SXJ200型減速機使用維護說明書

SXJ200型減速機使用維護說明書（2010-05-1711:06:26）轉(zhuǎn)載標簽：雜談1.型號含義和技術(shù)參數(shù)Definitionofmodelandparameters型號含義DefinitionofmodelJLX61Z/JLX69Z型號JLX61Z/JLX69ZmodelJ：指減速機gearreducer；L：指兩級減速two-stagegearreduction；X：指行星齒輪傳動planetarygeardrive；Z：指鑄造箱體castcasing；61/69:指減速機名義功率nominalpowerofgearreducer技術(shù)參數(shù)Parameters額定功率Ratedpower570/700kw電動機功率Powerofelectricmotor570/632kw輸入軸轉(zhuǎn)速RPMofinputshaft991/991r/min輸出軸轉(zhuǎn)速RPMofoutputshaft24.4/23.2r/min總傳動比Totalratiooftransmission40.91/42.7重量Weight?25900/28700kg容油量Oilcapacity?250/342L潤滑油牌號NameoflubricatingoilN320硫磷型重負荷極壓工業(yè)齒輪油N320sulfur/phosphorusindustrialgearoilforhighloadingandextremepressure設(shè)計軸向載荷Designedaxialloading1600/2000kN（靜載荷staticloading）4800/8000kN（動載荷dynamicloading）工作參數(shù)Controlparameters>0.2-04Mpa（油溫>>0.2-04Mpa（油溫>40°C）油壓報警值A(chǔ)larmvalueforinputoil<0.11MPa油壓停機值ShutdownvaluefOrinputoil<0.08Mpa潤滑油工作油溫最低值Min.valueofoperatingoiltemperatureforlubricatingoil>25r潤滑油工作油溫最高值Max.valueofoperatingoiltemperatureforlubricatingoil<60°C推力軸承油池油溫報警值A(chǔ)larmvalueofoiltemperatureinoilsumpforthrustbearing>80C推力軸承油池油溫停機值Shutdownvalueofoiltemperatureinoilsumpforthrustbearing>83C2.性能與結(jié)構(gòu)特點Featuresonperformanceandmechanism該減速機在傳動上由一級螺旋傘齒輪和一級行星齒輪傳動組成，與同樣額定功率和傳動比的三級普通螺傘一圓柱齒輪減速機相比，不僅體積小、重量輕，而且傳動平穩(wěn)、噪音低、效率高等。所有這些主要是由于利用了行星齒輪傳動的特點，同時又由于磨齒加工齒輪的數(shù)量占齒輪總數(shù)量的百分比提高，使得整個傳動的各種性能大大提高所致。Thegearreduceriscomposedofone-stagespiralbevelgearandone-stageplanetarygearintermsofdrive.Comparedwiththree-stagecommonspiralbevelgear一cylindricalgearreducer,thegearreducerproperisfeaturedbysmallvolume,lightweight,stabledriving,lownoiseandhighefficiency,etc.Allthesefeaturesareattributedtotheutilizationofplanetarygeardriveandincreasedratioofno.ofgrindingteethmachininggearstothetotalno.sofgears,whichresultinremarkableimprovementofallperformancesforthewholedrivingsystem.該減速機主要由以下幾部分組成。Thegearreducerisstructuredasfollows傘齒輪傳動部分Drivingpartofbevelgear減速機輸入級為一對克林貝爾格螺旋傘齒輪。大小齒輪均采用滲碳淬火鋼進行制造，并采用硬齒面加工方法加工而成，強度很高。小傘齒輪和大傘齒輪均通過軸承座裝入下殼體中，兩軸承座法蘭下設(shè)有調(diào)整墊，用于調(diào)整齒輪副接觸區(qū)的位置和齒側(cè)間隙。TheinputstageofthegearreducerisacoupleofKLINGELNBERGextensionepicycloidalspiralbevelgearshardened-steelandmachinedbymeansofhardtoothsurfaceprocessing,whichpresentshighstrength.Bullgearandpiniongeararemountedinlowercasingviabearingseat.Thereareadjustingspacersbeneathflangeoftwobearingseats,whicharedesignedtoadjustthepositionofgears’sub-contactareaandthegapofflankofteeth.行星級齒輪傳動部分Drivingpartofplanetary-stagegear行星級齒輪傳動主要由太陽輪、行星輪、內(nèi)齒圈等組成。