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鹽城工學院畢業(yè)設計說明書 2006
YQP36預加水盤式成球機設計
摘 要：為了滿足現(xiàn)代機立窯水泥生產過程中預加水成球的技術要求，發(fā)展第六代預加水盤式成球機，從而保證料球的粒徑均勻性、高強度、高孔隙率和高產量，提高水泥的煅燒質量和產量，本課題設計了YQP36預加水盤式成球機。根據最新的技術要求對 YQP36預加水盤式成球機的結構、傳動系統(tǒng)和刮刀系統(tǒng)進行了改進設計。本次設計采用理論設計和經驗設計相結合的方法，在通過類比設計保證機架與支架的支承強度的基礎上優(yōu)化了傳動系統(tǒng)和刮刀系統(tǒng)。參考實踐生產中的一些改進經驗，首先進行了總體方案的論證；然后根據分析的結果來計算各傳動軸的軸向力、扭矩以及功率，并校核了軸和螺栓的強度，從而選擇電機和減速機型號及設計其他相關零部件。根據已確定的部件參數分析擬定傳動裝置的運動簡圖，分配各級傳動比，確定了傳動零件的結構；接著對 YQP36預加水盤式成球機的潤滑和密封方式加以確定；最后對預加水盤式成球機的維護修理加以說明，從而完成預加水盤式成球機的總體結構設計。此次設計本著高產量、高質量成球，穩(wěn)定運轉的原則，實現(xiàn)了現(xiàn)代預加水盤式成球的節(jié)能、經濟、環(huán)保、可擴展的目的。
關鍵詞: 成球；預加水；刮刀；料球
The Design of YQP36 Disc Prewatering Pelletizer
Abstract: In order to satisfy the technical requirement of prewatering pelletizing in the process of cement production with modern kiln and develop the sixth generation of prewatering pelletizer, the topic which is designed is YQP36 Disc Prewatering Pelletizer. Consequently the proportion of diameters, the high strength, the high holes rate and the high output of raw meal pellets could be assured of. According to the new requirements, the structure, the transmission system and the drawknife system of YQP36 Disc Prewatering Pelletizer are improved and designed. This design has been completed by the method which combines theories design with experience design. The transmission system and drawknife system are optimized basing on that the strengths of chassis and support are assured with analogy design. Firstly, the projects of designation and improvement of prewatering pelletizer are demonstrated, including the structure, the ways of delivering the motivation and drawknife system by referring some improvement experience from production practice; Secondly, based on the analytical results, axial force, the torque and power are computed so that the electromotor, decelerator and other corresponding components could be determined; Thirdly, according to the parameters of the parts which has already been assured, the simple exercise diagram of the transmission device is analyzed and drawn up and the ratios of all levels are assigned. Then the structure design is carried on and the strength of part is followed to be checked. The ways of lubricant and seal of the equipment are determined in succession. Finally, the whole overall arrangement scheme of YQP36 prewatering pelletizing equipment is designed. This design is in the light of the principle of the high yield, high quantity of pelletizing and stable operation. In addition, the requirements of YQP36 will be satisfied, including economy of energy, economy, environmental protection and enlargement.
