5. Roller crusher installed at clinker cooler.pdf

Roller installed at clinker cooler after first stage.

1. Picture no. 1
Claudius Peters
Clinker Cooler Technology

2. Picture no. 2
克劳迪斯 彼得斯
熟料冷却技术

3. Picture no. 3
Claudius Peters
Clinker Cooler Technology
Design and function

of the roller crusher

4. Picture no. 4
克劳迪斯 彼得斯
熟料冷却技术

辊式破碎机的
设计与功能

5. Picture no. 5
Roller Crusher
1 Intended use
2 Structure and function of the roller crusher
3 Operation of the roller crusher
4 Requirements for the start of the roller crusher
5 Alarm messages
6 Interlocking
7 Emergency power operation
8 Operating status
9 Maintenance work

Table of contents

6. Picture no. 6
辊式破碎机
1 用途
2 辊破的结构与功能
3 辊破的运行
4 辊破的开起条件
5 报警提示
6 联锁
7 应急电源运行
8 运行状态
9 维护工作

目录

7. Picture no. 7
Design of the roller crusher
Installed between stages
4 crushing rollers
Gear motor for roller drive
Speed monitoring
Rollers:
Shaft
24 crushing rings each
Cooling and sealing air for crusher

8. Picture no. 8
辊破的设计
安装于两段冷却机衔接处
配有4条破碎辊
破碎辊由齿轮电机带动
配有速度监视
破碎辊结构 :
轴
24枚破碎环
破碎机配有冷却风和密封风

9. Picture no. 9
Design of the roller crusher

10. Picture no. 10
辊破的设计

11. Picture no. 11
Design of crushing rings
Uneven surface
“teeth” at irregular intervals
Arranged alternately on shaft
Improved pulling in and crushing of
clinker

12. Picture no. 12
破碎环的设计
表面不平整
破碎齿位置不规则
在轴上交错布置
改善对熟料的吞扯能力和破碎能力

13. Picture no. 13
Design of crushing rings and shaft
Crushing shaft with rings Crushing rings

14. Picture no. 14
破碎环和破碎轴的设计
上环之后的破碎轴 破碎环

15. Picture no. 15
Roller rotating as shown
Rollers forming crushing pair
(no. 3 and 4)
Clinker gets between rollers
Clinker is crushed
Function of the roller crusher

16. Picture no. 16
破碎辊转动情况如图所示
组成破碎组合的破碎辊是 3号和4号
细料从辊隙间漏下
粗料接受破碎
辊破的功能

17. Picture no. 17
Start of the crusher
Before start of crusher, start lane drive of grate 2
Start crusher in automatic operation
Do not start lane drive of grate 1 before start of crusher

18. Picture no. 18
破碎机的开起
开起破碎机之前，要先开起冷却机二段的列向单元驱动
自动模式开起破碎机
破碎机开起之后，方可开起冷却机一段的列向单元驱动

19. Picture no. 19
Operation mode depends on portion of oversized clinker
Operation modes of roller crusher
A – automatic operation with one crushing pair
(LCM – Low crushing mode)
B – automatic operation with two crushing pairs
(HCM – High crushing mode)
C – interval operation with one or two crushing
pairs

20. Picture no. 20
具体选用哪种运行模式，要看大块熟料量多还是量少。
辊破的运行模式
A – 采用一对破碎组合自动运行 (LCM – Low
crushing mode低破模式 )
B – 采用两对破碎组合自动运行 (HCM – High
crushing mode高破模式 )
C – interval operation with one or two crushing
pairs 时而一对时而两对破碎组合，交替运行

21. Picture no. 21
LCM – Low crushing mode
Automatic operation with one crushing pair
last two rollers (no. 3 and 4) form crushing pair
Fine clinker separated on first rollers, coarse clinker
is crushed

HCM – High crushing mode
Automatic operation with two crushing pairs
Two crushing pairs (1+2 / 3+4)
High portion of coarse clinker can be crushed

Interval operation of the rollers
Alternating rotation of roller 2
Optimized distribution of material in case of high
portion of coarse clinker
Operation modes of roller crusher

22. Picture no. 22
LCM – Low crushing mode 低破模式
采用一对破碎组合自动运行
最后两个破碎辊（ 3号和4号）组成破碎组合
经过前面的破碎辊时，熟料中的细料分流，而剩下的
粗料则接受破碎

HCM – High crushing mode 高破模式
采用两对破碎组合自动运行
两对破碎组合 (1号+2号、3号+4号)
可以破碎粗料量多的熟料

Interval operation of the rollers 破碎辊交替运行
2号破碎辊时而前转 ，时而后转
当熟料中含粗料多时 ，改善物料分配
辊破的运行模式

