High-Pressure Grinding Rolls

Third, the material moisture content

The raw ore produced on site often has a certain water content. With the change of the water content of the ore, the strength and viscosity of the ore change, which will affect the material characteristics of the crushing process. When the roller surface pressure and roller surface speed are constant, the ore moisture content increases, the uniformity coefficient of the middle material increases, and the particle size distribution is more concentrated; the crushing ratio of the side material increases, but the increase is not obvious, and the particle size distribution becomes wider.

It can be seen that the increase of the moisture content of the raw material has little effect on the particle size of the discharge. At the same time, the moisture content of the material at the production site of the high-pressure roller mill is generally between 3% and 5%, so in normal production, it will not affect The discharge has a greater impact.

In summary, in fact, most of the factors affecting the output particle size of the high-pressure roller mill are in the operation mode. When the appropriate roller surface pressure and roller surface speed are selected, the output particle size of the high-pressure roller mill can reach production. Demand, which requires the production personnel to have a considerable degree of familiarity with the raw ore materials and mechanical equipment, so for the actual operators, their professionalism is the key factor affecting the particle size of the high-pressure roller mill.

High-pressure roller mills are commonly used in the medium crushing, fine milling, and ultra-fine milling processes of various loose materials. Compared with other traditional crushers, they have the advantages of high productivity and low energy consumption. However, after a period of use, due to operating errors or inadequate maintenance work, high-pressure roller mills may operate abnormally. These failures are often seen in daily work, so how to deal with them to ensure the normal production of the equipment How about it?

metal briquette machine

First, the abnormal vibration of the high-pressure roller mill body

1. If the body of the high-pressure roller mill is experiencing abnormal vibrations, it is likely that the granularity of the material is not uniform, which leads to the imbalance of the squeeze force of the equipment. Therefore, the particle size of the material needs to be adjusted to make it as uniform as possible, so that The crushing force of the device is normal.

2. Another cause of abnormal vibration of the body may be caused by severe wear of the blade. When the blade is severely worn and the feeding amount is not large, it will cause the blade to be unable to scoop up the material, and sometimes there is no abnormal vibration caused when the roller squeezes the material. Generally, this situation can be periodically checked and replaced.

3. Sometimes the material is too hard, which will lead to abnormal start-up of the equipment. In severe cases, it may also cause deformation and wear of the grinding ring and the ring, which will aggravate vibration. In order to prevent this situation, in addition to no longer processing hard materials, it is necessary to periodically check and replace the grinding rollers, and be sure to remove the metal debris in the materials that will damage the rollers.

4. Another kind of vibration is caused by the high-pressure suspension shaft milling fan, which may be excessive powder accumulation on the blades, causing the blades to wear out, forming an unbalanced blade rotation, and causing abnormal vibrations. What we have to do is Remove the accumulated powder on the blade in time, and replace it in time if the blade wears.

5. When the equipment is used for a period of time, due to various internal vibrations or installation reasons, the anchor bolts may loose, causing abnormal vibration of the entire body. Therefore, pay attention to the tightness of the anchor bolts during routine maintenance. Loosen and tighten in time.

double-roller press

Second, the production of materials is abnormal

1. When the high-pressure roller mill is used for a long time, there will be no powder or less powder. One of the reasons for this situation is caused by the wear of the blade. Regular inspection and replacement can be used, and the lock may be locked. The powder device is not adjusted properly, and the seal is not tight, which causes the powder to suck back. This requires stopping in time, checking and adjusting the powder lock seal, and blocking the leak.

2. For materials, in addition to the abnormal situation of small output, the finished product may be too thick and too thin. This also has a certain relationship with the operation. It may be caused by incorrect adjustment of the fan air volume, or it may be due to the wear of the blade of the analyzer. Because it can’t achieve the effect of classification, this requires us to replace the blades in time, and adjust the size of the air volume according to the thickness of the material, and adjust the air volume too coarsely and the air volume too finely.