Key words: pelletizing; prewatering; drawknife; raw meal pellet
畢 業(yè) 設 計 說 明 書
YQP36預加水盤式成球機設計
專 業(yè) 機械設計制造及其自動化
學生姓名 楊 聞 達
班 級 B材機022
學 號 0210120211
指導教師 楊 曉 紅
完成日期 2006年5月28日
鹽城工學院畢業(yè)設計說明書 2006
目 錄
1 前 言………………………………………………………………………………………1
2 總體方案論證……………………………………………………………………………2
2.1 料球的技術要求及對成球盤的技術調整分析………………………………………………2
2.2 盤體的技術分析論證……………………………………………………………………2
2.3傳動機構的技術分析論證…………………………………………………………………2
2.4刮刀系統(tǒng)的分析論證………………………………………………………………………2
2.5 刮刀盤、刮刀桿和刀頭分析論……………………………………………………………3
3 盤式預加水成球機綜合參數計算………………………………………………………4
3.1生產能力計算……………………………………………………………………………4
3.2功率計算…………………………………………………………………………………4
3.3 成球機盤高計算…………………………………………………………………………4
3.4 成球機轉速計算…………………………………………………………………………5
3.5圓盤傾角計算……………………………………………………………………………5
3.6料球運動基本方程………………………………………………………………………5
4機械傳動裝置的總體設計………………………………………………………………8
4.1 選擇電機………………………………………………………………………………8
4.2 選擇減速機 ………………………………………………………………………………8
4.3計算傳動裝置的各參數…………………………………………………………………9
5機械傳動件設計…………………………………………………………………………11
5.1皮帶傳動設計……………………………………………………………………………11
5.2齒輪傳動設計……………………………………………………………………………13
5.3 Ⅲ軸設計及校核…………………………………………………………………………16
5.4 軸承校核………………………………………………………………………………20
5.5 雙鍵（Ⅲ軸）設計校核（普通平鍵）…………………………………………………………21
5.6盤體固定螺栓校核………………………………………………………………………21
6傳動機構的密封潤滑……………………………………………………………………23
6.1密封……………………………………………………………………………………23
6.2潤滑……………………………………………………………………………………23
7預加水盤式成球機的總體設計…………………………………………………………24
8預加水盤式成球機使用維護和修理……………………………………………………25
8.1預加水盤式成球機的使用維護……………………………………………………………25
8.2預加水盤式成球機的修理與修理周期……………………………………………………25
9 結 論……………………………………………………………………………………27
參考文獻……………………………………………………………………………………28
致 謝………………………………………………………………………………………29
附 錄………………………………………………………………………………………30
畢業(yè)設計任務書
課題： YQP36預加水盤式成球機設計
專 業(yè) 機械設計制造及其自動化
學 生 姓 名 楊 聞 達
班 級 B材機021
學 號 0210120211
指 導 教 師 楊 曉 紅
專 業(yè) 系 主 任
發(fā) 放 日 期 2006年3月28日
一、設計內容
結合生產實際，完成預加水盤式成球機的設計。
二、設計依據
生產能力Q=25t/h。
三、技術要求
所有結構及其零部件設計后考慮技術性、加工工藝性、經濟性，并保證安裝、
使用、經濟方便。要保證預加水成球盤的運轉平穩(wěn)，節(jié)能高產。
四、畢業(yè)設計物化成果的具體內容及要求
1、設計說明書1份，達1萬字以上，且要符合規(guī)范要求。
2、中文摘要不少于400字。并有對應英文摘要（電子文檔）。
3、設計圖樣總的繪圖量折合A0不少于3平方米（CAD）；
具體設計的圖樣有：
（1）預加水盤式成球機總裝圖一張；
（2）機架部件圖一張；
（3）傳動部件圖一張；
（4）機架及傳動部件相關零部件圖若干張。
4、翻譯3000以上漢字的課題相關外文資料。
5、實習小結（電子文檔）。
五、畢業(yè)設計進度計劃
起訖日期
工作內容
備 注
06.03.06—06.03.07
布置任務
下達任務書
06.03.06—06.03.17
調查研究，收集資料，熟悉課題,畢業(yè)實習
06.03.18—06.03.31
總體設計，方案論證
06.04.01—06.05.10
部件、零件設計階段
06.05.11—06.06.04
編寫說明書
06.06.05—06.06.07
畢業(yè)設計預答辯
06.06.08—06.06.11
修改整理畢業(yè)設計材料
06.06.12—06.06.13
材料評閱
06.06.14—06.06.16
畢業(yè)答辯
06.06.17—06.06.18
材料整理裝袋
六、主要參考文獻：
1、許林發(fā).建筑材料機械設計（一）[M].武漢：武漢工業(yè)大學出版社，1990.8.
