Design and Debugging of 500mm Vacuum Mud-Pulling Machine Zheng Yikun (Xi'an Xidian High Voltage Electric Porcelain Co., Ltd., Xi'an 0500mm Vacuum Mud-pulverizer in the whole process of design and commissioning, pointed out the success and insufficiency in the design and manufacture of the machine. The quality of the mud has been greatly improved after the machine has adopted "rubbing mud" to prevent soil pollution, strengthen the mud-sculpting process, reduce extrusion, reduce energy consumption and avoid overloading.
The spiral design of the aircraft selected the United States spiral spiral thrust, the ability to adapt to different moisture mud, squeeze out the mud compact, quality of pregnancy I carefully analyzed the United States spiral structure and various parameters, refer to the British FJGoodson test The relevant data on the spiral parameters and spiral combination made some improvements, namely the end of the spiral added 1/3 lap three-wire spiral spiral spiral aircraft design: 1 extrusion spiral, spiral angle changes in the range of 15 * 25 *; The helix angle order is large and large; the spiral section is the front end face perpendicular to the axle axis of the hub, the end spiral is inclined forward by 3°, and the spiral combination form is single-line, double-line, three-line, leaving space between double and triple lines, and Add a set of mud stick 2 feeding screw, using reamer, comb plate, taper spiral and rake plate, taper spiral from single line * double line; reamer, taper spiral angle is still selected in the range of 15 25 *; The number of knives is 4 more than that of the United States; the taper of taper spiral has been reduced to 9*7. Practice has proved that this spiral is a successful 2.2 seal design. In the design of the machine sealing system, pay attention to Points: Firstly, the “muddy 2.1 spiral design 1 inch 500mm vacuum clay machine was successfully trial-produced before feeding part of the mud through the rake plate into the vacuum chamber, which provided a feasible solution for the large-scale production of 110kV 22CkV rod-shaped large casing in China’s electric porcelain industry. The equipment, also designed for China's electric porcelain industry by itself, designed a vacuum clay-pulverizer, and created a route 2 design based on the technical parameters of the vacuum clay-pulverizer, and the revised data after the aircraft was used. The reference for the aircraft design is simulated The U.S. 250 model (formerly manufactured by Nanjing Electric Porcelain Factory) and the double-stage model 450 (designed and manufactured by China Northwest Institute of Architectural Design) are mainly 110kV 220kV bar and bushings (non-thin-walled), and the machine is medium. The specifications of the equipment, so designers refer to the German PV350 (VEB company) and imitation US 250 vacuum clay machine, made a two-axis, feeding reamer comb plate cone spiral, extrusion mud roller continuous spiral Germany PV350 (biaxial) extruded products, blank inspection pass rate of about 80%, porcelain inspection pass rate of 6 (% or so.
The thickness of the seal ""mud seal" should be appropriate, the structure does not use the screw shaft 40kW with the feed spindle through the vacuum chamber, and the second is the connection surface (planar and curved surface) of the parts designed with the 2.4 drive system connected to the vacuum chamber box. The static seal of the static seal, plus seal (or type 0 seal), and the dynamic seal of the rotary shaft (extrusion screw shaft and pressure mud roller shaft), adopt an improved seal structure, ie the shaft is in the vacuum chamber The front part uses a high-quality skeleton oil seal; the shaft is sealed with an oil-impregnated cotton yarn packing at the rear of the vacuum chamber box; at the same time, the structure of the two shafts is improved and the practice has proved that the effect is good.