Planetary-stagegearismainlycomposedofsunwheel,planetarygear,internalringgear,etc.工作時太陽輪浮動，以便使其輪齒同時和三個行星輪均勻接觸，達到均載目的；行星輪安裝在行星架上，在繞自身軸線傳動的同時，也隨行星架一齊轉(zhuǎn)動。內(nèi)齒輪安裝在殼體中固定不動。太陽輪，行星輪均為滲碳淬火后磨齒齒輪，內(nèi)齒輪為調(diào)質(zhì)齒輪。Wheninoperation,thesunwheelisfloatingsoastoallowitsgearstouniformlycontact3otherplanetarygearsforuniformloading.Planetarygearsaremountedontheplanetaryframeandisrotatingwiththeplanetaryframewhiledrivingaroundhisownaxis.Internalgearismountedinthecasingwithoutmovement.Sunwheelandplanetarygeararemadeofpost-carburizedhardenedgrindingteethgearwhileinternalgearisofquenchingandtemperinggear.2.3齒輪聯(lián)軸器Gearcoupling該減速機在兩級齒輪傳動之間設(shè)置了鼓形齒聯(lián)軸器，其作用是連接兩級齒輪之間的傳動。由于齒輪聯(lián)軸器的內(nèi)齒套也隨行星級中的太陽輪一起浮動，所以聯(lián)軸器齒輪也采用合金鋼材料來制造。Thereisabarrel-shapedgearcouplingbetweentwo-stagegeardriveforthegearreducerproper,thepurposeofwhichistolinkthedrivefortwo-stagegear.Sincetheinternalteethsleeveforthegearcouplingisfloatingwiththesungearintheplanetary-stage,couplinggearismadeofalloyedsteel.平面滑動推力軸承Planeslidingthrustbearing為了承受磨煤機工作中的動靜載荷，減速機上部設(shè)置了平面滑動推力軸承，靠推力盤旋轉(zhuǎn)在推力盤和推力瓦之間產(chǎn)生動壓潤滑油膜進行工作。Inordertosustaindynamicandstaticloadingofcoalmillinoperation,thegearreducerisequippedwithplaneslidingthrustbearingattheupperpart,whichmaygeneratedynamicpressurelubricatingoilfilmbetweenthrustdiscandthrustbushingbymeansofrotationofthrustdisc.推力盤為鋼制材料制成，推力軸承瓦面為塑料瓦材料制成。由于該軸承靠建立正常的潤滑油膜而工作，軸承材料硬度又很低，所以不能在磨煤機加載而又無煤的情況下使用。在使用盤車裝置時，要全部放松(對于變加載式磨煤機最好將磨輥抬起)磨煤機載荷來進行，以保證軸承的安全性。Thrustdiscismadeofsteelandthrustbearingbushingsurfaceismadeofplasticbushing.Sincethebearingisworkingbyestablishingproperlubricatingoilfilmandthereislowhardnessofbearingmaterial,itcannotbeusedwhileloadingcoalmillandwithnocoal.Whenusingbarringgear,itisadvisabletofullyunloadcoalmill(regardingadjustableloadingcoalmill,preferablyliftmillroller)soastoprotectthesafetyofthebearing.滾動軸承Rollerbearing本減速機均采用SKF和NSK軸承裝配，和平面滑動軸承一樣要求潤滑油保證質(zhì)量和清潔度。ThegearreducerisequippedwithSKFNSKbearingrequiringassuredqualityandcleanlinessforlubricantlikeplaneslidingbearing.殼體Casing減速機采用上下箱分開式殼體，目的是為了方便下箱體中零部件損壞時的維修。上下箱體強度和剛度好。上箱體設(shè)有兩個進油口和二個推力軸承回油觀察孔，下箱體設(shè)有二個回油口，二個檢修門和二個油位觀察口。Thegearreducerisassembledwithupperandlowersplit-typecasings,thepurposeofwhichistofacilitaterepairondamagedcomponentsinlowercasing.Upperandlowercasingsgoodstrength.Inuppercasing,therearetwooilfillingportsandtwoobservationholesforoilreturnofthrustbearing.Inlowercasing,therearetwooilreturnports,twomaintenancedoorsandtwooillevelobservationholes.