Briquetting Machine Structure

Third, the parts are abnormal

1. If the high-pressure roller mill is running, the pressure is too low and there is oil leakage from the oil cylinder, then it is most likely due to a problem with the hydraulic system of the machine. At this time, we need to timely repair the damaged zero. Replace the parts, and replace them with clean hydraulic oil, and then perform the corresponding debugging, so that the machine can be restored to normal use.

2. When the high-pressure roller mill is in operation, abnormal bearing temperatures may occur. This may be caused by a failure in the lubrication system. Therefore, it is necessary to deal with the oil inlet situation of each lubrication point in time and to the relevant components. Clean up to ensure the normal operation of the circulating cooling water circuit.

3. Another component that is prone to failure is the motor of the high-pressure roller mill. The phenomenon that occurs is that the current and temperature of the main machine of the high-pressure roller mill are increased, and the current of the fan is reduced. The reason may be that the feed is excessive and the air duct is powdered. The material is blocked and the exhaust is not smooth, which causes the circulating air flow to generate heat and cause failure. At this time, it is necessary to stop and clean up the powder accumulation in the air duct, and then reduce the feeding amount. At the same time, the Yu duct valve is opened to control the temperature of the material into the acceptable range.

In actual use, the common faults of the high-pressure roller mill are basically the above, which are mostly caused by improper operation. Therefore, it is necessary to operate in accordance with the regulations and also to do good maintenance. Corresponding solutions for different faults should not be dismantled and repaired selfishly, otherwise it may cause other undesired faults.

The roller skin of the mineral powder ball press is an important part of the pressing material. What kind of material is pressed and how the molding effect is directly related to it. The material of the roller skin of the general ball press can be divided into: ordinary steel, alloy material, cast steel and so on. After the running time is too long, it is unavoidable that the roller skin is worn, and it must be replaced with a new one after a certain degree. There is also a need to adjust the misalignment of the ball and socket after long-term use, otherwise it will directly affect the ball-making effect.

During the production process of the ore powder ball press, the fast rotation speed of the pressure roller can affect the pressure of the material, which is beneficial to the transmission of the force. In order to promote close contact between the materials, it can also overcome the stress occurring at the ball bowl interface, which can strengthen the ball pressing strength, but if the speed is too low, the ball press output will be greatly reduced.

It plays an important role for the rollers in the ore powder ball press. The fast rotation speed of the pressure rollers can affect the compression of the materials and is conducive to the transmission of force. In order to promote close contact between the materials, it can also overcome the stress occurring at the ball bowl interface, which can strengthen the ball pressing strength, but if the speed is too low, the ball press output will be greatly reduced.

During the pressing process, the distance between the two roller skins is a crucial element for pressing the ball. If the distance between the two rolls is small, it is not conducive to filling the entire mold with insufficient material, and the quality of the ball cannot reach the mark. If the distance between the two rolls is too large, the pressure cannot reach the sphere. In the middle, it has fallen off, affecting the strength of the ball. It can be seen that controlling the distance between the two rollers of the slag powder ball press is a key place to obtain an ideal pellet.

After the running time is too long, it is unavoidable that the roller skin is worn, and it must be replaced with a new one after a certain degree. There is also a need to adjust the misalignment of the ball and socket after long-term use, otherwise it will directly affect the effect of making ore powder balls.

The ore powder ball press has an influence on the roller distance and the forming of the material. When assembling the upper and lower rollers, special attention should be paid to adjusting the distance between the two. Generally, it is appropriate to control the distance between 2-3mm. In addition, when assembling the pressure rollers, special attention must be paid to the ball bowls on the upper and lower pressure rollers to be strictly aligned according to their rows and columns, so as not to cause misalignment and affect the strength of the briquettes. In addition, when the material is pressed by the mineral powder ball press, there are many factors that affect its forming.

The most important are two aspects: the nature of the material and the indicators of the ball press equipment. The material properties of the ball pressing machine are composed of raw material type, water content, and forming characteristics. This property also determines the size of the roller distance between the ball pressing machine. The distance between the pressure rollers is inversely proportional to the compression ratio. Although reducing the distance can increase the molding pressure, when the distance between the upper and lower pressure rollers is too small, it is difficult for the material to fill the ball bowl, which will affect the quality of the ball.

