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1、Target industry documentationCrushing of hard materials /Grading(screening)Cement productionContents1Crushing of hard materials1.1Processes used for crushing hard materials1.2Machines used for crushing hard materials1.2.1 Jaw crushers1.2.2 Cone crushers1.2.3 Hammer crushers1.2.4 Roller grinding mill
2、s1.2.5 Roller presses1.2.6 Tube mills2Grading(screening)2.1Introduction2.2Vibrating screen types2.2.1 Two bearing screen with circle throw2.2.2 Two bearing screen with straight-line motion2.2.3 Four bearing screen 2.3FAG vibrating screen bearing designs2.4Dimensioning of the bearings2.4.1 Two bearin
3、g screen in accordance with 2.2.12.4.2 Two bearing screen in accordance with 2.2.22.4.3 Four bearing screen in accordance with 2.2.32.5Sealing and lubrication of the beaings2.5.1 Grease lubrication2.5.2 Oil sump lubrication2.5.3 Oil splash lubrication2.5.4 Oil circulation lubrication2.5.5 Recommende
4、d lubrication2.6Trends3Cement production3.1Introduction3.2Cement production process3.2.1 Crushing of limestone,alumina etc.3.2.2 Drying/mixing3.2.3 Coarse grinding3.2.4 Dosage/mixing3.2.5 Burning the raw meal/cooling the clinkers3.2.6 Cement clinker storage3.2.7 Fine grinding of clinker3.2.8 Cement
5、storage/transport4SummaryPreface The processing technology is increasingly gaining in significance in the capital goodsindustry.Due to the huge demand for rolling bearings,the processing technology sector isa significant business area of FAG Industrial Bearings AG.A multitude of processes and machin
6、es are used to process Materials for furtherprocessing,but also to recycle all kinds of material.This documentation gives a survey of two sectors of the processing technology:crushingof hard materials and grading.It describes machines and plants which are used in mineralprocessing and coal preparati
7、on as well as in cement plants.The emphasis is on givingthe bearing such a design as to enable them to accommodate the special conditionsfound in these machines.This paper is intended for in-plant and field service staff as well as for FAG dealers.Itshall be used for application-related training in
8、the sector Crushing of hard Materials andmaterial grading,and gives a survey of the application of rolling bearings in the machinesused in this industry.1 Crushing of hard Materials 1.1 Processes used for crushing hard materials These processes are used to reduce a material from its original size to
9、 a smaller,definedoutput size.The main physical size reduction processes are:shattering(breaking),squeezing,grinding.Shattering(breaking)is used,as a rule,to reduce materials with grain sizes of 50 mm insize.In squeezing and grinding processes,materials already reduced to grains sizes of 550 mm are
10、reduced/ground to extremely small grains.The boundaries between squeezingand grinding are fluid.1.2 Machines used for crushing hard materials Machines used for crushing hard materials can take materials with edge lengths of up to2500 mm and reduce them to sizes of a few hundredths of a millimeter in
11、 a series ofprocesses.In these machines-crushers,mills and presses-moderately to extremelyhard stones,other minerals,coal and sands are processed.Depending on the materialand on the desired end product,the following machines may be used:-Jaw crushers-Cone crushers-Hammer crushers-Roller grinding mil
12、ls-Roller presses(cylinder crushers)-Tube mills Machines used for crushing hard materials must be characterized by a high efficiency andoperational reliability,and they must be easy to maintain.As a leading rolling bearingmanufacturer,FAG are making their contribution to meeting these requirements.1
13、.2.1 Jaw crushers 1.2.1.1 Principle of operation of double toggle jaw crushers The jaw crusher was invented in the middle of the 19th century,by an American namedBlake.It is also referred to as double toggle jaw crusher.Double toggle jaw crushers are used as coarse crushers and fine crushers.The pri
14、ncipleof operation is intermittent.On a horizontal shaft with an eccentric centre section sits thepitman,which actuates the swing jaw through a double toggle lever system.The swingjaw is supported in sliding sleeves or rubber-bonded-to-metal bondings.Rolling bearingsare installed in the pitman(inner
15、 bearings)and in the crusher frame(outer bearings).The crushers feed opening can span more than 2000 mm.The eccentric shaft speed isbetween 180 and 280 min-1,depending on the crusher size.1.2.1.2 Eccentric-shaft support in double toggle jaw crushers and single toggle jawcrushers The outer bearings(b
16、)both in double toggle jaw crushers(fig.1)and in single toggle jawcrushers(fig.2)have to support the eccentric shaft in the frame.The outer bearings aremore heavily loaded than the inner bearings as they have to transmit not only the crushingforces but also have to support the flywheel weight and tr
17、ansmit the loads resulting fromthe drive.The inner bearings(a)support the pitman in double toggle jaw crushers and the swingjaw in single toggle jaw crushers.Due to the eccentric shaft,the inner bearings have alarger bore than the outer bearings.1:Double toggle jaw crusherExample:Double toggle jaw c
