卧式砂磨机操作规程定稿.docx

卧式砂磨机操作规程定稿编号LCGY-004工艺守则第1张共5张卧式砂磨机操作规程一、本工艺适用于车间卧式砂磨机操作的技术指导性规程。二、砂磨机结构由主机,含单端面机械密封装置及与其相配套的润滑、冷却油路系统,、筒体、分散器、筛圈-动态分离复合分离器、内圆弧齿轮泵、压力和温度的监控系统、机身、辅助支架等部分组成.在筒体内装直径为1-3厘米的玻璃珠或错珠作为分散介质。三、砂磨机的分散原理1 .卧式砂磨机的主轴水平布局按一定的间距装有7-9个分散盘分散轴由主电动带动高速转动,从而使筒体内的分散介质作剧烈运动，同时经预混合的漆浆从送料系统送入筒体。研磨分散进行过程中物料从一端向另一端流动颜料的聚集体和附聚体在这里受到高速运动的分散介质的剪切和冲击作用，从而在分散盘之间得到分级分散。当漆浆和分散介质的混合物到达筒体另一端时,分散介质为筛圈-动态分离复合分离器截留,漆浆溢此从而完成一次分散。因漆浆受到剪切和冲击作用时会引起温度升高,因此研蘑筒体设有冷水夹套,通水进行冷却。2 .影响砂磨机分散效率的因素：a.主轴转数:砂磨机的分散效率和分散转数成正比.b.砂磨介质：一般情况下产品要求的细度越细,使用的研磨介质的直径也相应小一些.因介质直径,通常在1.5-2.5mm之间，愈小,球体之间相应碰撞发生剪切作用的机率越大,研磨分散效率也会提高。C.研磨介质的装填量:一般介质的装填量越大,研磨分散效率越高。但因介质比重,漆浆稠度和研磨机主轴功率的限制,装填量不能过大,否则启动困难,通常卧式砂磨的装砂量为筒体有效容量的85,。如出料温度过高应减少装填量若出料温度过低为了提高研磨效率而应适当增加装填量这里出料温度的高低与冷却水的温度与耗量有密切的关系单介质的装填量也是不能忽视的因素。d.操作温度:尽管砂磨机都有冷却夹套,但是操作温度均高于室温,温度对颜料分散将有较大影响。在漆浆粘度随温度上升而减少的情况下,可采用40-50度的温度操作，以提高功率。e.预混合程度:漆浆的预混合好坏,将直接影响砂磨机的正常运行和分散效率高低。因此,应注意漆浆预混阶段的充分润湿，以保证砂同分散效率的发挥。编制资料来源实施日期校正审定提出部门版本号批准编号工艺守则LCGY-004第2张共5张卧式砂磨机操作规程四、操作方法1 .启动前准备工作：a,给油箱灌要求的油液到油标中线以上5mm并经常观察消耗情况及时补充。b.检查电气线路是否接通c.检查冷却水是否通畅并有足够的流量d.检查主电机三角带松紧是否合适e.检查并调整电接头压力表的上限指针在0.IMpa刻度处。2 .加入研磨介质卧式砂磨机加砂口位置在筒中间加砂时拧下堵头用漏斗将适量的研磨介质导入筒体内重新装好堵头。，注意装好堵头上的密封圈,3 .清洗首次使用砂磨机时由于筒体内壁及分散盘、撑套等处有防锈油脂应进行清洗方法是用适量的漆料或溶剂泵灌入筒体进行循环主机可间歇性的微动运转以减少清洗液的阻力如此循环两、三分钟后拧开放液塞放出筒内的清洗液再重复一遍。切忌才长时间用溶剂清洗否则将严重磨损相关零部件并导致研磨介质破碎。在研磨某些易于干结前渗透性产品时每磨完一批料后应立即对物料系统进行清洗若不及时清洗将引起物料在出料筛圈、机械密封周围干结从而导致出料筛圈堵塞和密封失效的严重后果。4 .使用操作a.启动送料泵开始时应将进料速度跳到较低值。b.打开冷却进水阀。c.启动主机。出观察进料、进水、润滑油运行状况检查仪表的限定值。?.送料泵：a.由于工况条件特殊物料中有时会有异物,棉纱头、钉子等,混入应尽量避免从而将泵卡死有鉴于此在泵轴的联接处设有安全剪切键材质尼龙6或硬聚氯乙烯,亦可用毛竹硬质木代替，。这样在不慎将泵卡死时安全键即被剪断使设备得到可靠保护此时应找出卡泵原Three,arrangethewholeprojectconstructionorganizationandmanagementsystemduringconstruction,theprojectmanagers,technicians,installersandengineerofnumberandtheirapproachtoavoidunnecessarywasteoflabor,increasedlaborcosts.Thatcombinationofmanagementneedtoworkcloselywithconstructionschedulemanagement.Four,projectdocumentmanagementprojectdocumentsmanagementsystemrequirementsforprojectdocumentsimplementeddetailedandorderlymanagement.Including:customersourcesofrawmaterials,contract,contract,projectschedule,projectbudget,projectdesign,constructionandacceptancecriterion,basisandstandard,projectrecords,documentsrelatedtosendingandreceivingrecords,documentmanagement,documentmanagement,andsoon.Duringtheconstructionprocess,weworkaccordingtoattributesbyhandtheresponsibilitytoimplement.Regularprogressreports;Aftertheprojectiscompletedtoprovideas-builtdrawingsandtestreports.Wewillsubmittothenextinformation:thedesignspecification;Packaging,hand!ing,transport,storagerequirementsandprogrammes;Wirespecifications,installationrequirements,testingtechniques,acceptancecriteriaandotheraspectsoftechnicalsupervisionandeffectivemanagement.Fifthsection,technicalstandardsandstandardizedmanagementinthecountriesinvolvedintheprojectorindustrystandardspecificationformany,therefore,wewillcarefullyinsystemsdesign,equipmentsupplyandinstallationoflinkcheckagainsttherelevantstandardsandnormssothatthewholemanagementiscontrolled.Sixthsection,installationmanagementsystemsengineeringisatechnical,process编号工艺守则LCGY-004第3张共5张卧式砂磨机操作规程因并更换新键。b.泵卡死后应将泵盖拆下检查清洗若异物已将齿轮或壳拉伤可用细锤、刮刀、油石等工具进行修理在将泵盖重新装上时应注意泵盖上偏心所对方位此方位一错泵即失去工作能力。?.变速器DWBO.75/1.1带式无级变速器未开机严禁调速调速手轮应开机调速低速停车。五、注意事项1.当筒体内未装入研磨介质和物料时主电机只能点动不能启动否则易造成分散轴弯曲和整机振动。2 .本机机械密封液品种可在煤油、200#溶剂、5#高速机油、乙二醇中选择一种我公司常用200#。3 .筒体内腔在正常工作时压力一般在0.05Mpa以下但若在物料粘度过高、泵送量过大、物料未经充分预湿分散处理等情况下则压力将上升。为了保证设备安全运行本机设置有电接点压力表将上限压力调整在0IMpa,不得超过,当筒体内压力达到该值时机器自动停车温度表安装在出料口用以监视出料温度此时应找出原因排除故障后方可启动。4 .机器长时间停用应进行全部清洗筒体研磨介质应浸泡于稀料中保持不干涸结皮。5 .机械长时间停用后在此开车前应先点主电机若主电机不能正常转动则应用泵打入稀料使筒体内研磨介质、物料松软并用手搬动主机带轮能搬动一圈后再点动主机正常后方可正式开机。六、故障及排除办法1.内圆弧齿轮泵电机不能转动或在转动中自停a.总电源是否接通b.熔断器是否熔断C.热继电器是否在动作d.压力表是否超压2 .主电机不能转动或在转动中自停a.泵电机是否启动b.熔断器是否熔断c.热继电器是否在动作编号工艺守则LCGY-004第4张共5张卧式砂磨机操作规程d.压力表是否超压e.润滑液在正常循环时压力在0.02-0.08范围内高于或低于这个范围都将引起自动停车压力过低是因系统润滑液不足应立即补充压力过高是因视镜内冲动六角形叶轮的冲油管堵塞拆下视镜将冲油管捅通即可。3 .主电机即使运转,分散轴也不转动a.三角皮带是否打滑,调整三角皮带松紧度b.分散轴是否被介质或物料卡住4 .主电机超负荷运转：a.物料粘度是否过高b.介质是否加的过多c.电器线路是否异常5 .进料泵压力过高：a.物料粘度是否过高b.泵转速是否过高c.介质加的是否过多d.从筒体出料管起以后管道扬程是否过高或管道是否过长e.出料部件是否堵塞6 .机械振动a.泵转速是否过快b.介质是否加得太少,介质密度是否太小e.物料温度是否太低,物料粘度是否太高d.三角皮带松紧是否适当e.分散轴是否弯曲.7 .进料泵吸不进料：a.管道中是否进入空气.b.进料管是否堵塞c.进料泵是否反转Three,arrangethewholeprojectconstructionorganizationandmanagementsystemduringconstruction,theprojectmanagers,technicians,installersandengineerofnumberandtheirapproachtoavoidunnecessarywasteoflabor,increasedlaborcosts.Thatcombinationofmanagementneedtoworkcloselywithconstructionschedulemanagement.Four,projectdocumentmanagementprojectdocumentsmanagementsystemrequirementsforprojectdocumentsimplementeddetailedandorderlymanagement.Including:customersourcesofrawmaterials,contract,contract,projectschedule,projectbudget,projectdesign,constructionandacceptancecriterion,basisandstandard,projectrecords,documentsrelatedtosendingandreceivingrecords,documentmanagement,documentmanagement,andsoon.Duringtheconstructionprocess,weworkaccordingtoattributesbyhandtheresponsibilitytoimplement