Technical Service Report for ATOX50 Mill at a Specific Cement Plant's Line Three
Publishdate：2024-08-22 Views：1753
摘要：客戶ATOX50原料磨利用檢修時間更換磨輥軸承，我公司技術到現(xiàn)場對安裝更換過程進行了協(xié)助、指導和監(jiān)督。
Summary: The customer's ATOX50 raw mill utilized the maintenance period to replace the roller bearings. Our company's technician assisted, guided, and supervised the installation and replacement process on-site.
一、至現(xiàn)場時，設備的安裝狀況 Equipment Installation Status On Site
1、至現(xiàn)場時，磨輥已經解體并部分進行清洗，2#磨輥外間隔套未進行拆卸，位置確認未發(fā)生移動。
Upon arrival at the site, the roller had been disassembled and partially cleaned, with the outer distance ring of roller #2 not yet disassembled, and its position confirmed to have not shifted.
2、2#磨輥使用全新的FAG軸承。軸承型號為F-679545.NU（NU20/800-E-M1A)和F-679568.PRL(241/710-B-K30-MB-H44-SA)
Roller #2 used brand new FAG bearings. The bearing models were F-679545. NU (NU20/800-E-M1A) and F-679568. PRL (241/710-B-K30-MB-H44-SA).
3#磨輥使用一只標志僅有“GERMANY X.D”雙列圓錐軸承，該軸承為已使用過的舊軸承，軸承滾珠表面鍍層有明顯的磨損和銹蝕的痕跡，另一只軸承型號為F-679545.NU，全新，生產商為FAG.
Roller #3 used a double-row tapered roller bearing marked only with "GERMANY X.D", which was a used bearing. The coating on the bearing balls showed noticeable wear and rust, and the other bearing model was F-679545.NU, which was new and manufactured by FAG.
二、安裝服務過程 Installation Service Process
1、對部件潤滑油路進行清理和檢查。Cleaning and inspection of the component lubrication oil circuit.
（1）清洗前檢查 Inspection before cleaning.
（2）清洗 Cleaning
（3）清洗后 After cleaning
2、主軸和輪轂清理 Cleaning of the main shaft and hub
3、內側端蓋清理、間隔圈清理、骨架油封安裝、內側空氣密封內環(huán)安裝。
Cleaning of the inner cover, distance ring, installation of the rotary shaft seal, the inner sealing ring.
4、用油煮NU20/800軸承內圈并安裝到主軸上，安裝軸承內間隔套于主軸上。過程中使用銅棒輔助安裝。
Heating the inner ring of the NU20/800 bearing in oil and installing it onto the main shaft, then installing the bearing inner distance ring onto the main shaft. A copper rod was used to assist with the installation.
5、安裝內側端蓋O型圈，涂抹美孚1500潤滑脂于骨架油封唇口，將內側端蓋安裝于主軸上并固定。
Installing the inner cover O-ring, applying Mobil 1500 lubricating grease to the lip of the rotary shaft seal, installing and securing the inner cover onto the main shaft.
6、用液氮冷凍安裝3#輥外間隔套、2#3#輥NU20/800外圈和241/710軸承。檢查間隔套和軸承接觸正常。
Using liquid nitrogen to freeze and install the outer distance ring of roller #3, the outer rings of NU20/800 for rollers #2 and #3, and the 241/710 bearing. Ensuring the proper contact between the outer distance ring and the bearing.
7、清理安裝軸承外圈和主軸，將主軸小心套入輪轂，用葫蘆拉緊，促使241/710軸承內圈與內間隔套緊密接觸。用支架撐起主軸，保持輪轂能盤動。
Cleaning the installation of the bearing outer ring and main shaft, carefully placing the main shaft into the hub, and using a hoist to tighten it, ensuring tight contact between the inner ring of the 241/710 bearing and the inner distance ring. Support the main shaft with a stand to keep the hub rotating.
8、清理退卸套，將退卸套安裝入磨輥，安裝壓盤，涂抹密封膠，緊固內側端蓋，轉動磨輥，現(xiàn)場采用人工方式逐步緊固壓盤螺栓調整241/710軸承游隙，調整結果：2#輥軸承游隙為0.11mm，3#軸承游隙為0.13mm。測量軸承內圈到退卸套端面的高度為：2#平均71.24mm 、3#平均60.50mm,加工壓環(huán)后，對壓環(huán)按扭矩對壓環(huán)螺栓進行了緊固，壓環(huán)與軸承內圈接觸緊密。
Cleaning the conical sleeve, installing it into the roller, installing the bearing retainer ring, applying sealant, tightening the inner cover, and rotating the roller. The bolts of the bearing retainer ring were gradually tightening manually on-site, adjusting the clearance of the 241/710 bearing. The results were that the clearance of the roller #2 bearing was 0.11mm, and the bearing #3 clearance was 0.13mm. The measured height from the bearing inner ring to the end face of the conical sleeve was an average of 71.24mm for #2 and 60.50mm for #3. After processing the bearing retainer ring, the bolts of the bearing retainer ring were tightened according to the torque, ensuring close contact between the bearing retainer ring and the bearing inner ring.