2、褚瑞卿.建材通用機械與設備[M].武漢：武漢理工大學出版社，1996.9.
3、 朱昆泉，許林發(fā).建材機械工業(yè)手冊[M].武漢：武漢工業(yè)大學出版社，2000.7.
4、徐灝.機械設計手冊[M].北京：機械工業(yè)出版社，1991.9.
5、胡家秀.機械零件設計實用手冊.北京：機械工業(yè)出版社，1999.10.
6、趙忠.金屬材料與熱處理[M].北京：機械工業(yè)出版社，1991.5.
7、甘永立.幾何量公差與檢測[M].上海：上海科學技術出版社，2001.4.
8、錢志鋒，劉蘇.工程圖學基礎教程[M].北京：科學出版社，2001.9.
9、閻瑞敏，常敏.水泥工業(yè)自動控制預加水成球技術及裝備[M].江蘇科學技術出版社，1990.10.
10、黃有豐.預加水成球技術及其應用[M].北京：中國建筑工業(yè)出版社，1991.9.
11、彭常皓.對老式成球盤的改造[J].四川水泥,1996.No.2:32～34.
12、馬正先.合理調整成球盤 降低爆球率[J].水泥技術,1994.No.6:50～51,32.
13、王振宇,孟德忠.清理成球盤邊掛泥的辦法[J].水泥,1996.No.12:59.
14、李國權.成球盤減速機的選型[J].水泥,1996.No.12:43.
15、徐雙龍.成球盤減速機漏油的處理[J].四川水泥,2001.No.6: 32.
16、黃勝.成球盤減速器輸入軸的改進[J].水泥,2001.No.1:49.
17、侯義杰.成球盤孔與軸鍵聯(lián)接失效的修復及改進[J].工程師園,2000.No.4:27.
18、孫德隆,姜勇.成球盤擴徑改造的實踐及論證[J].四川水泥,1998.No.2:23～25.
19、梁東武.φ3.6m成球盤傳動機構的改造[J].水泥,1996.No.3:23.
20、郝志東.φ3.2m成球盤傳動裝置的改進[J].水泥,1998.No.12:49～50.
21、李銀鋒.預加水成球盤傳動裝置的現(xiàn)狀及改進[J].水泥,1994.No.4:32～34.
22、黃金平.φ3.2m預加水成球盤成球刮刀機的改進[J].中國建材裝備,2001.No.3:16～17.
23、張貴春.φ3.2m 成球盤曲柄滑塊式刮刀裝置[J].水泥,2000.No.5:39.
24、李升朝.成球盤邊刮刀的改進[J].水泥,1996.No.12:41.
25、趙文濤.成球盤底刮刀傳動系統(tǒng)的改進[J].水泥,1998.No.11:48.
26、楊軍.成球盤刮刀的改造[J].水泥,2004.No.2:65.
27、郭紅軍.成球盤刮刀系統(tǒng)的改造技術[J].水泥,1996.No.12:42～43.
28、鄧清華.成球盤刮料裝置的改進[J].江西建材,1998.No.1:31～32.
29、王樹華.成球盤無動力刮刀的改進[J].四川水泥,1998.No.1:31,25.
30、郝志東.預加水成球盤底刮刀裝置簡介[J].水泥工程,1999.No.4:29～30.