潤滑與冷卻Lubricationandcooling為了保證齒輪和軸承在運轉(zhuǎn)中得到可靠地潤滑與冷卻，減速機選用了硫磷型極壓工業(yè)齒輪油作為潤滑與冷卻介質(zhì)，并采用過濾精度很高的潤滑站對減速機提供合適溫度的潤滑油。減速機內(nèi)部各潤滑點的供油量是通過計算與試驗確定下來的，可以充分滿足所有存在相對運動零件的使用要求。同時進油管安裝有溢流閥以控制低油溫時(?25°C)最高油壓不超過允許值V0.58MPa在正常油溫下(40~60C)溢流閥不工作。Inordertomakesurethatgearsandbearingsareproperlylubricatedandcooledduringoperation,weutilizesulfur/phosphoroustypeextremepressureindustrialgearoilaslubricatingandcoolingmediaforthegearreducerandalsochooselubricatingstationwithfinefilteringtoprovidelubricatingoilofpropertemperatureforthegearreducer.Thequantityofoilsupplytoeachlubricatingpointinsidethegearreducerisdeterminedbasedoncalculationandtest,whichcansatisfytherequirementofoperationforallpartswithrelativemotion.whisttheoilfeedingpipesisequippedwithoverflowvalvestocontrolthemaximumoilpressurenotexceedingallowedvalveatlowoiltemperature(?25C).Theoverflowvalvecannotworkatnormaloiltemperature(40-60C)3.安裝Installation因為減速機既是磨煤機的驅(qū)動部件，又是磨煤機中主要轉(zhuǎn)動部件(如磨輥、磨環(huán)等轉(zhuǎn)動件)的最初安裝基準，同時又是磨煤機碾磨加載力的支撐體，所以減速機的安裝正確與否嚴重關(guān)系到磨煤機的工作性能問題。因此，在整個磨煤機安裝過程中，必須有懂得減速機安裝技術(shù)的工程師和技術(shù)工人(或者是經(jīng)過專門技術(shù)培訓(xùn)的這些人員)一起進行。Sincethegearreducerisnotonlythedrivingpartforcoalmill,buttheoriginalerectionbenchmarkforthemainrotatingpart(suchasmillroller,millring,etc.)forcoalmillandthesupportforloadingforceofgrindingofcoalmillaswell,thecorrecterectionofthegearreducerhasacloserelationwithitsperformance.Therefore,theerectionofthegearreducermustbecarriedoutbyexperiencedengineersandtechnicians(orpeoplesubjecttoparticulartraining).安裝減速機前，必須仔細審閱減速機外形圖和潤滑站外形圖，了解上述設(shè)備后進行下述工作。Priortoinstallation,dimensionaldrawingofthegearreducerandlubricatingstationandlubricatingstationmustbecarefullyreviewedtohaveagoodunderstandingoffollow-upworks.齒輪箱基礎(chǔ)底板的檢驗Inspectionofsoleplateforgearbox：由于磨機粉磨裝置的重量和粉磨壓力都將通過齒輪箱傳到基礎(chǔ)底座上，所以整個齒輪箱必須放置在基礎(chǔ)底板的整個平面上.將齒輪箱安裝在基礎(chǔ)底板上時，整個基礎(chǔ)底板必須經(jīng)過嚴格的水平檢驗，基礎(chǔ)底板的水平誤差不能超過0.05mm/M，并且要仔細地清洗齒輪箱和基礎(chǔ)底板的結(jié)合面，然后用潤滑脂涂抹基礎(chǔ)底板，以便在安裝齒輪箱時能夠移動之.Sincetheweightandpulverizingpressureofmill’spulverizingunitaretravelingtosoleplateviagearbox,thewholegearboxhastobelaidacrosstheplaneofsoleplate.Wheninstallingthegearboxontothesoleplate,thewholesoleplatemustbecarefullyinspectedhorizontallywithhorizontalerrornotmorethan0.05mm/M.Meanwhile,thoroughlycleanthejointsurfacebetweengearboxandsoleplatebeforeapplyinggreasetothesoleplatesoastomoveitwheninstallingthegearbox.在基礎(chǔ)底板上安裝齒輪箱Installgearboxontosoleplate首先確定基礎(chǔ)底板上磨機中心線的位置，然后利用齒輪箱下部的起吊孔將其起吊到預(yù)定位置,仔細調(diào)整減速機位置，使減速機底板上中心刻線對準基礎(chǔ)底板上磨機中心線，然后通過箱體底板上的8個螺栓孔用螺栓將齒輪箱緊固在基礎(chǔ)底板上。