2.3 Selection of parameters For the design of the machine's production capacity, screw shaft speed, and screw shaft power requirements, the designer takes into consideration that these three parameters are related to each other and to each other, and there are many factors affecting them. Therefore, the final determination of the aircraft's three parameters, production capacity, 6t / h; screw shaft rotation, feeding screw shaft 11i7min, extrusion screw shaft 9r / min; screw shaft power required, feeding screw shaft 17kW, extrusion For the design of the drive system of the machine, taking into account the reliability of the equipment used, the future of equipment maintenance, ease of operation and other factors, but also take into account the level of manufacturing, the length of the processing cycle, and finally determine the choice of separate transmission program specifically: 1Feeding part is composed of motor V-belt pulley, non-standard gearbox, feeding screw shaft, reamer and taper spiral. 2 Extrusion part is the standard deceleration of motor and V-belt wheel (large pulley is equipped with manual friction clutch) elastic coupling. Box, Cross Coupling Extruded screw shaft (This shaft is divided into two segments with a clamp coupling between them) Gear, Scraper and Extruder Spiral 2.5 General layout design Technical data and finalization of this prototype After the technical data and the technical data of the two are similar, see Table 13. Table 1 Replace the reamer and investigate the installation angle.
Put on the outlet of the machine head and run for less than 20 minutes. Extrude the back end of the spiral first-stage spiral blade to rub the inner wall of the vacuum chamber box.
The bearing seats extruding the screw shaft are tilted backwards and the shaft is snagged.
The bearing seat is cushioned to adjust the assembly position.
When trying to squeeze a small diameter rod product, the reducer gear portion of the extrusion was damaged.
Poor gear quality and inconsistent assembly.
When replacing the gear and reassembling the extruded sleeve product, the clamp shaft coupling of the extruded screw shaft is misused by the twisted material and improperly processed.
When the cast steel is re-machined according to the design drawings and the casing diameter is relatively small and the wall thickness of the casing mud is small (when the water content of the mud is low), the friction clutch will generate heat and slip.
Friction plates are not smooth and poorly assembled.
When the equipment is reworked and equipped with friction plates, the equipment sometimes stops automatically and sometimes automatically.
Electronic control part of the wiring is wrong, poor electrical quality to improve wiring, replace electrical components.
In order to assess the maximum carrying capacity and operational reliability of the equipment, an extraordinary extrusion test was also conducted. That is to say, with the largest and fastest mud volume, the bar-shaped slime is extruded with harder mud. The results show that the equipment operates normally and the extrusion conditions are good.
4 Design Improvement For the current status of 500mm vacuum clay machine, the author chose the design scheme of O500D vacuum clay machine. This machine consists of three parts: kneading device, feed transmission and vacuum extrusion. The extrusion part is reamer and continuous. Spiral structure.
1 Kneading device: Kneading groove (slotted hole at the bottom of the groove) Z-shaped kneading knives (2 pieces) Mud-adjusting plate (2 pieces) Curved ring gear (2 pieces, fixed on adjusting plate) Cylinder Gears (2) Control handles (2 on the left and right sides) Each of the constituent gears and handlebars is connected to the left and right shafts by keys. The operation of the Z-shaped kneading knives is provided by the power supply of the deceleration gear box. The schematic diagram of the kneading device is shown in the operation principle of the kneading device: After the mud (mud cake or mud section) is added into the kneading tank, two Z-shaped kneading knives are made Slowly move towards each other, chop the mixture, knead, squeeze into a “noodle-like†clay strip and feed it continuously and evenly into the feeding screw. Feeding the amount of mud in the feed spiral, the joystick is used to drive the mud control plate to rotate through gears and arc gear ring to control the amount of mud in the mud.
Technical performance of the kneading device: Z-shaped kneading knife turning diameter is Q350mm; Z-shaped kneading knives rotates at 12r/min; kneading ability is 550mnK550mm2. Feeding transmission part: by cylindrical spiral, case and transmission (reduction Box) composed of cylindrical spiral: combination, single-line and double-line; pitch pitch; spiral angle from large to small, varying between 14 ° ~ 17; spiral section vertical.
