摘要：客戶一線ATOX50立磨，此次檢修更換我司高鉻輥皮與磨盤襯板，我司提供了安裝指導(dǎo)服務(wù)。現(xiàn)場服務(wù)期間，測量了輥皮與磨盤襯板磨損數(shù)據(jù)分析等，詳細(xì)情況見下文報告。

Summary: For the Line 1 ATOX50 vertical mill, high-chromium roller segments and table liner from NPM were replaced during this maintenance shutdown. NPM provided installation guidance services. During the on-site service, wear data for the roller segments and table liner were measured and analyzed. Details are provided in the report below.

一、高鉻輥皮安裝 High-Chromium Roller segment Installation

1、安裝位置及日期 Installation Location and Date

安裝位置：2#磨輥

Position: Roller 2#

安裝日期：2025年9月14日-9月19日

Date: September 14, 2025 - September 19, 2025

2、安裝過程及注意事項 Installation Process and Key Points

(1) 吊裝前清理干凈輥皮安裝面防銹脂。

(1) Clean the anti-rust grease from the roller segment mounting surface before hoisting.

(2) 使用手持百葉片磨光機(jī)多次清理輪轂表面（此輪轂使用輥皮由30°輥皮改為45°輥皮）。

(2) Repeatedly clean the hub surface using a hand-held flap disc grinder (The roller segments used on this hub were changed from 30° to 45° profile).

(3) 放置輥皮到正確位置后，測量輥皮與輪轂間隙超過0.15mm，因此全部輥皮安裝使用了高分子金屬修復(fù)劑進(jìn)行填充。

(3) After placing the roller segment in the correct position, the measured gap between the segment and the hub exceeded 0.15mm. Therefore, a polymer metal repair agent was used for filling during the installation of all segments.

(4) 根據(jù)OEM要求，螺栓緊固Tightening force是987KN。現(xiàn)場工具是tentec液壓螺母，根據(jù)液壓螺母面積換算手動泵壓力1162bar。

(4) According to OEM requirements, the bolt tightening force is 987 KN. The on-site tool used was a Tentec hydraulic nut. Based on the hydraulic nut area, the corresponding manual pump pressure was calculated to be 1162 bar.

(5) 注意事項——輥皮螺栓復(fù)緊

(5) Key Point ------ Roller segment Bolt Re-tightening

Re-Tightening of the bolts are to be carried out after 8 hours, 24 hours and after 48 hours of mill operation subsequently until the bolts torque were found to be constant.

二、磨盤襯板安裝 Table Liner Installation

1、安裝日期 Installation Date

2025年9月18日-9月23日

September 18, 2025 - September 23, 2025

2、安裝過程及注意事項 Installation Process and Key Points

(1) 吊裝前，清理干凈磨盤襯板安裝面防銹脂。

(1) Clean the anti-rust grease from the table liner mounting surface before hoisting.

(2) 使用手持百葉片磨光機(jī)反復(fù)打磨干凈磨盤。

(2) Repeatedly grind and clean the grinding table surface using a hand-held flap disc grinder.

(3) 使用塞尺檢查磨盤襯板與磨盤間隙符合要求。

(3) Use a feeler gauge to check the gap between the table liner segments and the table; ensure it meets requirements.

(4) 此次拆卸磨盤襯板時發(fā)現(xiàn)固定螺栓斷裂較多，因此為了限制磨盤襯板位置，防止磨盤襯板在使用過程中出現(xiàn)橫向移動，內(nèi)外側(cè)全部使用墊片塞緊。

(4) During the removal of the table liner, a significant number of broken fixing bolts were found. Therefore, to restrict the position of the liner segments and prevent lateral movement during operation, shims were used to tightly pack both the inner and outer sides.

(5) 根據(jù)OEM要求，磨盤襯板螺栓緊固扭矩為1900Nm。現(xiàn)場使用工具是液壓扭矩扳手（TWS150N），對應(yīng)的要求扭矩的泵壓力為90bar。

(5) According to OEM requirements, the tightening torque for the table liner bolts is 1900 Nm. Hydraulic torque wrench (TWS150N) was used on site, with a corresponding pump pressure of 90 bar for the required torque.