Firstofall,determinethepositionofmill’scentrallineonthesoleplateandthenliftthesoleplatetotieexpectedpositionbymeansof4liftingeyesonthelowerpartofgearbox.Carefullyadjustthepositionofgearreducertoallowitscentrallineonthebaseplatetoalignwithmill’scentrallineonthesoleplate.Andthentightenthegearboxtothesoleplatewith8boltsoncasingbaseplate.清理與檢查Cleanandcheck安裝前用煤油擦洗掉減速機底面，輸入軸頸，輸出傳動法蘭端面上的防銹漆和其它雜質(zhì)污物等。檢查并排放干凈減速機內(nèi)部的殘留潤滑防銹油。Getridofcorrosionandotherimpuritywithkeroseneoilfromgearreducer’sbottom,neckofinputshaftandoutputdriveflangeendsurface.Checkandemptyresidualrust-preventativeoilinsidethegearreducer.為保證減速機精確定位，修磨因不慎而造成的減速機底面上和基礎(chǔ)臺板表面上的凸痕等。為防止安裝后并且在長期使用情況下，減速機底面與臺板表面銹蝕在一起，應(yīng)在臺板表面上均勻涂以一層薄薄的MoS2潤滑脂°Inordertoensuretheaccuratealignmentofthegearreducer,grindandremovetheimprintmarksunintentionallyleftonthegearreducersurfaceandfoundationbedplatesurface.Inordertopreventcorrosionofgearreducersurfaceandbedplatesurfaceoccurringduringoperationafterinstallation,applyauniformthinfilmofMoS2lubricatinggreasetobedplatesurface.注意！減速機輸入軸迷宮防銹包裝密封，輸出傳動法蘭迷宮防銹包裝密封，呼吸器上的防銹包裝膠帶最好在減速機啟動前拆除，以免安裝周期過長，內(nèi)部零件發(fā)生銹蝕。Caution：Itisadvisabletoremovethelabyrinthsealforinputshaftandoutputdriveflange,rubbertapeonrespiratorbeforestartupofthegearreducersothatinternalpartscanbefreeofcorrosionduetolong-termerection.安裝減速機Installationofgearreducer安裝減速機的基準精度要求為：減速機臺板的水平度誤差不大于0.1mm/m，平面度誤差不大于0.1mm。Thebenchmarkingaccuracyofinstallinggearreducerisdefinedasfollows:Horizontalerrorforbedplateofgearreducernotmorethan0.1mm/m,Flatnesserrornotmorethan0.1mm,減速機以底面法蘭側(cè)面的四條刻線對準臺板劃線進行找正。Thegearreducerisalignedbasedon4marklinesonsidesofbottomflangeandbedplatemarks.地腳螺栓應(yīng)采用液壓預(yù)緊設(shè)備進行擰緊，并進行防松處理。Anchorboltsaretightenedwithhydraulicpretighteningequipmentandlockingmeasuresareemployed.為了防止減速機在工作中因磨煤機振動而產(chǎn)生位移，減速機底部方法蘭四邊必須用螺栓頂住定位，定位螺栓要進行防松。Inordertopreventdisplacementofthegearreducerduetovibrationofcoalmillduringoperation,foursidesofsquareflangeatthegearreducer’sbottommustbejackedinplaceandlockingmeasuresareemployedforlockingbolts.注意！減速機底面不允許加墊片。Caution：noshimmingonthebottomofgearreducer.3.3安裝潤滑站：按《稀油潤滑站說明書》執(zhí)行。Installationoflubricatingstation：tobecarriedoutagainstInstructionsonThinOilLubricatingStation.3.4加油Oilfeeding在加工作油之前，應(yīng)先放凈系統(tǒng)內(nèi)的殘油，清除包裝用盲法蘭、絲堵、膠帶并且恢復(fù)呼吸器的安裝。再加入牌號正確、質(zhì)量和清潔度合格的工作油。