23. Picture no. 23
Overload caused by extremely hard clinker
Overload caused by metal parts
Detected by excessive motor current
Excessive motor current for too long time
Roller is stopped
Roller rotates in other direction
Roller stops
Roller rotates in original direction
Overload reversing

24. Picture no. 24
熟料太硬导致过载
金属块导致过载
检测到超高的电机电流
电机电流处于超高状态过久
破碎辊停转
破碎辊换向转动
破碎辊停转
破碎辊按原向转动
过载反转

25. Picture no. 25
Reversing cycle

26. Picture no. 26
反转循环

27. Picture no. 27
Stop time (roller stop time) T
STP

to minimize load peaks when changing direction
Fixed value adjustment: T
STP
= 4 seconds

Active reversing time T
RAC

Time of backward rotation
Longer than the stop time.
Recommendation of adjustment: T
RAC
= 12 seconds
Reversing waiting time T
RWA

Minimum time between two reversing cycles
protects drive and rollers
Recommendation of adjustment: TRWA = 12 seconds
Reversing cycle time T
RCY

Total time of reversing cycle
Reversing cycle

28. Picture no. 28
停止时间 (破碎辊停转时间 ) T
STP

将换向时出现的负荷峰值降到最低
固定值: T
STP
= 4 seconds

有效反转时间 T
RAC

往后转的时间
比停止时间长
建议设定为 : T
RAC
= 12 seconds
反转等待时间 T
RWA

反转循环结束后，起码要等待一段时间之后，才能开始
下一次反转循环。这段时间就是反转等待时间。
保护驱动和破碎辊
建议设定为 : TRWA = 12 seconds
反转循环时间 T
RCY

反转循环总共耗费的时间
反转循环

29. Picture no. 29
Reversing monitoring time (T
RMO
)
started for every reversing cycle.
Reset if no further reversing happens
Recommendation of adjustment: T
RMO
= 2 * T
RCY
(= 48 seconds)

1st alarm delay reversing fault (warning) (T
RAD1
)
Alarm if monitoring time is still active after this time
Recommendation of adjustment: T
RAD1
= 5 * T
RCY
(= 120 seconds =
2 minutes)

2nd alarm delay reversing fault (disconnection) (T
RAD2
)
Stop of crusher if monitoring time is still active after this time
Obstructions in crusher have to be removed manually
Recommendation of adjustment: T
RAD2
= 10 * T
RCY
(= 240 seconds =
4 minutes)
Reversing monitoring

30. 反转监视时间 (T
RMO
)
•从每次反转循环开始时算起
•如果反转再没有出现 ，就会归零
•建议设定为 : T
RMO
= 2 X T
RCY
(= 48 seconds)

反转故障 1次报警延时 (警告) (T
RAD1
)
•过了这段时间之后 ，如果监视时间还有 ，就会发出报警
•建议设定为 : T
RAD1
= 5 X T
RCY
(= 120 seconds = 2 minutes)

反转故障 2次报警延时 (断电) (T
RAD2
)
•过了这段时间之后 ，如果监视时间还生效 ，辊式破碎机就会停机
•卡阻破碎机运行的东西要人工清除
•建议设定为 : T
RAD2
= 10 X T
RCY
(= 240 seconds = 4 minutes)
反转监视
Picture
no. 30

33. Picture no. 33
Reversing monitoring

34. Picture no. 34
反转监视

35. Picture no. 35
Overfilling above the rollers
Can occur due to intense fall of kiln coating
No danger for damages to crusher
If necessary, reduce raw meal feed and lane speed on
grate 1

Overfilling below the rollers (several rollers stop)
Possible causes:
Standstill of grate 2
Lane speed of grate 2 too low
Remedy:
Check movement of grate 2
Increase lane speed of grate 2
Troubleshooting

36. Picture no. 36
破碎辊上方堵料
掉窑皮严重会导致发生堵料
破碎机没有损坏的风险
必要时，降低生料喂料量和冷却机一段的列向单元速度

破碎辊下方堵料 (几个破碎辊停转 )
疑因:
冷却机二段停机
冷却机二段列向单元速度太慢
对策:
检查冷却机二段的动作情况
加快冷却机二段的列向单元速度
故障处理

37. Picture no. 37
Troubleshooting
Roller drive failure
Rotation of rollers is monitored
In case of drive failure, manual
operation of remaining rollers
If necessary, reduce raw meal feed!
Ring fracture
Ring fracture very unlikely
Operation with 2 rings less per shaft possible
Broken rings have to be replaced as soon as possible