9、清理外側端蓋和隔圈、凸密封，安裝外側端蓋O型圈，安裝外側端蓋和隔圈。安裝骨架油封。
Cleaning the outer cover, outer distance ring, convex seal, installing the outer cover O-ring, installing the outer cover and outer distance ring and then installing the rotary shaft seal.
10、清理凸密封并安裝。Cleaning and installing the convex seal.
11、對中心架法蘭和總成法蘭進行清理，安裝O型圈，吊裝總成，使用液壓拉伸器使用葫蘆拉緊-100Bar-125Bar對稱緊固M80螺栓，總成與中心架法蘭接觸正常。
Cleaning the center frame flange and flange assembly, installing the O-ring, lifting the assembly, and using a hydraulic stretcher and hoist to tighten the M80 bolts symmetrically at 100Bar-125Bar. The flange assembly made proper contact with the center frame flange.
三、安裝過程中的不足 Shortcomings During the Installation Process
1、3#輥241/710無明顯軸承型號，使用時間長，滾珠表面存在較嚴重缺陷，且該軸承在安裝過程中發(fā)現(xiàn)該軸承保持架定位銷斷裂導致保持架移位，保持架移位導致滾珠磨損不一致，在調整游隙過程中，也發(fā)現(xiàn)同一位置不同滾珠的游隙存在稍許差異，因此該軸承的運行狀態(tài)將會對全新的F-679545.NU安全運行產生影響，影響F-679545.NU運行狀態(tài)和壽命。
The #3 roller 241/710 bearing lacks a clear model marking, had been in use for a long time, and the bearing balls showed severe defects. During the installation, the positioning pin of the cage was found to be broken, causing the cage to shift, which led to uneven wear on the bearing balls. During the clearance adjustment process, slight differences in clearance were observed among the bearing balls at the same position. Therefore, the operating condition of this bearing would affect the safe operation of the new F-679545.NU bearing, impacting its operational status and lifespan.
保持架雖然對定位銷進行了更換，建議運行過程中加強對油品的檢查，防止保持架再發(fā)生問題，影響軸承壽命和磨機的運行。
Although the positioning pin of the cage was replaced, it is recommended to strengthen oil inspection during operation to prevent further issues with the cage that could affect the bearing's lifespan and the mill's operation.
2、調整游隙時對壓板進行人工加壓的效果比使用液壓螺母（專用工具）的效果差，主要表現(xiàn)在人工加壓過程中螺栓對螺孔螺紋造成傷害，在運行中有造成緊固螺栓松動的風險。
The effect of manual pressure plate tightening during clearance adjustment was inferior to that of using a hydraulic nut (professional tool), primarily reflecting in the manual pressurization process of the bolt to damage the threads of the screw holes. This might lead to the loosening of securing bolts during operation.
3、3#輪轂內側O 型圈位置銹蝕嚴重，表面凹凸，影響O型圈的密封效果，運行中有漏油的風險。
The O-ring position on the inner side of the #3 hub was severely corroded, with an uneven surface, which affects the sealing effect of the O-ring and poses a risk of oil leakage during operation.
4、其它 Other Issues
（1）二線立磨出現(xiàn)夾板開裂的情況，經入磨檢查輥皮與輪轂的接觸情況，發(fā)現(xiàn)輥皮與輪轂的間隙較大，最大的間隙大于0.4mm，設備安裝要求小于0.15mm，因此，建議對輥皮與輪轂間的間隙重新進行調整，以降低夾塊繼續(xù)開裂的風險。
The second line vertical mill experienced clamp cracks. Upon inspection, it was found that the gap between the roller tires and the hub was large, with the maximum gap exceeding 0.4mm, while the equipment installation requirement should be less than 0.15mm. Therefore, it is recommended to readjust the gap between the roller cover and the hub to reduce the risk of further cracking of the clamp.
（2）三線輥皮存在輥皮與夾塊的接觸位置出現(xiàn)開裂和掉塊的現(xiàn)狀，存在運行中輥皮脫落的風險，有可能造成嚴重的設備事故，建議更換。
The third line roller tires cracked and fell apart at the contact points with the clamp, posing a risk of roller tires detachment during operation, which could lead to a serious equipment accident. It is recommended to replace it.