Caution：TheresidualoilinthegearreducerdeliveredtocustomersisSRCParticularSealingAnti-rustOildevelopedbyBeijingSanlianFineChemicalPlantforourspecialduty.Priortofillingworkingoil,emptytheresidualoilinthesystem,removeblindflange,pipeplugandtapeforpackageandrestoretheinstallationofrespirator.Feedworkingoilwithcorrecttype,qualityandcleanliness.IncaseofworkingoiltobeusedfromotherCo.s,moreattentionshallbepaidtotheabovesteps.減速機的加油應(yīng)該在稀油潤滑站和減速機與潤滑站之間的管路全部安裝完畢之后進行。當這些部分安裝完畢后，可以卸下減速機進出油口法蘭和上下箱體上的測溫座螺塞，安裝測溫兀件等。注意：應(yīng)該先安裝好.Feedingoiltothegearreducershallbecarriedoutwhenthepipelinesbetweenthinoillubricatingstationthegearreducerandlubricatingstationaswellarefullyinstalledinplace.Whenthesepartsareinstalled,disassembleinput/outputoilportflangeandplugscrewoftemperature-measuringbaseattheupperandlowercasingsandtheninstallcomponentsformeasuringtemperature.Caution：installationinplacefirst.因減速機采用滑動推力軸承來承受磨煤機的工作載荷，所以對潤滑油的粘度和加油過濾精度有嚴格的要求，用戶必須注意。Sinceslidingthrustbearingofthegearreducerisusedtosustaintheoperationloadingofcoalmill,therearestrictrequirementsonlubricanfsviscosityandfilteringaccuracyforoilfilling,towhichusersshallpayattention.加油工作應(yīng)該在潤滑站安裝完畢并且與減速機之間連接好潤滑管路之后進行。在啟動潤滑站之前，系統(tǒng)各種儀表、開關(guān)和線路等必須接好。Oilfillingshallbecarriedoutwhenthelubricatingstationisinstalledandlubricatingpipelineslinkingthegearreducerareinstalled.Beforestartupofthelubricatingstation,allinstruments,switchesandwiringsmustbeinplace.在向減速機加油之前，認真審定所購油品是否為減速機規(guī)定用油，生產(chǎn)廠家是否為國家承認的正式單位，油品有無檢驗報告和合格證等。嚴禁使用偽劣油品和與本說明書規(guī)定牌號不一致的油品。Beforefeedingoiltothegearreducer,reviewtheprocuredoilagainsttheoilspecificationforthegearreducer,suchaswhetherthemanufactureristhenationallyapprovedunit,whetherthereareexaminationreportandcertificate,etc.Oilofpoorqualityorthosedifferentwiththespecificationarenotallowedtobeused.本減速機推薦的國內(nèi)油品生產(chǎn)廠商為北京三聯(lián)精細化工廠生產(chǎn)的N320硫磷型重極壓工業(yè)齒輪油。國外用油應(yīng)使用性能相同的潤滑油。TherecommendedoilmanufacturerforthegearreducerproperisN320sulfur/phosphoroustypeextremepressureindustrialgearoilmadebyBeijingShanlianFineChemicalPlant.LubeoilwithsamepropertiesshallbeusedifnotmadeinChina.表3-1.北京三聯(lián)精細化工廠生產(chǎn)的N320硫磷型重極壓工業(yè)齒輪油性能指標Table3-1PerformanceIndexofN320sulfur/phosphoroustypeextremepressureindustrialgearoilmadebyBeijingShanlianFineChemicalPlant.比重Density,g/cm3凝點Freezingpoint（最?。鉉閃點Flashingpoint（最小）C粘度Viscosity40C（100C）cst粘度指數(shù)Viscosity（最低）符合標準Standardtobeemployed-15200288~35290Q/SH018.3215-89潤滑油應(yīng)采用過濾精度不低于0.025mm的濾油機注入減速機。較為方便的方法是拆除減速機箱體中分面法蘭上的呼吸器（整個拆下），利用其安裝孔對減速機下箱體進行加油，當減速機下箱中的油位到達后油窗中間刻線時（不停止濾油機對減速機的加油），可以啟動潤滑站油泵對減速機上箱體進行加油。油位到達后油窗中間刻線時，說明上箱體油已加滿。