18、rusher type 12K lnner bearings:2 spherical Toller bearings FAG 23168BKMB(340 x 500 x 190 mm)Adapter siceve FAG H3168HGJ Outer bearings:2 spherical Toller bearings FAG 23256KMB(280 x 500 x 176 mm)Adapter sleeve FAG H2356HGJ Mainly spherical roller bearings of series 222 are used as inner bearings,and
19、 series 223bearings as outer bearings.In some machines,spherical roller bearings of series 231 and232 as well as 240 and 241 have been used successfully.Outer bearing mountings usually consist of a locating bearing and a floating bearing.Forinner bearing mountings a floating bearing arrangement(axia
20、l displaceability 1 to 2 mm)ispreferably used.The bearings can be mounted either directly on the cylindrical or tapered shaft,or onadapter or withdrawal sleeves.The bearings are preferably fastened with hydraulic adapter sleeves(HGJ).1.2.1.3 Dimensioning of the bearings The required dynamic load rat
21、ing,and thus the bearing size,is determined for doubletoggle jaw crushers and single toggle jaw crushers using the following formula:kNnfLfnrN29000or25000C=Factor 25 000 for double toggle jaw crushers Factor 29 000 for single toggle jaw crushers N=required power(kW)r=eccentric radiusmmn=speedmin 1fL
22、=3.3.5 index of dynamic stressing fn=speed factor(according to catalogue)Based on the formula developed by A.Bonwetsch and on experience gained with field proven bearing arrangements as well as tests,FAG has developed the above formula.The bearings calculated using this formula aresufficiently dimen
23、sioned for crushers with a feed opening of up to approx.1200 x 800 mm.In the case of larger crushers the application of this formula may yield overdimensionedbearings.Therefore,the mean power required by the machine-ca.60 to 70%of N-should be entered in the calculation instead of the power installed
24、.in cases of doubt,thecrusher manufacturer must be consulted about the mean power required.When specifying the exact bearing design,the crusher manufacturers unique experiencein the field has to be taken into consideration.kNnrN123000PMAX=1.2.1.4 Bearing seats We recommend to machine the bearing sea
25、ts to tolerance h7 for the shaft(if adapter orwithdrawal sleeves are used)and to H7/J7 for the housing bore.If the bearings are mounted directly onto the shaft,the latter should be machined to m6.1.2.1.5 Bearing clearance The FAG spherical roller bearings for jaw crushers are normally supplied with
26、clearancegroup CN(normal).1.2.1.6 Bearing lubrication We recommend to lubricate the FAG rolling bearings in jaw crushers with a lithium soapbase grease with EP additives and corrosion inhibitors,e.g.our rolling bearing-tested FAGgrease Arcanol L186 V.1.2.2 Cone crushers 1.2.2.1 Principle of operatio
27、n Cone crushers,also referred to as gyratory crushers due to their gyroscopic motionsduring the size reduction process,were developed in the USA,where they were also firstbuilt and put into operation.The Symons brothers contributed considerably to the development of cone crushingmachines.The basic p
28、rinciple of cone crushers has remained the same to this day.The principle of operation of cone crushers is continuous,and the crusher axis onto whichthe crushing cone is mounted revolves at a defined angle to the perpendicular.Dependingon the crusher gap adjusted,cone crushers are used either for co
29、arse crushing or finecrushing of materials,effected by the gyratory movement relative to the crusher shell.Cone crushers are designed for large throughputs and are primarily used in mineralprocessing and in quarries.The throughput can reach up to several thousand tons per hour,depending on themachin
30、e used and on the original size(approx.8 to 300 mm)of the material to becrushed.The output size of the crushed material can range from 0 to 70 mm,depending on thecrusher size.1.2.2.2 Crusher axis/crushing cone support Shafts in cone crushers are supported either in rolling bearings or in plain beari
31、ngs,depending on the crusher type.Figs.3 and 4 show cone crushers in which rolling bearings are used.in the lower sectionof the crusher shaft the bearing axis is vertical.In the upper section,the bearingArrangement supporting the crushing cone is eccentric,and the bearing axis is inclinedrelative to
32、 the perpendicular.The crushing cone performs a gyratory movement.The crusher shaft is driven via a pinion meshed with the ring gear at the base of thecrusher shaft.Fig.3 shows how the inner system(crusher axis)is radially supported in two successivespecial cylindrical roller bearings of NU design(a
33、),and axial support is provided by aspecial-design double-row cylindrical roller thrust bearing(b)with a high load carryingcapacity.The same bearing Arrangement is used in these crushers to support the outersystem(crushing cone).3:Cone crusher 4:Cone crusher CFBK Pegson Example:Cone crusher type Eur