摘要：客戶ATOX50原料磨利用檢修時間更換磨輥軸承，我公司技術到現(xiàn)場對安裝更換過程進行了協(xié)助、指導和監(jiān)督。
Summary: The customer's ATOX50 raw mill utilized the maintenance period to replace the roller bearings. Our company's technician assisted, guided, and supervised the installation and replacement process on-site.
一、至現(xiàn)場時，設備的安裝狀況 Equipment Installation Status On Site
1、至現(xiàn)場時，磨輥已經解體并部分進行清洗，2#磨輥外間隔套未進行拆卸，位置確認未發(fā)生移動。
Upon arrival at the site, the roller had been disassembled and partially cleaned, with the outer distance ring of roller #2 not yet disassembled, and its position confirmed to have not shifted.
2、2#磨輥使用全新的FAG軸承。軸承型號為F-679545.NU（NU20/800-E-M1A)和F-679568.PRL(241/710-B-K30-MB-H44-SA)
Roller #2 used brand new FAG bearings. The bearing models were F-679545. NU (NU20/800-E-M1A) and F-679568. PRL (241/710-B-K30-MB-H44-SA).
3#磨輥使用一只標志僅有“GERMANY X.D”雙列圓錐軸承，該軸承為已使用過的舊軸承，軸承滾珠表面鍍層有明顯的磨損和銹蝕的痕跡，另一只軸承型號為F-679545.NU，全新，生產商為FAG.
Roller #3 used a double-row tapered roller bearing marked only with "GERMANY X.D", which was a used bearing. The coating on the bearing balls showed noticeable wear and rust, and the other bearing model was F-679545.NU, which was new and manufactured by FAG.
二、安裝服務過程 Installation Service Process
1、對部件潤滑油路進行清理和檢查。Cleaning and inspection of the component lubrication oil circuit.
（1）清洗前檢查 Inspection before cleaning.
（2）清洗 Cleaning
（3）清洗后 After cleaning
2、主軸和輪轂清理 Cleaning of the main shaft and hub
3、內側端蓋清理、間隔圈清理、骨架油封安裝、內側空氣密封內環(huán)安裝。
Cleaning of the inner cover, distance ring, installation of the rotary shaft seal, the inner sealing ring.
4、用油煮NU20/800軸承內圈并安裝到主軸上，安裝軸承內間隔套于主軸上。過程中使用銅棒輔助安裝。
Heating the inner ring of the NU20/800 bearing in oil and installing it onto the main shaft, then installing the bearing inner distance ring onto the main shaft. A copper rod was used to assist with the installation.
5、安裝內側端蓋O型圈，涂抹美孚1500潤滑脂于骨架油封唇口，將內側端蓋安裝于主軸上并固定。
Installing the inner cover O-ring, applying Mobil 1500 lubricating grease to the lip of the rotary shaft seal, installing and securing the inner cover onto the main shaft.
6、用液氮冷凍安裝3#輥外間隔套、2#3#輥NU20/800外圈和241/710軸承。檢查間隔套和軸承接觸正常。
Using liquid nitrogen to freeze and install the outer distance ring of roller #3, the outer rings of NU20/800 for rollers #2 and #3, and the 241/710 bearing. Ensuring the proper contact between the outer distance ring and the bearing.
7、清理安裝軸承外圈和主軸，將主軸小心套入輪轂，用葫蘆拉緊，促使241/710軸承內圈與內間隔套緊密接觸。用支架撐起主軸，保持輪轂能盤動。
Cleaning the installation of the bearing outer ring and main shaft, carefully placing the main shaft into the hub, and using a hoist to tighten it, ensuring tight contact between the inner ring of the 241/710 bearing and the inner distance ring. Support the main shaft with a stand to keep the hub rotating.
8、清理退卸套，將退卸套安裝入磨輥，安裝壓盤，涂抹密封膠，緊固內側端蓋，轉動磨輥，現(xiàn)場采用人工方式逐步緊固壓盤螺栓調整241/710軸承游隙，調整結果：2#輥軸承游隙為0.11mm，3#軸承游隙為0.13mm。測量軸承內圈到退卸套端面的高度為：2#平均71.24mm 、3#平均60.50mm,加工壓環(huán)后，對壓環(huán)按扭矩對壓環(huán)螺栓進行了緊固，壓環(huán)與軸承內圈接觸緊密。
Cleaning the conical sleeve, installing it into the roller, installing the bearing retainer ring, applying sealant, tightening the inner cover, and rotating the roller. The bolts of the bearing retainer ring were gradually tightening manually on-site, adjusting the clearance of the 241/710 bearing. The results were that the clearance of the roller #2 bearing was 0.11mm, and the bearing #3 clearance was 0.13mm. The measured height from the bearing inner ring to the end face of the conical sleeve was an average of 71.24mm for #2 and 60.50mm for #3. After processing the bearing retainer ring, the bolts of the bearing retainer ring were tightened according to the torque, ensuring close contact between the bearing retainer ring and the bearing inner ring.