這時請不要立即關(guān)閉潤滑站油泵，因為啟動潤滑站油泵對減速機上箱體進行加油過程中致使下箱體油位下降，應(yīng)待減速機下箱中的油位再次到達后油窗中間刻線時停止用濾油機對減速機的加油。在加油完畢后，如果下箱體中油位低于油窗中間刻線，應(yīng)對減速機補油，若油位高于中間刻線，應(yīng)進行適當放油。此油位均以減速機運行狀態(tài)為準。Lubricatingoilshallbefedtothegearreducerthroughfilterpresswithfilteringaccuracynotlessthan0.025mm.Aeasymethodistofullydisassembletherespiratoratthesplitflangeinthecasingandfeedoiltothelowercasingthroughtheerectionhole.Whentheoillevelinthelowercasingreachestheintermediatemarkintheoilwindow（notstopfeedingoiltothegearreducerfromfilterpress）,startupoilpumpinthelubricatingstationtofeedoiltolowercasing.Inordertoassesstheoillevelintheuppercasing,itisallowedtoremovetheplugscrewofobservationholeatthrustbearingoilsumpintheuppercasing.Whenlubricatingoilisfoundtooverflowfromoilsump,indicatingthattheuppercasingisfull,pleasedonotstopoilpumpimmediately.Sinceoillevelinthelowercasingdropsintheprocessofoilfeedingtotheuppercasingfromstartupofoilpump,donotstopoilfeedingtothegearreducerfromthefilterpressuntiltheoillevelinthelowercasingreachestheintermediatemarkintheoilwindowagain.Afterthecompletionofoilfilling,iftheoillevelinthelowercasingisbelowtheintermediatemarkintheoilwindow,addmoreoiltothegearreducer.Iftheoillevelisbeyondtheintermediatemark,draintheoilslightly.Theoillevelshallbedependantontheoperationstatusofthegearreducer.運行后觀察油窗中的油位在油窗中間刻線處為宜，略高或略底均不會影響減速機的正常運行。當減速機中油位下降到油窗“下邊緣”處時，應(yīng)進行補油。Afteroperation,observetheoillevelintheoilwindow,preferablyattheintermediatemark.Slightlybeloworbeyondthemarkwillnotaffectthenormaloperationofthegearreducer.Whentheoillevelinthegearreducerdropsto“l(fā)owerlimit”intheoilwindow,exerciseoiladdition.注意！嚴禁將油位加至過高，以免造成減速機輸入軸漏油。Caution：Itisprohibitedtofilloiltoohightopreventinputshaftofgearreducerfromleaking.注意！必須及時補油，以免減速機中油位過低發(fā)生事故。Caution：Exercisetimelyoiladditiontopreventanyaccidentduetotoolowoillevelinthegearreducer.注意！嚴禁打開減速機下箱體上的檢修門對減速機進行加油和觀看，以免發(fā)生漏油現(xiàn)象。Caution：Itisprohibitedtoopenthemaintenancedooratthelowercasingtoaddoilandtakealooktopreventoilleak.注意！技術(shù)參數(shù)中提到的減速機容油量，不包括潤滑站內(nèi)部的存油量°Caution：Oilcapacityasmentionedinthespecificationdoesnotincludetheoilstoringinthelubricatingstation.啟動Startup啟動前應(yīng)除去減速機輸入軸迷宮密封端面和輸出傳動法蘭迷宮密封外圓表面，以及呼吸器上的防銹包裝及膠帶。Priortostartup,getridoftapefromlabyrinthsealendofinputshaft,labyrinthsealoutersurfaceofoutputdriveflangeandrespirator.減速機和潤滑站以及控制系統(tǒng)安裝完畢后應(yīng)進行試運轉(zhuǎn)工作。減速機的試運轉(zhuǎn)工作對于變加載式磨煤機，可以采用抬起磨輥或者是減少磨輥加載力的方式來進行；對于非變加載式磨煤機，只能和磨煤機試運轉(zhuǎn)同步進行。一旦啟動減速機，必須首先啟動潤滑站。潤滑站的試運轉(zhuǎn)工作應(yīng)安排在減速機試運行轉(zhuǎn)之前進行。