(6) 注意事項——磨盤襯板螺栓復(fù)緊

(6) Key Point ------ Table Liner Bolt Re-tightening

Re-Tightening of the bolts are to be carried out after 8 hours, 24 hours and after 48 hours of mill operation subsequently until the bolts torque were found to be constant.

3、擋料圈實際高度 Actual Dam Ring Height

更換新磨盤襯板后，擋料圈實際高度（從磨盤襯板表面到擋料圈頂部距離）215mm，在合理范圍內(nèi)，開機(jī)前不需要重新調(diào)整擋料圈高度。

After installing the new table liner segments, the actual dam ring height (distance from the table liner surface to the top of the dam ring) is 215mm, which is within the reasonable range. No adjustment of the dam ring height is required before start-up.

開機(jī)后根據(jù)磨機(jī)吐渣量、料層及主電機(jī)電流波動情況以及工藝控制要求，可適當(dāng)微調(diào)擋料圈高度。

After start-up, the dam ring height can be fine-tuned appropriately based on the mill spillage, material bed thickness, fluctuations in the main motor current, and process control requirements.

三、輥皮與磨盤襯板磨損檢查 Roller Segment and Table Liner Wear Inspection

1、輥皮與磨盤襯板使用情況統(tǒng)計 Usage Statistics for Roller segments and Table Liner

2、輥皮與磨盤襯板磨損數(shù)據(jù)、磨損輪廓 Wear Data and Wear Profiles for Roller segments and Table Liner

Roller 1#

Roller 2#

Roller 3#

Table liner

3、結(jié)論與建議 Conclusions and Recommendations

(1) 從磨損輪廓上看，即使2#磨輥更換了新輥皮，但三個磨輥輥皮磨損程度還是存在一定差異。這樣在磨機(jī)運行過程中容易造成料層不穩(wěn)，磨機(jī)振動偏大從而引起其他設(shè)備故障（如磨輥軸承損壞、豎直拉桿斷裂等）。

(1) Based on the wear profiles, even though a new roller segment was installed on Grinding Roller 2#, there is still a certain degree of difference in the wear levels of the three roller segments. This can easily lead to an unstable material bed during mill operation, causing increased mill vibration, which may lead to other equipment failures (such as roller bearing damage, vertical tie rod fracture, etc.).

(2) 石灰石粒度偏大，這樣不僅降低粉磨效率、增加電耗，而且還會加快輥皮與磨盤襯板磨損速度、引起磨機(jī)振動。建議控制石灰石粒度在合理范圍內(nèi)（最大粒度不超過100mm，≤50mm粒度占比不低于85%）。

(2) The limestone particle size is relatively large. This not only reduces grinding efficiency and increases power consumption but also accelerates the wear rate of the roller segments and table liner, and can cause mill vibration. It is recommended to control the limestone particle size within a reasonable range (maximum particle size not exceeding 100mm, proportion of particles ≤50mm should be no less than 85%).

(3) 建議明年大修期間更換1#磨輥輥皮，同時根據(jù)2#、3#輥皮磨損情況進(jìn)行調(diào)面，這樣降低三個磨輥輥皮磨損差異程度。

(3) It is recommended to replace the roller segment on Grinding Roller 1# during next year’s overhaul. Simultaneously, reverse Roller 2# and 3# segments based on the wear condition. This will help reduce the disparity in wear among the three roller segments.

(4) 建議后續(xù)三個磨輥輥皮同步進(jìn)行更換，這樣在輥皮磨損差異相近的情況下，可以使得磨機(jī)運行更加穩(wěn)定。

(4) It is recommended to replace the roller segments on all three grinding rollers at the same time in the future. This will allow the mill to operate more stably when the three roller segments have similar wear level.

(5) 建議控制磨盤襯板最大磨損量（不超過70mm），有利于使得磨機(jī)保持較高的粉磨效率。

(5) It is recommended to control the maximum wear amount of the table liner (not exceeding 70mm), which is beneficial for maintaining high grinding efficiency of the mill.