Feeding section transmission: The mud ("noodle-like" mud) consisting of motor V-belt pulleys, non-standard gearboxes, feed screw shafts and spiral leaves enters the continuous spiral, and is pushed forward with the rotation of the spiral (formed " Mud layer "), after cutting into 40mmK (5~6)mm pieces of mud into a vacuum chamber, the technical performance of this part: screw diameter C400mm, screw shaft speed 10r/min, motor type Y225M~8 , Power 22kW, 3 vacuum extrusion part: composed of vacuum chamber, screw case and transmission device a, vacuum chamber box in the structure has been greatly modified, such as increasing the spacing between the two axes of the vacuum chamber, appropriately reduced Small box body axial size, staggered the location of the two axes in the vertical plane, remove the pressure mud roller, both sides of the box are installed to observe the repair of windows and doors, etc. b, design extrusion spiral made a series of improvements: combination form For the reamer one line, one line, one line, one line and three lines (or double lines); the pitch is not equal; the helix angle varies from large to small and varies between 13*16*, and the surface condition of the cross-sectional shape of the spiral and related dimensional accuracy are all performed. Improved in single and double lines Between the double and triple lines (or double lines), there are vacancies, and equipped with a new type of mud bar c, extrusion part of the transmission device: by the motor, V-belt wheel (large pulley with pneumatic clutch or electromagnetic clutch ) Non-standard gearboxes, extruded screw shafts (this shaft is divided into two sections with a clamp coupling between them) and the extrusion screw constitute the technical performance of this part: the extrusion screw is 500mm; extrusion screw shaft speed 7.5r/min; extrusion spiral pitch is not equidistant; motor model is Y280S-8, power 37kW, rotation speed 730i./min; mud capacity is (6~8)t/h; vacuum chamber relative vacuum degree is 95%; The overall dimensions of the equipment are length X width X height = 5 2300mm; the total weight of the equipment is about 5 Conclusion “knead mud†measures have been adopted. In the equipment, a kneading device has been specially designed to make the mud added to the clay machine. After the kneading, the spiral can be fed evenly and continuously.
Measures to prevent mud contamination are taken. Parts that come in contact with the mud and are exposed to the air, such as reamers, comb plates, rake plates, vacuum chamber walls, etc., are made of stainless steel (or aluminum).
The measures of strengthening the mud-removing process and reducing the disadvantages of extrusion were adopted to optimize the structure and parameters of the feeding screw and the extrusion screw, reduce the rotation speed of the screw shaft, limit the ability to squeeze mud, and strengthen the rubbing of the mud.
The measures taken to reduce the disadvantages of the mud during the vacuum treatment have been systematically improved in the structural shape and size of the vacuum chamber, and the mud entering the vacuum chamber has been cut even thinner, so that the vacuum treatment time has become longer. Reduce leaks (such as removing the pressure roller), strengthen dynamic and static sealing, avoid incomplete extraction of mud in the vacuum chamber and produce dry mud blocks. Take measures to reduce energy consumption to avoid overloading. Add mud to the mud machine. The material is limited in quantity, simplified in the chain, reduced useless power, selected energy-saving components, and added an overload protection device to the electrical equipment to optimize the spiral structure parameters and shaft speed. Measures to strengthen weak links were taken to increase the size of the gearbox , and transform it into a form suitable for the need of the clay machine; for shaft parts, the size is appropriately enlarged and the structure is improved; and the non-integral box such as the feeding tank is also made in the structure size. Improvement measures have been taken to overcome the looseness of the overall structure. In terms of overall layout design, the mud-forming machine shape was better selected, the time for feeding and extruding was better allocated, and the various arrangements were rationalized. In the position of the machine member. In the design of the transmission chain, some measures were taken to simplify the manufacturing and maintenance operations. The extrusion screw shaft was changed from a long shaft to two sections. The reduction box was split and the two boxes were overlapped. Form; the vacuum chamber is changed from single door to double door; the first housing of the vacuum chamber is changed from directly connecting the box wall to the flange protruding from the front wall. Practice has proved that after the above measures are taken, the quality of the extrusion is improved. , Reduced equipment energy consumption and overcome the major problems existing in the current B00mm vacuum clay machine
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