In order to protect cement mechanical equipment, a hydraulic coupler is often installed in the equipment transmission system to connect the motor and the reducer end to achieve flexible start and reduce the impact when starting the equipment. However, the installation and use of the hydraulic coupler requires high centering, and the motor, The vibration of the reducer is difficult to alleviate, resulting in transmission problems caused by the vibration of the motor and the reducer, increasing the amount of maintenance and replacement of accessories. When encountering impact load, it will lead to oil leakage from the liquid couple, and each treatment time should be more than 2 hours, resulting in a low linkage rate of the equipment, which restricts the normal production of the cement mill, and even causes the explosion of the fusible plug-in severe cases, resulting in shutdown. . When the weather is hot and the ambient temperature is high, the failure of the hydraulic coupling is more prominent.
Magnetic transmission products are currently a new green product that achieves the dual indicators of safety, reliability, energy saving and consumption reduction. A Chinese company has adopted a new type of flexible transmission protection device, the synchronous permanent magnet coupling, in the transmission of a 500kW roller press. The operation effect is very good, and the vibration is greatly reduced. mm/s, axis 0.2 mm/s; reducer end horizontal 0.4 mm/s, vertical 0.2 mm/s, axis 0.4mm/s).
The staff said that when the rolling system was in operation, a hydraulic coupling was required to be kept aside. Now, after the transformation with the synchronous permanent magnetic coupling:
△Reduces system vibration, relieves impact load, protects the equipment on the entire transmission chain, prolongs the service life of the entire shafting system, and improves system reliability;
△Solved the problem of frequent oil leakage and injection of the original hydraulic coupler, reduced maintenance costs and improved production efficiency.
Another typical case of roller press drive system: Cement plant roller presses originally used hydraulic couplings:
1. The operating condition of the roller press is bad. Due to the unevenness of the feeding material and the different size, sometimes there are stones or even iron parts in the feeding material, resulting in frequent short-term impact loads;
2. The moving roller needs to adapt to the working conditions and can swing laterally, so when the existing universal joint coupling is used at a large angle, the shafting will have alternating axial forces;
3. The diameter of the hydraulic coupling is 750mm, all of which are suspended on the load shaft;
4. When the working temperature is high, the hydraulic coupling will leak oil;
5. When the pressure roller is stuck, the hydraulic coupler is prone to overload and oil injection, and occasionally the hydraulic coupler explodes, resulting in high maintenance frequency and high maintenance costs, which affect normal production.
After being transformed into a synchronous permanent magnet coupling:
1. The permanent magnetic coupling is installed at the end of the reducer, and it can be replaced with the same size as the hydraulic coupling. There is no need to change the foundation, and there is no need to move the motor during installation, so it is easy to replace.
2. The removal method of the permanent magnetic coupling is consistent with the installation method of the hydraulic coupling. The tolerance of the installation hole of the permanent magnetic coupling is enlarged, and the small clearance fit is adopted, and the shaft hole is easy to install.
3. The weight of the permanent magnetic coupling has been reduced and optimized, which is about the same as the weight of the existing hydraulic coupling after filling with oil. The total weight of the hydraulic coupling is 227Kg, and the weight of the permanent magnetic coupling is 230Kg.
4. The permanent magnetic coupling of this scheme adopts the cold installation method, and the disassembly method adopts the bolt top screw attachment.
5. All displacements of moving and fixed rollers are compensated by universal couplings, and permanent magnetic couplings, like hydraulic couplings, do not participate in displacement compensation in all directions.
6. After the permanent magnetic coupling replaces the hydraulic coupling, it can effectively buffer the impact of large materials. Power fluctuations will not affect the permanent magnetic coupling. At the same time, the elastic displacement angle of the permanent magnetic coupling can compensate for part of the shock wave. move.
After modification with permanent magnetic coupler, the effect is very good:
1. Provide flexible transmission and overload protection for the reducer and roller press, avoiding the damage of the reducer gear and roller surface under impact load.
2. After canceling the hydraulic coupling, the maintenance workload is reduced, the maintenance cost is saved, and there is no oil leakage damage.
3. Because the synchronous permanent magnet coupling operates synchronously, there is no slip, and the efficiency reaches 99.9%, which improves the energy consumption and output rate.
4. The vibration value of the pressure roller transmission shaft system is greatly reduced, especially the vibration value at the end of the reducer.