該項工作必須在調(diào)試工程師的指導(dǎo)下進行，控制技術(shù)參數(shù)按1.3條的要求進行。Afterthecompletionofinstallationofthegearreducer,lubricatingstationandcontrolsystem,startcommissioning.Forthevariableloadingcoalmill,thegearreduceriscommissionedbyliftingrollerorreducingrollerloadingforce.Fornonvariableloadingcoalmill,thecommissioningofgearreducercanonlybecarriedouttogetherwithcoalmill.Oncestartupgearreducer,youhavetostartlubricatingstationfirst.Lubricatingstationshallbecommissionedbeforegearreducerundertheguidanceofcommissioningengineer.Referto1.3forcontroltechnicalparameters.試運轉(zhuǎn)中主要開展如下工作Mainworkstobedoneduringcommissioning：一是檢查運行參數(shù)是否滿足設(shè)計規(guī)定；二是檢查系統(tǒng)零部件運轉(zhuǎn)是否正常。Checkoperationparametersforcompliancewithdesign.Checkeachpartisworkingproperly.檢查運行參數(shù)是指各處的油溫，油壓是否符合規(guī)定。檢查系統(tǒng)零部件運轉(zhuǎn)是否正常是指密切注意油泵，過濾器，冷卻器，加熱器，減速機運轉(zhuǎn)有無異常的噪音和溫升。因為減速機此時已經(jīng)是帶負荷運轉(zhuǎn)，所以應(yīng)特別注意輸入軸錐軸承的溫升和滑動推力軸承油池的溫升有無異?，F(xiàn)象等。Operationparametersarecheckedforcompliancewithdesign,ie.oiltemperatureandoilpressureateachlocation.Checkeachpartisworkingproperly,ie.anyabnormalnoiseandtemperatureincreaseonoilpump,filter,cooler,heater,gearreducer.Sincethegearreducerisworkingwithload,attentionshallbepaidtothetemperatureincreaseofaxialconebearingandslidingthrustbearingoilsump.所有減速機在出廠前已經(jīng)在廠內(nèi)進行過空載試運轉(zhuǎn)，現(xiàn)場進行試運轉(zhuǎn)主要目的是進一步觀察減速機在存在一定負荷時的運行情況。Allgearreducersaresubjecttono-loadtest-runintheworkshoppriortodelivery.Thecommissioninginthefieldisintendedtocheckthegearreduceroperatingwithload.注意！電動機轉(zhuǎn)向必須與減速機輸入軸端蓋上箭頭指示的方向相一致。Caution：Rotationofmotormustbethesameasthearrowasshownoninputshaftendcover.注意！決不允許在磨煤機內(nèi)無煤，而且存在加載力的情況下運行減速機。Caution：Itisprohibitedtooperategearreducerwhenthereisnocoalinthecoalmillandloadingforcepresent.停運Shutdown正常停運Normalshutdown當減速機在正常情況下停止運行時，應(yīng)該先停減速機，后停潤滑站。為了將剛剛停止下來的減速機內(nèi)部的熱量散掉，潤滑站至少要延遲5分鐘停止oWhenthegearreducerisrequiredtoshutdownundernormalcondition,firststopgearreducerbeforelubricatingstation.Inordertodischargetheheatinginsidethegearreducerbeingstoppedjustnow,lubricatingstationshallbestopped5minlater.緊急停運Emergentshutdown如果因為減速機事故造成減速機緊急停止運行，應(yīng)立即查明故障原因并進行解決。決不允許在沒有搞清問題的請況下將減速機投入運行。Ifthegearreducerrequiresemergentshutdownduetoitsaccident,firstdotroubleshootingandaddressit.Itisnotallowedtoputthegearreducerbackintooperationwithoutfindingoutthecause.維護與保養(yǎng)Maintenanceandservice6.1換油Oilchange換油是減速機維護與保養(yǎng)的重要工作之一，必須嚴格執(zhí)行。由于磨煤機減速機的工作環(huán)境煤粉粉塵較大，溫度較高，煤粉很容易從減速機輸出傳動法蘭的迷宮縫隙處進入減速機，污染內(nèi)部潤滑油，使?jié)櫥偷男阅芟陆?。