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The damage form and replacement plan of rotary kiln roller

Date:2019-11-11 13:58     writer:cement editor     Views:

The supporting wheel is an important part of the rotary kiln. It supports the rotary kiln through the pulley belt. Therefore, the quality of supporting wheel directly influences the operation quality of the kiln, and the damage form and replacement plan of the supporting wheel of the rotary kiln
 

1. Form of damage of rotary kiln supporting wheel


rotary kiln
 

1.1 Peeling surface


The surface of the supporting wheel is crushed and flaked, and the reasons are mainly casting defects and excessive local stress in the rotary kiln, which cause fatigue and loss of metal materials.
 

1.2 accuracy is poor


Due to the poor contact accuracy between the supporting wheel shaft and the tile, the rotary kiln shaft and tile are heated and wire-drawn and irregularly worn.
 

1.3 cracking


The cracking of the supporting wheel and the slippage of the shaft are mainly caused by excessive assembly interference and casting defects.
 

1.4 shaft broken


The cause of shaft fracture is generally too large interference, which causes the shaft of rotary kiln and the contact end of supporting wheel to shrink neck, which causes the shaft fracture due to stress concentration.Of course, the fracture caused by manufacturing defects cannot be ruled out.
 

1.5 service life


The supporting wheel has a long service life, serious wear and stairs, etc., which seriously affects the running quality and affects the up and down running of the rotary kiln. It can be understood that the service life has reached and needs to be replaced.
 

2. Rotary kiln supporting wheel replacement method


rotary kiln
 

(1) prepare maintenance plan, master key size and accuracy requirements of rotary kiln, and make technical preparation.

(2) clean up oil pollution on the spot, find out the center line of rotary kiln and supporting wheel, and mark it on the base and foundation plate of supporting wheel.

(3) deliver jack, chain reversing and other tools to the maintenance site.

(4) after the rotary kiln cools, place the jack steadily in the middle of the belt under the wheel, place a board on the top of the jack to prevent skidding and tighten the jack.

(5) remove the heat shield of the roller tile and place it where it won't be in the way.

(6) remove the cover of the supporting wheel, oil ladle, circulating water pipe, etc., and put them in a place that will not affect the maintenance.

(7) jacking the belt so that it leaves the supporting wheel about 10mm.Check whether the jack leakage sinking phenomenon, if yes, should first discharge fault.If there is no sinking phenomenon, pad steel plate or special-purpose iron between the two sides of the cylinder of the jack and the belt to prevent the leaking belt from sinking, and check the pressure relief of the jack.If there is no adverse reaction, re-tighten the jack and tighten the pad iron.

(8) mark the number around the base of rotary kiln supporting wheel.

(9) loosen the anchor bolts of the foundation of the supporting wheel to be replaced, and push the supporting wheel to a convenient lifting position with the chain reversing or jack.

(10) hang a wire rope on the supporting wheel and lift the supporting wheel away from the site.

(11) clean the supporting wheel, measure the diameter of supporting wheel, shaft head and wear.

(12) clean up oil pollution on the site.Clean tiles and determine if they are still in use. If not, remove them.

(13) if new tiles are replaced, relevant dimension inspection should be carried out on the new tiles.

(14) clean the foreign body oil stains on the new support wheel and measure the size.

(15) according to the inspection results, open the tile mouth to ensure that the clearance on the side of the tile mouth is about two thousandths of the axle diameter, and the oil guide wedge groove is too natural.

(16) the tile is pitted against the shaft so that its envelving Angle is about 60 degrees, and the contact scar is achieved so that the space between the left and right is no more than 3mm.The thrust disc is tightly combined and the scar is even.

(17) examination of the wattle back: grind the wattle to the wattle tyre so that the contact scar is less than 5mm apart.It is then fixed to the tile tyre.

(18) according to the measurement size of the supporting wheel, calculate the position of the new supporting wheel and draw the position of the tile base after the replacement, so as to ensure that the stress state of the supporting wheel of the rotary kiln is basically unchanged from that of the old supporting wheel.

(19) lift the new support wheel on the tile and align it, then remove the sling.

(20) place and align the tile seat of rotary kiln with chain or jack and wire, and check the coincidence degree with the new position.

(21) when there is no problem, tighten the anchor bolt and tighten the top wire.

(22) set a little of the belt, remove the square iron, and slowly put the belt on the supporting wheel.

(23) clean the shaft and tile, install oil spoon, connect circulating water and conduct experiments. If no water leaks, buckle the tile cover.

Add lubricating oil and heat shield.

(25) slowly turn the rotary kiln and check the contact between the thrust plate, tile and shaft according to the oil film.Check whether the oil scoop interference, thrust disc and tile skirt clearance, etc.

(26) check and accept normal, clean up tools, clean up the site, and replace the supporting wheel.

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