七、其他
5
機械工程學院畢業(yè)設計（論文）選題申報表
機械設計制造及其自動化 專業(yè)
指導教師楊 曉 紅 學生姓名 楊 聞 達 2006年 1月 4日
設計（論文）
題 目
YQP36預加水盤式成球機
設計
題目類別
畢業(yè)設計
題 目 來 源
結合生產實際
題目性質
工程設計
設計原始數據
生產能力Q=25t/h
設計內容
結合生產實際，完成預加水盤式成球機設計。
物
化
成
果
形
式
□工程設計類要求
說明書字數
圖紙數
其他附件
□工程研究類要求
論文字數
附件要求
□軟件開發(fā)類要求
說明書字數
附件要求
1、 設計說明書1份，達1萬字以上，且要符合規(guī)范要求（電子文檔）。
2、 中文摘要不少于400字。并有對應英文摘要（電子文檔）。
3、 設計圖樣總的繪圖量折合A0不少于3平方米（CAD）；具體設計的圖樣有：
（1）預加水盤式成球機總裝圖一張；
（2）機架部件圖一張；
（3）傳動部件圖一張；
（4）機架及傳動部件相關零部件圖若干張。
4、翻譯3000以上漢字的課題相關外文資料。
5、實習小結（電子文檔）。
專業(yè)系審查意見：
專業(yè)系主任（簽名）：
學院審批意見：
院長（簽名）：
注：
一、題目類別：1、畢業(yè)設計；2、畢業(yè)論文
二、題目性質：1、工程設計；2、技術研究；3、軟件開發(fā)；4、理論研究
三、題目來源：1、結合科研；2、結合生產實際或工程建設；3、結合課程和實驗室建設；4、自擬題目
Feasibility study requirements for a new cement plant
R.Hogg, D Frame and M.E. Asim, WS Atkins Consultants, UK, discuss the theory and practice of undertaking large cement plant projects.
FOR SPANISH AND FRENCH VERSIONS PLEASE REFER TO THE SPECIAL TRANSLATED SECTION AT THE BACK OF THE ISSUE
Introduction
The decision to start the construction of an entirely new cement plant facility, or a major capacity extension at an existing cement works, should always be based on a detailed techno-economic feasibility study. Such a study will indicate to the promoter the viability of the business in terms of the best technical solution, the overall capital and operating casts, the magnitude of the operation in terms of production and workforce needed, and the return on his investment over a period of time.
A typical feasibility study deals with the following issues:
Marketing study.
Raw materials proving.
Site studies.
Conceptual engineering and process design.
Analysis of alternatives.
Project cost including infrastructure.
Project schedule.
Investment analysis, risk assessment, development of financial structures.
Project finance.
Discussion with financing institutions.
Whilst any feasibility study must include technical aspects, it is important to realize the full implications of marketing research and accurate financial projections.
Pro-feasibility study
In order to minimize front end expenditure and to quickly obtain a firm indication of the likely project viability, a pre-feasibility study is performed.
The pre-feasibility study is carried out at low cost, but in sufficient detail to show whether a full feasibility study is justified. The pre-feasibility study will examine the market place, the raw materials, capital and operating costs, and develop a business plan to show the likely returns on the investment, and identify the risks and scale of operation involved.
Typically this exercise will take four to six weeks to complete, commencing with a site visit. However, the study is largely performed by desk research and reference to the in-house date base. The site visit is used to determine the suitability of raw materials for cement manufacture, local building and civil engineering costs, cost of land and peculiarities of the particular site location, and local cost of consumables required in the operation of the plant. The desk research concentrates upon current plant and machinery costs, financial and marketing considerations and preliminary plant sizing and determination of the process route.
In the event of the pre-feasibility study showing a clear indication that it is worthwhile to proceed with the project, then a full feasibility study can be initiated.
Full feasibility study
Market research
The objective of the market study is to establish the demand for the various types of cement in the context of the region or market area of the proposed plant. The study seeks to establish the current and forecast cement usage over a 5-7 year period. The forecast is then used together with the indicated selling prices to generate the likely revenue stream for the proposed operation.
The consultant must have considerable experience in the global cement industry and be able to approach a feasibility study with an excellent knowledge of prevailing market conditions and likely trends. Each individual company and market does, however, present a unique set of circumstances which must be fully understood. The normal approach adopted is first to study the company and identify its strengths and weaknesses, strategic direction and motivation. This is essential in providing an immediate picture of the company’s likely success in achieving its aims.
The second stage of the marketing survey, desk research, puts the initial discussions into context by examining a wide range of published data relevant to the industry.
Sources of published data are collated and compared by a team of researchers and consultants in an operation to substantiate known trends and uncover new information. It is not sufficient to rely on information several months old, and without an international perspective, trends in cement production and demand are frequently misleading.
