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The damage form and replacement method of rotary kiln roller

  The supporting wheel is an important part of the rotary kiln, which is supported by the wheel belt. Therefore, the supporting wheel directly affects the running quality of the kiln. The following is a brief introduction of the damage form and replacement method of the supporting wheel of the rotary kiln, for the reference of peers.

  A, the form of wheel damage

  There are many forms of wheel damage.

  First of all, the surface of the supporting wheel is crushed and peeled off, which is mainly caused by casting defects, excessive local stress and other fatigue of metal materials.

  Second, due to the poor contact precision of the bearing wheel shaft and tile, resulting in hot wire drawing and irregular wear of the shaft and tile.

  Thirdly, the roller cracked and the shaft slipped, which were mostly caused by excessive assembly interference and casting defects.

  Fourth, shaft fracture, the cause of shaft fracture is usually too much interference, causing the end of the shaft and the supporting wheel contact necking, resulting in the shaft fracture due to stress concentration;

  Fracture due to manufacturing defects cannot be ruled out.

  Fifth, the service life of the roller is long, and the steps are severely worn, etc., which seriously affects the operation quality and affects the up and down running of the kiln. It can be understood that the service life has expired and it needs to be replaced, etc.

  Second, the method of the replacement of the pulley

  1. Prepare maintenance plan, master key size and precision requirements, and make technical preparations.

  2. Clean up oil stains on site, find out the center line of kiln and supporting wheel, and mark on the supporting wheel base and foundation foundation plate.

  3. Transport the jack, chain reversal and other tools to the maintenance site.

  4. After the kiln cools down, place the jack under the belt in the middle stably and put a board on the top of the jack to prevent slipping and tighten the jack.

  5. Remove the heat shield of the roller shoe and put it in an unobstructed place.

  6. Remove the bearing wheel tile cover, oil spoon, circulating water pipe, etc. and put them in a place that does not affect the maintenance.

  7. Jacking the pulley belt so that it leaves the supporting wheel about 10 mm.

  Check whether the jack is leaking and sinking, if so, discharge the fault first.

  If there is no sinking, tighten the pad steel plate or special square iron between the two sides of the oil cylinder of the jack and the pulley belt to prevent the leaking pulley belt from sinking, and conduct pressure relief inspection on the jack.

  If no adverse reaction occurs, re-tighten the jack and tighten the shim.

  8. Type and mark around the base of the supporting wheel.

  9. Loosen the anchor bolt of the base of the supporting wheel to be replaced, and push the supporting wheel to a position convenient for lifting with chain backward or jack.

  10. Hang the steel wire rope on the supporting wheel, and lift the supporting wheel off the site.

  11. Clean up the supporting wheel and measure the diameter and wear of the supporting wheel and shaft head.

  Clean up oil on site.

  Clean the tile and determine whether it is still used, if not, remove it.

  13. If new tiles are replaced, relevant dimensional inspection should be carried out for new tiles.

  14. Clean up the foreign body oil stains on the new supporting wheel and measure the size.

  15. According to the inspection and test results, open the tile, ensure that the gap on the side of the tile is about two thousandths of the axle diameter, and the oil wedge groove is excessively natural.

  16. The tile should be lapped with the shaft so that the wrapping Angle is about 60 degrees and the contact scar can be reached to a distance of no more than 3 mm.

  The thrust plate is tightly combined and the scar is even.

  17. Examination of the tile back: grind the tile against the tile so that the contact scar is less than 5 mm apart.

  Then fix it on the tile tire.

  18. According to the measured size of the roller, calculate the position of the new roller and draw the position of the replacement tile base to ensure that the stress state of the roller and the old roller are relatively unchanged.

  19. Hoist the new supporting wheel on the tile and align it, then remove the sling.

  20. Put the tile seat in place and align it with the top wire by using chain backward or jack, and check the coincidence degree with the new position.

  21. When there is no problem, tighten the anchor bolt and the top wire.

  22. Set the belt a little, remove the square iron, and slowly put the belt on the supporting wheel.

  23. Clean the shaft and tile, install the oil spoon, connect the circulating water and conduct experiments. If no water leakage, buckle the tile cover.

  24. Add lubricant and install heat shield.

  25. For slow rotary kiln, check and judge the contact between thrust disc, tile and shaft according to the oil film condition.

  Check whether the oil spoon interferes with the thrust plate and the gap between the tile skirt.

  26. Check and accept normal, clear tools, clean the site, and replace the supporting wheel.

  Three, the conclusion

  Because the supporting structure of each enterprise is slightly different, the maintenance scheme is not the same;

  For the accuracy of the tile requirements of the units are also different, out of the larger, at the same time, this paper to the replacement of the roller as the center, involving not much scraping tile.

  To sum up, this scheme can only serve as a reference, and due to the limited level of the author, it is inevitable to make mistakes.

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