Liaoning Metallurgy&Mining Heavy Machinery Co.,Ltd.

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Ball mill fault judgment and solution

Ball mill fault judgment and solution

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Ball mill grinding operation fails, you may even affect the mill production work progress, it is very critical thing, once a failure occurs, should be developed as soon as possible solutions, and to troubleshoot as soon as possible, so that the ball mill to resume production in order to Ensure that the interlocking production lines are completed within the specified time and smoothly meet the standards. Therefore, the failure of the ball mill can not be underestimated.  the following is sorted out of the ball mill fault, and for different types of fault classification of the judgment method, convenient to find, hope to help you!
First, judge the fault from the sound
When the ball mill is in normal operation, the grinding sound is clear and loud, there is no rattling sound of the steel ball rushing out of the liner, and there is also a less intense impact sound. If the sound is abnormal and the ball mill is too loud, it may be a malfunction of the ball mill.
1. When the ball mill is running, there are regular knocking sounds, and the sound is loud
The reason is that some of the liner bolts are not tightened. When the ball mill is rotating, the liner hits the ball mill barrel. Determine the position of the ball mill liner according to the sound, find the loose bolts, and tighten them separately.
2.The running sound of the ball mill reducer is abnormal
The sound of the normal operation of the ball mill reducer should be uniform and stable. If the gear has a slight knocking sound, hoarse friction sound, there is no obvious change during operation, you can continue to observe and find out the reason, the ball mill stopped for processing, if the sound is getting louder, you should immediately stop the ball mill for inspection.
3. The operation sound is dull, the discharge volume is reduced, and the output is too low.
The solution is to adjust the feeding amount and feeding granularity in time, reduce the material moisture, clean the ladle, adjust the proportion of the grinding body, stop and replace the compartment board, adjust the length of each bin, adjust the cycle load, and repair the powder selection machine.
4. After the ball mill has been running for a long time, due to the serious wear of the inner lining or the loosening of the connecting bolts, the inner lining is often dropped, which affects the normal operation of the equipment. The specific process manifests itself as follows: abnormal sounds appear in the mill, and the noise is relatively loud; the grinding medium at the lining board is impacted with excessively loud and crisp sound. If the above situation is found, the ball mill should be stopped immediately, and the liner or the liner with better quality should be replaced.
Second, judge the failure of the ball mill from the temperature
1. The ball mill bearing is overheating or melting, and the motor is overloaded
Check whether the lubricating oil is sufficient, whether the bearings or couplings are installed correctly, whether the gap between the journal and the bearing bush is proper, whether the oil groove is damaged, and oil cannot flow into the journal or the bush, whether the barrel or the drive shaft is bent, and the main bearing is cooling Whether the water is sufficient or the water temperature is normal; if problems are found, they should be promptly handled and repaired properly.
2. Main bearing bush burning failure
If the main bearing bush burns out, the ball mill should be improved. The specific improvement measures are as follows:
The main bearing is replaced by a type structure, which adopts a rocker structure, which increases the adjustment space and reduces the contact frequency. The adjustment is more flexible and convenient, and the installation is efficient and fast.
The contact surface between the mill pressure plate and the tile body is replaced with a large arc surface, which increases the range of the tile body and eliminates friction and jamming.
The mill lubrication system uses static pressure lubrication to ensure the normal operation of the high-pressure system in the mill production, so that there is always a certain oil film thickness between the hollow shaft and the bearing shell, which not only plays a role in reducing the bearing temperature, but also in this lubrication state The thickness of the oil film between the lower hollow shaft and the bearing shell is relatively large, and the friction during the main bearing operation is smaller and safer.
Ensure that the cooling water system is unobstructed, and clean and clean the cooling water system regularly.
3. Judging the Ball Mill Failure from Abnormal Vibration
The vibration of the ball mill motor with the reducer started, the main reasons are:
1. Bearing outer ring activities
Treatment method: Adjust the wheel clearance according to the regulations so that the two axes are concentric. Tighten the coupling bolts of the coupling symmetrically with equal torque.
2. When the rotor is unbalanced, take out the ball mill rotor and find another static balance.
Large ball mills are bulky and heavy, causing the foundation to sink; displacement occurs. Set a monitoring settlement point next to the foundation; make observations and adjust if you find that there is subsidence.