減速機中滑動推力軸承過早的發(fā)生磨損和燒瓦，滾動軸承和齒輪的磨損，點蝕等，均和油品的質(zhì)量有關(guān)，因此，要及時換油。其次推薦的按經(jīng)驗的換油周期為第一次，300小時；第二次，1000小時；第三次，3000小時；以后均為3000小時/每次。Oilchangeisoneoftheimportantworksforthemaintenanceandserviceofgearreducer,whichhastobecarriedoutinaccordancewiththeregulation.Sincethegearreducerofcoalmillisexposedtotheenvironmentwithdensecoaldustandhightemperature,itisverypossiblethatcoaldustmayberoutedtothegearreducervialabyrinthclearanceofoutputdriveflangeofgearreducer,contaminatinginternallubricantandresultingindecreasedperformanceoflubricant.Prematuredamagetoslidingthrustbearingandbushing,wornrollerbearingandgearsandpitting,etc.allhavecloserelationwithqualityoftheoilbeingused.Therefore,timelychangetooilisnecessary.Therecommendedintervalforchangingoilbasedonexperienceis300hrforthe1sttime,1000hrforthe2ndtime,3000hrforthe3rdtimeand3000hreachtimelater.粗略判別潤滑油是否變質(zhì)的辦法是按規(guī)定期限抽取油樣進行觀察：1.顏色變深，甚至成黑色；2.流動困難；3.在移動零件上留下褐色膠狀物；4.出現(xiàn)沉積物或固體顆粒；5.金屬表面出現(xiàn)腐蝕痕跡；6.散發(fā)出難聞的氣味；7.必要時化驗成分。Aroughmethodtoassesslubricant’sdeteriorationistosampletheoilatspecifiedintervaltocheckif1.thecolorchange,evendark;2.anydifficultmotion;3.anybrownjellyisleftonmovingparts;4.precipitationorsolidparticlesoccur;5.corrosionimprintoccuronmetalsurface;6.foulingodorisdetected.7Examinewherenecessary..以上是對減速機正常運轉(zhuǎn)換油時間的規(guī)定。如果發(fā)生意外，例如，因潤滑系統(tǒng)冷油器漏水導(dǎo)致油品潤滑性能下降時，應(yīng)及時提取油樣，送到專門的技術(shù)部門對油品進行鑒定，確保用油質(zhì)量。Theaboverequirementsareappliedtointervalforchangingoilforgearreducerundernormaloperation.Ifanyunexpectedthingshappen,suchaslubricatingperformanceofoilbecomeworseduetowaterleakfromoilcooleroflubricationsystem,exercisetimelysamplingandsendthesampletotechnicaldepartmentforevaluationtoensurethequalityofoil.換油時還要注意的是所換油品不僅要求符合有關(guān)國家標準規(guī)定，還要與以前運行中的一致。兩個廠家生產(chǎn)的牌號相同的潤滑油不得混用°Duringoilchange,precautionshouldbetakentoensurethatthenewoilshallbenotonlyinlinewiththenationalstandard,butbeconsistentwiththepreviousone.Sametypeoflubricantfromtwodifferentmanufacturersarenotallowedtobeusedatthesametime.換油工作也可利用潤滑站上的油泵進行，此時需要打開油泵后面的三通法蘭，接上排油管向夕卜排油。Oilchangingcanbecarriedoutonoilpumpinthelubricatingstation.Opentriple-flangedownstreamofoilpumptoconnecttooilsupplyline.換油時，減速機內(nèi)部的殘油必須徹底排放干凈，以利于新油有較長時間的工作壽命。殘油的排放可由減速機尾部的閥門和推力軸承油池的放油閥門來進行。Beforeoilchange,residualoilleftinthegearreducermustbefullydrainedtobenefitthelongerlifeofnewoil.Residualoilcanbedrainedviavalveattherearofgearreducerandoildrainvalveinthrustbearingoilsump.換油時，如果發(fā)現(xiàn)減速機內(nèi)過臟，應(yīng)開啟潤滑站對減速機進行清洗。清洗油最好采用減速機工作用油，并排放干凈