When the distance is too large, the forming pressure will have to be transmitted to the center of the ball in the future, and the formed ball will fall off. It will not even hit the ball.

Due to rain, snow, sand and temperature, frost, etc., these weather factors and natural phenomena are inevitable, so the high pressure ball press must be waterproofed when installed outdoors. It is necessary to fully consider various factors, try to think of all possible situations, and make the waterproof treatment more comprehensive and complete, so as to make greater use of the potential of the ball press and generate more benefits in the process of use.

In the case of rain and snow, water often penetrates into the interior of the high pressure ball press along the gap, causing damage. This is because for the suspension installation, there is a gap between the ball and the bracket, which creates rainwater injection. Condition, then how to solve this problem? Waterproof sealing measures should be taken during installation. It is also very important to prevent rainwater from entering the ball machine mounting bracket from the screw interface. It is recommended to use the original bracket. The original bracket fully considers the waterproof problem, such as the tilting design to make the ball machine rotate. The terminal is slightly higher. Even if the water in the bracket is filled, it will only flow back into the column without flowing into the ball.

Since rainwater may flow into the rack, the user should fully consider the waterproof factor when making the bracket. Why is there water droplets in the bracket? In general, the temperature during the day is high and the water vapor in the pole enters the bracket. When the night temperature drops, the water vapor condenses into water droplets that condense along the wall. When the bracket is not tilted or tilted in the opposite direction, water droplets will flow into the dome along the wall, causing damage. In order to reduce the entry of water vapor into the bracket, the joint between the bracket and the pole can be sealed with plasticine or silica gel.

In order to give full play to the role of the high pressure ball press, it must pay attention to its waterproof problem during installation. This is not only a tool to improve the efficiency of the user, but also to extend the service life of the device and provide more benefits and value to the user. This is a necessary step in the user’s use.

As a molding equipment, the ball press machine is very important in all industries, whether it is reprocessing of materials, or for convenient transportation, or direct molding, it plays a very important role. If you buy a ball press for the first time, we don’t know how to choose a variety of models, and we don’t know which one we need. The ball press manufacturer summarizes the classification of the ball press and learns together. Let’s have a look.

First, classification by pressure

In the manufacturing industry, the classification of ball presses is mainly related to pressure. In today’s market, ball presses can be basically divided into low pressure, medium pressure, high pressure, etc. In addition, our company has also developed and produced ultra high pressure. Ball machine for materials that require more pressure for forming.

1, experimental pressure ball machine

Smaller volume and lower energy consumption, different press roller pressure ratios can be adjusted according to different materials, ranging from 0-15t/cm. It is specially designed by our company for universities, laboratories, design units and factories and mines. The small experimental equipment manufactured is 1920*2100*1640 (unit mm) and is mainly used for small-scale simulation production.

2, medium pressure ball machine

Mainly relying on the material weight to enter the rolling zone to suppress the material with higher bulk density. According to different models, the line pressure ratio is between 2.5-3.0 (t/cm). The medium pressure ball press will change the structure of the traditional external gear transmission. In order to adopt the structure of the double-shaft reducer, the precision of the roller is effectively improved, and the gear of the reducer adopts a hard-toothed gear, which greatly improves the performance and service life of the reducer.

Briquetting Machine Structure

3, high pressure ball machine

Mainly used for pressing materials that are difficult to form. Compared with medium pressure, the line pressure ratio varies from 5-11 (t/cm) according to the model. The pre-press machine adopts speed-regulating motor, and all wear parts are welded. Wear-resistant alloy for improved performance and longevity, hydraulic standing, adjustable pressure and overpressure protection. Among today’s molding equipment, high pressure ball presses are widely used. Many of the types of ball presses mentioned below are actually one type of high pressure ball presses.