Four, judging the ball mill failure from material leakage, stringing, and rough running
1. Leakage of bolt holes in cylinder liner
The reasons for this are: loosening of the bolts of the liner, wear of the gaskets, and breakage of the bolts of the liner; it can be solved by tightening and replacing the bolts, putting on new gaskets, changing the nut nut ring of the mill outside the body to a waste belt .
2, bearing feed slurry failure
The ball mill bearing has a string of materials. The slurry penetrates into the bearing at the discharge end, which damages the bearing seal and the seal is severely damaged. Production practice has proved that during the dynamic operation of the ball mill, the main reason for the bearing feed slurry is the unreasonable factor in the structure design of the discharge end of the ball mill.
improvement measures:
Select the corresponding sealing device according to the actual situation, and complete the hot-loading process with the bearing on the discharge end according to the process condition parameters, so that there is no relative movement between the discharge end, the slag discharge port and the labyrinth ring, and there is no gap at the same time, which effectively controls the material. The problem that the slurry often enters the bearing.
The slag discharge opening and the discharge opening are modified to increase the diameter of the inner hole to a certain diameter and extend the position of the discharge opening to ensure that the position of the discharge opening and the slag discharge opening are separated by 120-122mm to avoid the discharge opening and slag discharge. The gap between the mouths flows into the slurry.
Weld a fender at the corresponding position between the discharge port and the slag discharge port, and add a backflow device to the slag discharge port and the fender outlet, and choose to weld another circle of round steel, so that no material appears in the normal production process. The phenomenon of slurry entering the bearing.
3. Failure of the compartment board
After the ball mill is operated for a period of time, the compartment board is destroyed by the steel ball and fails, causing the material to run coarse, the particle size of the pulp product is unqualified, and the replacement cycle of equipment spare parts is short, which is not a normal wear failure.
improvement measures:
It is recommended to replace the single-layer compartment plate structure with a double-layer compartment plate structure.
The material of the compartment board is a steel structural frame material. The internal lifting plate is added to allow the material to effectively enter the second bin, reduce the impact of the material on the compartment board, and protect the frame.
The T-shaped or L-shaped fixed structure is selected to make the steel structure compartment plate and the barrel bolted together to increase the service life of the compartment plate and maintain the rigidity and stability of the steel structure.
Five, other failures
1.Breaker bolt failure
The ball mill mill uses multi-head combined feeder to feed, and the 16-M30 bolts are used to connect with the feeding port. During the operation of the ball mill, the bolts often break.
Improving measures: Regularly inspect the bolts at the outlet, and tighten and replace the bolts when they are found to be broken.
2.The ball mill cannot be started or the motor is overloaded during startup
The cause of this failure may be: a problem with the motor system, obstacles in the turning part, long-term shutdown, the material and the grinding body in the ball mill were not removed in time, the wet materials condensed into agglomerates, the grinding body did not fall when the machine was started, and aggravated Motor load.
Solution: Check and repair the motor system, clear the obstacles in the rotating part, clean the materials and grinding bodies in the ball mill, clean out the agglomerated materials and some grinding bodies, and stir and mix the remaining materials and grinding bodies.
3. The current is too large and the current is unstable
The reasons for the current instability are: excessive mill loading, poor bearing lubricants, excessive wear or failure of the transmission system, and uneven weight around the liner.
The solution: adjust the load, increase the oil supply, check the transmission parts such as the bearing shaft or gear, and repair and adjust the liner.
4.The oil pressure of the lubrication system is too high or too low
Causes include: blocked oil pipes, insufficient oil in the fuel tank, air or oil leaking from the oil pump or oil pipes, and malfunction of the oil pump.
Solution: Stop the grinding, check whether the oil pipe is blocked or leaking, check or repair the oil pipe in time, replenish oil regularly, check whether the oil pump enters the air or leaks oil, and handle it in time.
5.Thickness of transmission gear
Causes of failure: long-term operation, material fatigue, gear vibration, increased gear dynamic load, loose bolts in the transmission part, large bearing clearance, curved transmission shaft or skewed centerline of the transmission part.
Solution: wear more than 30%, replace with new gear, wear slightly. Turn over the gears, find out the cause of vibration, troubleshoot, tighten bolts, reduce bearing pads or replace bearings, straighten and straighten.