34、ocone 1500 Example:Cone crusher type Autocone 120OMKII Outer System:Outer System:1 cylindrical roller bearing 1 cylindrical roller bearing FAG 800898FAG NU2240E.M1.C3(330.146 x 558.8 x 311.17 mm)(200 x 360 x 98 mm)1 cylindrical roller thrust bearing 1 angle ring FAG HJ 2240E FAG 530311A 1 tapered ro
35、ller bearing(711.327 x 964.514 x 127.127 mm)FAG 561290C(570 x 920 x 195 mm)Inner system:Inner System:1 cylindrical roller bearing 2 cylindrical roller bearings FAG 800898 FAG NU2240E.MI.C3.N12B(330.146 x 558.8 x 311.17 mm)(200 x 360 x 98 mm)1 cylindrical roller thrust bearing 1 tapered roller bearin
36、g FAG 530311A FAG 561292(711.327 x 964.514 x 127.127 mm)(400 x 676 x 152.4 mm)As shown in fig.4,the inner system is radially supported at the top position by twosuccessive standard cylindrical roller bearings of NU design(a).To achieve an evendistribution of the external load among both bearings,the
37、 bearings are adjusted to N11B.At the bottom position the inner system is supported radially and axially by a special-design tapered roller bearing(b)with a high lead carrying capacity.The crushing cone(outer system)which is mounted onto the crusher axis is supportedat the top position by a standard
38、 cylindrical roller bearing of NU design(c).To prevent thecrushing cone from being lifted off by a gyroscopic moment,the cylindrical roller bearing islocked by means of an HJ angle ring.At the bottom position the crushing cone(outersystem)is radially and axially supported by a special-design tapered
39、 roller bearing(d)with a high load carrying capacity.1.2.2.3 Bearing dimensioning Determining the crushing force FBkNxnNxnNFB100081,9sintan8,2411065sin21918785,022+=babN=Required power kW n=Drive speed min-1 x=Distance between the cone lines mm a=half the crushing cone =gyroscopic or eccentric angle
40、 Based on the crushing force FB,(Fa,Fr),the forces acting on the bearings of the outer and inner system are calculated using trigonometric functions and the geometrical distances(crushing force/bearing).1.2.2.4 Bearing seats Fig.3:Radial cylindrical roller bearings:we recommend to machine the bearin
41、g seats to m6(shaft)and N6(housing bore).Cylindrical roller thrust bearings:we recommend to machine the bearing seats to j6(shaft)and H6(housing bore).Fig.4:Radial cylindrical roller bearings:we recommend to machine the bearing seats to k6(shaft)and N6(housing bore).Tapered roller bearings:we recomm
42、end to machine the bearing seats to j6(shaft)and N6(housing bore).1.2.2.5 Bearing clearance Taking into consideration the fit recommendations and the temperature differencebetween inner and outer rings,a special radial clearance was selected for the radialcylindrical roller bearings in fig.3,and C3
43、radial clearance for the cylindrical rollerbearings in fig.4.1.2.2.6 Bearing lubrication Rolling bearings in cone crushers are very heavily stressed.The heat generated in bearings with a high percentage of sliding friction,e.g.cylindricalroller thrust bearings and tapered roller bearings,must be rem
44、oved.Oil circulationlubrication is the best choice,figs.3 and 4.To keep the operating temperature within reasonable limits,and thus to achieve aviscosity ratio of x=v/v1=2,we recommend to use a rolling bearing-tested lubricating oilin accordance with ISO VG 220 or 320 specifications.Suitable are,e.g
45、.doped oils of series-Shell Omala-Aral Degol-Mobil Mobilgear It is important to observe the oil volume,oil cleanliness and oil change interval specifiedby the machine manufacturer.1.2.3 Hammer crushers 1.2.3.1 Principle of operation Single-shaft and double-shaft hammer crushers have been used for ma
46、ny decades tocrush a variety of materials As primary and secondary crushers,they are used for crushing bulk materials,e.g.limestone,marl,coal,gypsum,clay,etc.Huge hammer crushers in quarries can reduce material with edge lengths of up to 2.5 mand weighing up to 5 tons to an output size of approx.25
47、mm in one single operation.They can reach throughputs of up to 2500 t/h.In single-shaft crushers,the material is smashed against one or several jaw plates byrotating beater works(hammers attached to the rotor).The rough-crushed material isfurther reduced in size between the rotating hammers and the
48、grinding tracks.The endproduct falls through the grid openings in the bottom plate of the crusher.In double-shaft hammer crushers,the material is first rough-crushed above the rotors andthen reduced to their final grain size by the two counterrotating beater works.The endproduct falls through the gr
49、id openings in the bottom plate of the crusher.Hammer crushers work,depending on their size,at speeds ranging from approx.200 to2000 min-1.The required power can be 1000 kW and more.1.2.3.2 Rotor support Operation under rugged operating conditions and shaft deflections require spherical rollerbearin
50、gs to support the rotating beater works,see example in fig.5.5:Double-shaft hammer crusher KHD Humboldt Wedag Example:Double-shaft hammer crusher HDS 1600 x1980 2 housings FAG SUC3260AHAL 151049 2 housings FAG SUC3260AHBF.151049 4 spherical roller bearings FAG 23260K.MB (300 x.540 x 192 mm)4 withdra