.Regularprogressreports;Aftertheprojectiscompletedtoprovideas-builtdrawingsandtestreports.Wewillsubmittothenextinformation:thedesignspecification;Packaging,handling,transport,storagerequirementsandprogrammes;Wirespecifications,installationrequirements,testingtechniques,acceptancecriteriaandotheraspectsoftechnicalsupervisionandeffectivemanagement.Fifthsection,technicalstandardsandstandardizedmanagementinthecountriesinvolvedintheprojectorindustrystandardspecificationformany,therefore,wewillcarefullyinsystemsdesign,equipmentsupplyandinstallationof1inkcheckagainsttherelevantstandardsandnormssothatthewholemanagementiscontrolled.Sixthsection,installationmanagementsystemsengineeringisatechnical,process编号工艺守则LCGY-004第5张共5张卧式砂磨机操作规程d.进料泵是否严重磨损e.进料管道是否太长或曲度太小f.物料粘度是否过高,粘度超过2pa.s时应正压进料，8.生产能力下降a.分散盘是否过度磨损b.研磨介质是否太小大小是否合适是否大量研碎。9.循环泵吸不进油液循环泵,微型液压泵,在砂磨机第一次启动时由于输油管系统充满的是空气可能吸不进油遇到这种情况只需拔出进油管将管口向上并提高用油枪向油管内注入润滑液注满后将油管迅速插入油箱同时启动主机油液即能顺利吸入以后停车后再启动主机由于输油管系统内已充满油液每次启动都能迅速自吸。Three,arrangethewholeprojectconstructionorganizationandmanagementsystemduringconstruction,theprojectmanagers,technicians,installersandengineerofnumberandtheirapproachtoavoidunnecessarywasteoflabor,increasedlaborcosts.Thatcombinationofmanagementneedtoworkcloselywithconstructionschedulemanagement.Four,projectdocumentmanagementprojectdocumentsmanagementsystemrequirementsforprojectdocumentsimplementeddetailedandorderlymanagement.Including:customersourcesofrawmaterials,contract,contract,projectschedule,projectbudget,projectdesign,constructionandacceptancecriterion,basisandstandard,projectrecords,documentsrelatedtosendingandreceivingrecords,documentmanagement,documentmanagement,andsoon.Duringtheconstructionprocess,weworkaccordingtoattributesbyhandtheresponsibilitytoimplement.Regularprogressreports;Aftertheprojectiscompletedtoprovideas-builtdrawingsandtestreports.Wewillsubmittothenextinformation:thedesignspecification;Packaging,handling,transport,storagerequirementsandprogrammes;Wirespecifications,installationrequirements,testingtechniques,acceptancecriteriaandotheraspectsoftechnicalsupervisionandeffectivemanagement.Fifthsection,technicalstandardsandstandardizedmanagementinthecountriesinvolvedintheprojectorindustrystandardspecificationformany,therefore,wewillcarefullyinsystemsdesign,equipmentsupplyandinstallationoflinkcheckagainsttherelevantstandardsandnormssothatthewholemanagementiscontrolled.Sixthsection,installationmanagementsystemsengineeringisatechnical,process