4, ultra high pressure ball machine

Designed for the production of finer particles (above 300 mesh) and lighter weight, the pressure of higher pressure is larger, the line pressure ratio is between 20-25t/cm, and the pre-presser is used to scrape the nozzle. The arc baffle is made of wear-resistant composite material, and the roller sleeve is composed of multiple contact seals, which greatly increases the sealing property of the triangular compression zone and effectively protects the roller sleeve from damage.

Second, pressing material classification

For the user, the pressure of the ball press is only a parameter, and the material to be pressed is the key factor for the classification of the ball press. The parameters required for different material forming are not the same, thus the various materials are separated. Various ball presses, such as dry powder, briquette, mineral powder, bauxite, etc.

1, dry powder ball machine

It is mainly used to suppress some moisture-free materials, such as quicklime powder, alumina powder, etc., water should not be added during the molding process, and the air between the materials is discharged and extruded into balls by high pressure, which is used in some metallurgical and chemical industries. .

2, mine powder ball machine

It is mainly used for the forming of some metallurgical wastes, as well as materials for re-returning the medicines, such as chrome ore powder, manganese ore powder and dust ash. For material sizes between 0 and 3 mm, the pressure requirements are within the scope of high pressure ball machines.

metal briquette machine

3, briquette pressure ball machine

It is suitable for pressing some materials which contain a certain amount of water, or need to add a certain amount of water or binder, and can also be subjected to anhydrous press forming. The molding process of the briquette ball press is divided into cold pressing and hot pressing, mainly in cold pressing forming, and the cold pressing determines whether to add the binder according to the bonding force between the materials. The briquette press is a medium and high pressure forming equipment. The configuration of different materials is slightly different, and customized production is required.

The above three ball presses have obvious requirements for the production process, while other ball presses require only a slight difference, but in general, there is no water, water and the binder to be added. Wait, some materials require the same material to be different in the molding process.

Third, the pressure roller diameter classification

1, small pressure ball machine

The diameter of the pressure roller is within 800mm. There are three models of the roller diameter of the small pressure ball machine produced by our company:

(1) Roller diameter 520mm ball press, under the roller diameter, the total pressure of the ball press is 100t, 150t.

(2) Roller diameter 650mm ball press, under the roller diameter, the total pressure of the ball press is 120t, 220t.

(3) Roller diameter 750mm ball press, under the roller diameter, the total pressure of the ball press is 150t, 200t, 300t.

Suitable for small and medium-sized enterprises in the processing of various materials, especially the powdery materials are not particularly small and medium-sized enterprises, the small overall size is small, the space requirements for the plant are not particularly harsh, the weight is light, if necessary, can be Move the adjustment device position during shutdown. However, the small ball press has a small roll surface, so the output is not particularly large. If it is a slightly larger medium-sized enterprise that has a large demand for production, it is more suitable for a medium-sized ball press.

Mineral powder ball machine

2, medium pressure ball machine

The pressure roller is between 800mm and 1200mm in diameter:

(1) Ball diameter 800mm ball press, the total pressure of the ball press is 380t.

(2) Roller ball with a diameter of 1000mm, the total pressure of the ball press is 300t, 350t, 500t, 540t, 800t.

(3) Roller ball with a diameter of 1200mm, the total pressure of the ball press is 300t, 800t and 1000t.

Compared with small-scale production and wider application range, both medium-sized enterprises and large enterprises can meet the production and molding pressure, and the roll surface is large enough and wide, and the output is high, but for the site. It requires a lot of space, and it may be necessary to install supporting facilities to help feed and dry.

3, large pressure ball machine

The pressure roller has a diameter of 1200mm or more. The Central Plains produces a ball press with a diameter of 1400mm. The total pressure is divided into 360t and 1000t. The body is larger and the output is higher. At the same time, it can meet some special molding needs, and is suitable for some large coal, mining and metallurgical industries.

The above is the classification of several common pressure ball machines. It can be seen that there are many types of such molding equipment, and there may be more than these. At the same time, for different pressure ball machine manufacturers, the classification of the pressure ball machines is not the same. However, when choosing, it is always inseparable from the size, output and use of the ball press.