Collecting published data is an on-going process, but having established a background to the study, information should, where possible, be verified using independent sources with firsthand accounts of the industry and its outlook. Companies, government organisations and other industry associations are often willing to provide their own assessment lf markets, but care needs to be taken not to compromise any party prepared to give its view.
Armed with a comprehensive selection of published data and industry opinion, the job of the consultant at this stage is to accurately define not only the market size for a particular product, but the likely change in that market. Such changes are often predicted by historic relationships between, for instance GDP and overall construction activity; economic growth and housing starts of cement consumption and population size. Figure 1 illustrates this point. Without taking into account subjective opinion and recognizing changing user requirements for different cement types, such forecasts can be flawed. Analysis of such factors is particularly important in lesser developed countries where impressive growth rates can change the balance of construction activity over remarkably short periods of time.
Other economic information likely to have a bearing on the market are government tariffs, import duties and sector subsidies. Even in free market areas, many aspects of economies are regarded as being of strategic importance and governments frequently strive to preserve national interests wherever possible by fixing prices of imposing import tariffs. Should import tariffs be relaxed of prices allowed to move in line with supply and demand, there will be an appreciable change in the market conditions. National companies, for instance, might suddenly find themselves uncompetitive. With cheaper imports, the balance between cement grinding and clinker production requirements could change quite dramatically. It would be up t the government to accommodate these changes, but one of the principle tasks of the consultant is to anticipate them.
This last point highlights what is perhaps the single most important yet difficult to determine aspect of a market study: competitor reaction. Knowing of others investment plans, government licensing, likely dates of completion, principle contractors involved and distribution partners is difficult and time consuming, but it is not enough. Competitors are not just nationals of those who have historically sold their product through the same predictable channels of distribution. There are an increasing number of companies who would like to reduce dependence on suppliers by vertically integrating their operations. This could entail building their own plant or developing their own deep water terminal to import cement directly. Others might decide to diversify into selling, for example, ready missed concrete. Some large users might be on verge of entering into long term agreements with one company or looking to buy form further afield. The combinations are numerous but it is up to the company investing in expensive plant and machinery to understand its customers and convince both itself and the investors that it really does have the best view of the market.
Raw materials proving
The volume and quality of the raw material deposits have to be established with accuracy. A wide ranging search for raw materials may start with desk research and consultation with National Geological Survey data and available geological mapping. The search will include examination of aerial photography records and satellite imagery e.g. Landsat or SPOT.
The desk research is followed buy site visits to the proposed location by geologists who take the study a step forward by making on-site examinations of previously identified geological horizons and outcrops. The first samples are taken by channeling from promising outcrops, road cuttings, recent excavations or from purpose excavated test pits. Field testing of the samples is required to provide an initial indication of the calcium carbonate, silica, alumina and iron content of the deposit. The testing is simple, rapid and economical and the geologist can adjust the field investigations and maximize the recovery of useful information.
The most promising samples are chemically analysed in testing laboratories and when sufficient data has been obtained in terms of chemical quality, and the probable volume established, a decision to mount a full drilling campaign can be made.
The primary raw material or limestone, is core drilled and careful records of the geological progression is made as the cores are recovered, recorded and laid sequentially in the core boxes,(Figure 2). Individual and composite samples are taken from the cores and sent to laboratories experienced in the testing of cement raw materials. In order to minimize drilling costs is essential that the initial results of the first borehole are analysed rapidly and the results known in order to make further decisions on location, angle and direction of subsequent boreholes.
The information obtained from the chemical analyses and the geological record derived from the cores in then used to establish the geological structure and the volume of the deposit. The optimum quarry developments are then developed.
The secondary raw materials, clays or shales, may be proven by means of auger drilling of by test pit excavation using mobile hydraulic excavators or in some cases by hand excavation. These materials are similarly recorded and chemically analysed as for the limestones.