9、清理外側端蓋和隔圈、凸密封，安裝外側端蓋O型圈，安裝外側端蓋和隔圈。安裝骨架油封。
Cleaning the outer cover, outer distance ring, convex seal, installing the outer cover O-ring, installing the outer cover and outer distance ring and then installing the rotary shaft seal.
10、清理凸密封并安裝。Cleaning and installing the convex seal.
11、對中心架法蘭和總成法蘭進行清理，安裝O型圈，吊裝總成，使用液壓拉伸器使用葫蘆拉緊-100Bar-125Bar對稱緊固M80螺栓，總成與中心架法蘭接觸正常。
Cleaning the center frame flange and flange assembly, installing the O-ring, lifting the assembly, and using a hydraulic stretcher and hoist to tighten the M80 bolts symmetrically at 100Bar-125Bar. The flange assembly made proper contact with the center frame flange.
三、安裝過程中的不足 Shortcomings During the Installation Process
1、3#輥241/710無明顯軸承型號，使用時間長，滾珠表面存在較嚴重缺陷，且該軸承在安裝過程中發(fā)現(xiàn)該軸承保持架定位銷斷裂導致保持架移位，保持架移位導致滾珠磨損不一致，在調整游隙過程中，也發(fā)現(xiàn)同一位置不同滾珠的游隙存在稍許差異，因此該軸承的運行狀態(tài)將會對全新的F-679545.NU安全運行產生影響，影響F-679545.NU運行狀態(tài)和壽命。
The #3 roller 241/710 bearing lacks a clear model marking, had been in use for a long time, and the bearing balls showed severe defects. During the installation, the positioning pin of the cage was found to be broken, causing the cage to shift, which led to uneven wear on the bearing balls. During the clearance adjustment process, slight differences in clearance were observed among the bearing balls at the same position. Therefore, the operating condition of this bearing would affect the safe operation of the new F-679545.NU bearing, impacting its operational status and lifespan.
保持架雖然對定位銷進行了更換，建議運行過程中加強對油品的檢查，防止保持架再發(fā)生問題，影響軸承壽命和磨機的運行。
Although the positioning pin of the cage was replaced, it is recommended to strengthen oil inspection during operation to prevent further issues with the cage that could affect the bearing's lifespan and the mill's operation.
2、調整游隙時對壓板進行人工加壓的效果比使用液壓螺母（專用工具）的效果差，主要表現(xiàn)在人工加壓過程中螺栓對螺孔螺紋造成傷害，在運行中有造成緊固螺栓松動的風險。
The effect of manual pressure plate tightening during clearance adjustment was inferior to that of using a hydraulic nut (professional tool), primarily reflecting in the manual pressurization process of the bolt to damage the threads of the screw holes. This might lead to the loosening of securing bolts during operation.
3、3#輪轂內側O 型圈位置銹蝕嚴重，表面凹凸，影響O型圈的密封效果，運行中有漏油的風險。
The O-ring position on the inner side of the #3 hub was severely corroded, with an uneven surface, which affects the sealing effect of the O-ring and poses a risk of oil leakage during operation.
4、其它 Other Issues
（1）二線立磨出現(xiàn)夾板開裂的情況，經入磨檢查輥皮與輪轂的接觸情況，發(fā)現(xiàn)輥皮與輪轂的間隙較大，最大的間隙大于0.4mm，設備安裝要求小于0.15mm，因此，建議對輥皮與輪轂間的間隙重新進行調整，以降低夾塊繼續(xù)開裂的風險。
The second line vertical mill experienced clamp cracks. Upon inspection, it was found that the gap between the roller tires and the hub was large, with the maximum gap exceeding 0.4mm, while the equipment installation requirement should be less than 0.15mm. Therefore, it is recommended to readjust the gap between the roller cover and the hub to reduce the risk of further cracking of the clamp.
（2）三線輥皮存在輥皮與夾塊的接觸位置出現(xiàn)開裂和掉塊的現(xiàn)狀，存在運行中輥皮脫落的風險，有可能造成嚴重的設備事故，建議更換。
The third line roller tires cracked and fell apart at the contact points with the clamp, posing a risk of roller tires detachment during operation, which could lead to a serious equipment accident. It is recommended to replace it.