The structure of the high-pressure roller mill is relatively complicated, the load is large, and there are many systems and components. In order to make better use of the device, it is necessary to understand its various components and nightly and necessary. The high-pressure roller mill is composed of a shafting system, a main frame, a feeding device, a transmission system, a hydraulic system, a lubrication system, a roller cover, and a detection system.

First, the spindle shaft system

The component consists of a grinding roller spindle with a certain thickness of wear-resistant material, a double row spherical roller bearing, a bearing seat, and inner and outer bearing end caps, a positioning ring, an end face thermal resistance, a water cooling system and the like.

The main shaft adopts split type and consists of two parts: the shaft body and the sleeve. The surface of the sleeve is welded with a wear layer. After the wear layer is worn, it can be repaired directly on the surface. If the sleeve is used, it cannot be repaired. To the extent that a new bushing can be replaced. The bearing support of the main shaft of the main shaft is a conical section, so that the disassembly of the main bearing can be carried out by means of an ultra-high pressure oil pump, which is convenient for inspection and replacement.

The main bearing of the high-pressure roller mill uses double row spherical roller bearings with self-aligning function. The bearing has the characteristics of large carrying capacity and long service life. It is concentrated with dry oil to ensure good lubrication.

The end face thermal resistance is used to detect the working temperature of the main bearing. It is closely attached to the outer ring of the main bearing to ensure continuous detection, alarm and control of the main bearing temperature. The water cooling system is used to reduce the operating temperature of the main shaft and the bearing, so that the shaft system can operate stably and continuously.

Second, the main frame

The main frame is the basis of the entire extrusion pulverization, and the crushing force is absorbed by it. In order to reduce the weight, all the welded structures are composed of upper and lower beams, left and right columns, bearing pins, positioning pins, guide rails and connecting bolts. See the main frame assembly schematic. The upper and lower beams and the left and right columns are integrally annealed after welding to eliminate the welding stress.

The upper and lower beams adopt the I-shaped structure and have greater rigidity and strength. The left and right columns and the structure of the I-shaped and box-shaped structures also have high rigidity, so that the entire frame can be connected into one. Rigid whole.

The load bearing pin mainly functions until the pulverizing force received on the column is transmitted to the upper and lower beams. Pay attention to the marking when installing.

The main role of the locating pin is to determine the center distance of the upper and lower beams on both sides.

The guide rails are provided as guides for the movable roller chocks. The rail widths on both sides are different, and the guide rails on the drive side should be wider.

Bolt sets are the key to ensuring the connection of the rack. Therefore, the high-strength bolts cannot be replaced by ordinary bolts, and the tightening torque should be controlled when tightening.

Third, the feeding device

The high-pressure roller mill feeding device is an important device to ensure that the material can enter the pressure zone uniformly and quantitatively, and the material is well squeezed. In operation, the material always fills the entire feed device and is directed into the pressure zone of the grinding roller. The feeding device is composed of a feeding port, a regulating inserting plate, a bracket, and a side plate pressing device. At the lower end of the side baffle, a hard alloy material of high hardness is provided in the portion of the pressure zone where the wear is severely punished. This reduces wear and improves the quality of the extruded material. The adjustment insert is used to control the thickness of the material cake to achieve the control of the treatment amount. It consists of a hand wheel, an adjusting screw and a card with welded material.

The side plate pressing device is used for controlling the gap between the side baffle and the end surface of the grinding roller. The device is composed of a bracket, a top screw, a butterfly spring and a spring seat.

The over-tightening screw can adjust the gap between the lower end of the side baffle and the end face of the grinding roller. Adjusting the pressure plate can adjust the top tension of the butterfly spring, so that the side baffle can ensure proper clearance with the end surface of the grinding roller during normal operation, and reduce the leakage of the end surface of the grinding roller.

Fourth, the main motor and transmission system

The main motor is the main power source for the entire high pressure roller mill. Two high-voltage three-phase asynchronous motors are used, which can be purchased by the user or commissioned by the manufacturer.