Using the chemical analysis of the raw material, computerized raw mix designs can be carried out. The in-house program used has several facilities which can be called upon. Firstly, all the necessary standard equations which must be satisfied for lime saturation, silica ratio, alumina ratio, hydraulic modulus, etc., are built into the program. Secondly, the mix design can be refined by adjusting the compound composition and observing the effect upon the standard ratios. Finally, cost factors can be added to the raw materials to obtain the optimum raw mix which minimizes the most expensive raw materials, but satisfies the above criteria.
Process design
The optimum process route for a specific plant is dependent upon a number of factors including the physical and chemical nature of the raw material deposits. The selection of plant and machinery is made based on the following factors”
Disposition of the raw material deposits.
Moisture content and other physical properties of the raw materials.
Level of undesirable chemical elements.
Mineralogy (particularly the content and size of silica).
Abrasiveness, grindability and the burnability of the raw materials.
Fuel types and relative costs.
Environmental protection requirements.
Electrical power availability, cost and energy efficiency requirements.
Site topography and congstraints.
Market constraints.
Labour and maintenance constraints.
The disposition of the raw materials in terms of dip and strike and physical location dictate how the primary and secondary raw material quarries are opened up, how they are to be worked and how the access roads are to be developed. The geological method of deposition and hardness of the raw materials will also determine how the quarry is to be planned and the methods of extraction determined.
The moisture content of the raw materials and the change in their characteristics as the moisture content alters has an important effect upon the choice of the primary crusher and storage systems. The moisture content has even greater implications when considering the raw milling system to be proposed in conjunction with the optimum temperature of preheater exit gas. A balance has to be struck between the requirements of the kiln system, the number of cyclone stages that can be used, and the heat requirements of the raw mill for raw materials drying.
The level of undesirable chemical elements in the raw materials, such as potassium, sodium, magnesia, chlorides and sulfur requires careful consideration in the selection of the type of kiln system. The varying levels of impurity elements in conjunction with the sulfur in the raw material and possible additional sulfur intake from the kiln fuel, lead to the necessary decisions to be made relating to the acceptance and sizing of a bypass system.
The mineralogy can vary greatly among raw materials in different countries. The method of deposition and the occurrence of the chemical elements in each of the raw materials can have a marked effect on the characteristics of combination in the kiln burning process. Notably this leads to variations in kiln fuel conditions. Predictions upon how the raw-materials will behave when combined in the necessary proportions to obtain a commercial cement, are based upon laboratory burning and grinding tests conducted as part of the feasibility study.
Energy and fuel usage are two key matters high on the agenda of all potential and existing cement plant operators. The cement industry has always been very conscious of making the maximum use of heat energy, and to this end heat transfer from the kiln gases to the raw materials, of from the hot clinker to the combustion air, has always been utilized.
Today more than ever the efficient use of energy and fuel is sought affair and a range of plant and equipments available for consideration. Technical economy of scale is also an important factor and where the market justify large capacity plant, correspond with reductions in the cost of products are achieved.
Energy consumption is be reduced through the use of roll-milling systems for raw meal in plant of tube mills, high efficiency separators in both the raw milling and cement milling departments, low pressure drop cyclones in the preheater of the burning process, and by the preheater of high pressure grinding rolls, and recent introduction of the horizontal roller mill, the so-called Horomill. The selection of the optimum planning processes ensures that the KWh/h electrical power consumption minimised.
Fuel consumption is reduced the introduction of efficient cyclones construction with heat resistant tubes and an increase in the number of stages of preheater to mount maximum use of the hot gases leaving from the kiln. Fuel consumption is also siderable affected by the designation ancillary plant such as the kiln separators, gas ducting, kiln burner, flow control valves and instrumentation.
Another recent development is the transfer of all the hot exhausted gases form the clinker cooler back onto the raw mill, thus saving on the heat required for drying the raw material. This arrangement also has the acute advantage of reducing the capital of the plant by the elimination of a cipitator or other clinker cooler collection system and its associating equipment.