The transmission system adopts the internationally advanced planetary reducer suspension transmission. The output shaft of the planetary reducer is rigidly fixed to the grinding roller spindle by a shrink sleeve coupling. The gear unit is mounted on the basis of the grinding roller spindle and the gear unit can withstand the horizontal movement of the spindle. The output torque of the reducer is balanced by the torque support. The torque support includes a four-bar linkage and an elastic system. The torque support can satisfy the horizontal movement of the movable roller, and at the same time, it can play the role of load sharing, vibration absorption and buffering, and can reduce the processing and installation precision. All the hinge points in the four-bar linkage adopt the joint bearing with the sealing ring, which is highly adaptable. The elastic member in the elastic system employs a butterfly spring having a small axial dimension and a large coefficient of rigidity. In the working of the equipment, the top tension of the spring can be adjusted by adjusting the device to adapt the elastic system to the condition of the equipment load, and the universal joint drive shaft is used between the main motor and the planetary reducer. Since the universal joint drive shaft is disposed at the high speed end, the torque required to transmit itself is relatively small, and the rotational speed is high. And the cross-shaft universal joint drive shaft has the characteristics of high transmission efficiency, large transmission torque, balanced transmission, good lubrication conditions and large node inclination.

The shrink sleeve coupling used in the transmission system is a non-standard accessory, which consists of a conical sleeve, two shrink discs, a high-strength bolt set and a dust seal. The working principle is: tightening the high-strength bolt, so that the conical sleeve presses the hollow shaft of the reducer, and elastically deforms it, and is hung on the journal shaft of the grinding roller, and uses the friction generated by the positive pressure therebetween. It functions to transmit torque and reducer positioning.

Five, hydraulic system

The hydraulic system is designed to provide the required crushing force for the grinding rolls. Its main function is the hydraulic springs, which also have hydraulic protection. Its performance directly affects the quality of the crushed material and the safety of the equipment.

The system consists of three parts: pump station, valve table and cylinder (see hydraulic system diagram). The valve table, pump station and cylinder are mounted directly on the frame and are compact.

The pump station provides a hydraulic oil pump, which is mainly composed of an oil pump, an oil pump motor relief valve, a pressure gauge and an oil filter.

The oil filter of the pumping station is arranged in series with the pressurized main oil circuit, so that the hydraulic oil is filtered by the oil filter and then enters the main oil circuit to avoid blockage of system components caused by impurities entering the main oil circuit, and the system pressure can be based on The operation requires stepless adjustment. The pressure required to control the system can be adjusted steplessly. A pressure differential device is attached to the oil filter. When the filter cartridge is clogged and the pressure difference between the two sides reaches a certain value, an alarm signal is issued to clean or replace the filter cartridge by the operator. The valve table section is the main oil circuit and control oil circuit of the hydraulic system, and is composed of two capacity accumulators and an electromagnetic overflow valve. During operation, the four main cylinders are connected to the two accumulators through large diameter pipes so that the pressure between them is always the same and the dynamic characteristics of the cylinders are sensitive. The pilot-operated relief valve mainly protects the hydraulic system. It has the characteristics of dynamic response and large flow. Once the roller enters the foreign object and the system pressure increases, it can open the pressure relief in time to protect the host equipment. The relief valve can be hydraulically controlled and electronically controlled.

When commissioning and handling accidents, you can press the push button to relieve pressure or high speed pressure. A pressure sensor and an electric contact pressure gauge are additionally provided on the valve table. The hydraulic system pressure signal main control room and control cabinet can be interlocked with the main unit through the pressure sensor, which is also convenient for the operator to observe the operation. The electric contact pressure gauge is mainly used to control the upper and lower limits of the hydraulic system pressure. Control the opening and closing of the pump pump motor.

The four cylinders act directly on the movable roller bearing housing to provide the appropriate crushing force for the grinding roller. The cylinder force can be applied to the single-side bearing seat or the double-side bearing seat by the displacement of the oil circuit control system. When the grinding roller is moved, the horizontal displacement of the two bearing seats is detected and controlled by the displacement sensor. The cylinder consists of a cylinder, a piston, an end cap, a wear ring and a sealing ring. See the schematic diagram of the cylinder assembly. The cylinder is a double-acting cylinder, so that once the black system of the equipment fails. The movable roller can be pulled back in time with the cylinder to increase the nip and eliminate the malfunction. At the end face of the cylinder rod of the cylinder, a toroidal head is provided to prevent the radial load from being added to the cylinder when the axis of the moving roller is deflected.

Sixth, lubrication system

The lubrication system is used for the lubrication of the main bearing, the sealing and the lubrication of the movable roller bearing housing. The lubrication system can adapt to the dusty working environment and ensure the lubrication of the main bearing and the movable roller bearing housing under good lubrication conditions. It is mainly composed of a oil storage cylinder, a pump component with a flange connected, and a geared motor. Grease can be manually or electrically filled with a pump and added to the oil cylinder through a hose to prevent the grease from being exposed to dust and contaminating the grease. A pressure limiting valve and a fuse are provided in the lubrication pump to adjust the maximum pressure of the lubrication system. When the pressure in the system is exceeded for some reason, the rupture plate breaks and the grease overflows. A filter screen is provided on the lubrication pump to filter grease to prevent debris from entering the system and to ensure normal operation of the system. The grease from the lubrication pump is proportionally distributed to each lubrication point by the progressive distributor. There are two oil separators in the system, one on each side of the main frame.

This type of oil separator is a relatively advanced oil separator. It is characterized in that any one of the divided roads is blocked, and the whole system stops working. This avoids the Achilles heel that one or more lubrication points are broken and the operator cannot detect in time. A proximity switch is placed on the oil separator to signal the operator as soon as the oil separator stops working.

Seven, detection system

The detection system is distributed among the various systems as the detection control signals. The signals detected by the detection elements enable interlocking, indication and alarm between the systems. Realize automatic control of the device.

1. The nip detection between the two grinding rolls adopts two inductive displacement sensors, which are respectively arranged on the two bearing seats of the movable roller. Through the sensor, the nip of the two grinding rolls can be reflected at any time, that is, the material cake is reflected. thickness. When the two bearing seats move unevenly, the deviation can also be reflected. When one of the two bearing housings or the two-shaft bearing housing retreats to the set maximum displacement, an alarm is issued, and the main motor is locked in parallel to ensure the safety of the equipment.

2, the main bearing temperature detection end face platinum thermal resistance. Each bearing is tested separately. The end face thermal resistance is attached to the outer ring of the bearing to detect and reflect the working test of the main bearing at any time. When the operating temperature reaches the set maximum value, an alarm is issued to notify the operator.

3. Pressure sensor is used for pressure detection of hydraulic system. The sensor detects the signal and transmits it to the host control cabinet. When the system pressure exceeds the set maximum system pressure, an alarm is issued and the main drive motor is stopped.

4. Lubrication system work detection uses proximity switch. The proximity switch is installed on the system oil separator. When the oil separator is working normally, the proximity switch is instructed once every other time. When a certain oil circuit is blocked, the proximity switch does not operate at all times. However, it must be noted that the premise of the oil separator or the proximity switch must be based on the normal operation of the lubricating oil pump motor and the unbroken grease in the oil reservoir.

5, the pressure difference alarm of the oil filter, using the differential pressure device. When the oil filter is used for a period of time, the impurities under filtration may block the filter cartridge, causing the pressure difference between the oil passages on both sides of the oil filter to increase. When it is increased to a certain value, the sound and light alarm signal is emitted from the main control cabinet. It is worth noting that the signal is only sent when the oil filter is working.

Eight, roller cover

The main function of the roller cover: one is to prevent accidental casualties and equipment damage accidents; the other is to seal and reduce dust. Observation and repair door holes are provided on both roller covers to check the wear of the roller surface at any time while the equipment is running.