38. Picture no. 38
故障处理
破碎辊驱动故障
监视破碎辊的转向
如果驱动出现故障，则手动运行其余
的破碎辊
如果情况需要，那就降低生料喂料量 !
破碎环断裂
破碎环选用特殊材料，基本不可能断裂
就算每条轴上少 2个破碎环，运行仍然可以继续
损坏的破碎环要尽快更换

39. Picture no. 39
General condition of the crusher
Check for unusual sounds
Check bearing temperature
Check cooling / sealing air supply
Clean cooling ribs of motor
Daily inspection and maintenance

40. Picture no. 40
破碎机大体情况
检查有无异响
检查轴承温度
检查冷却风、密封风的供风情况
清洁电机的散热片
每日检查和维护

41. Picture no. 41
General condition of the crusher
Remove dirt / dust
Check crusher frame for signs of heat influence

Check for unusual sounds
Unusual sounds may indicate problems

Check bearing temperature
High temperatures can cause damages to bearing
High temperatures limit bearing lifetime
Daily inspection and maintenance

42. Picture no. 42
破碎机的大体情况
清除尘土
检查破碎机框架有无高温烧伤痕迹

检查有无异响
有异响，就可能有问题

检查轴承温度
温度高会导致轴承损坏
高温降低轴承使用寿命
每日检查和维护

43. Picture no. 43
Check cooling / sealing air supply
Check air ducts for leakages
Check function of fans
Insufficient air flow damages crusher!




Clean cooling ribs of motor
Only clean motor ribs can dissipate
motor heat
Dirty ribs result in overheated motor
Overheating damages motor!
Daily inspection and maintenance

44. Picture no. 44
冷却风、密封风的供风情况
检查风管有无泄漏
检查风机功能
风量不足，破碎机会损坏！




清洁电机的散热片
电机的散热片干净，方可有效散热
散热片有污垢会导致电机温度过高
高温损坏电机！
每日检查和维护

45. Picture no. 45
Condition of crushing rings
Condition of bearing
Grease bearing
Check electrical connections
Check connection between motor and roller
Annual inspection and maintenance

46. Picture no. 46
破碎环的情况
轴承的情况
干油的情况
检查电气接线
检查电机和破碎辊之间的连接
年度检查和维护

47. Picture no. 47
Condition of crushing rings
Check for broken crushing rings
Check wear of crushing rings
Replace worn / defective parts

Condition of bearing
Check bearing for wear
Replace bearing if required
Annual inspection and maintenance

48. Picture no. 48
破碎环的情况
检查破碎环有无损坏
检查破碎环的磨损情况
更换磨损、损坏部件

轴承的情况
检查轴承的磨损情况
如果有需要的话，更换轴承
年度检查和维护

49. Picture no. 49
Grease bearing
Dismantle bearing
Remove all old grease
Fill in 4 kg new grease per bearing:
Type: Norva HT2, Manufacturer: Esso
Viscosity: 480 cST at 40°C
Performance class: K2P-10, DIN 51502
Check electrical connections
Check if all cables are isolated and fastened properly
Fasten cables if required
Replace defective cables
Check connection between motor and roller
Check tensioning of all screws of connection between motor and
roller
Annual inspection and maintenance

50. Picture no. 50
轴承干油
拆下轴承
原来的干油全部除去
每个轴承加入 4kg新鲜干油:
型号: Norva HT2, 厂商: Esso
粘度: 480 cST at 40°C
性能等级 : K2P-10, DIN 51502
检查电气接线
检查所有线缆是否绝缘并且适当紧固？
必要时，紧固线缆
更换有问题的线缆
检查电机和破碎辊之间的连接
检查电机和破碎辊各连接螺栓的紧固程度
年度检查和维护

51. Picture no. 51
Dismantling and installation of crushing roller
Deposit cross arm (Pos.1) on crusher support frame (Pos.2)
fix with existing pins of wearing plates (Pos.3).
Mount large carrying strap with carrying beam and rolling wagon
(Pos.4).
Disassemble nuts on fixed bearing (Pos.12) and screws on movable
bearing (Pos.5) for fastening the shifting plate.
dismantle cooling air hose (Pos.7).

52. Picture no. 52
破碎辊的拆卸和安装
把横梁（1）放在破碎机支架 （2）上面。
使用原有的耐磨板定位销 （3）固定
在梁上装好大型挂具 （4）和辊轮小车
把固定轴承 （12）上的螺母 、在活动轴承的活动板紧固 螺丝（5）拆
下，
拆下冷却风管 (7).

53. Picture no. 53
Push the complete crushing roll (Pos.13) with movable bearing
unit out of the crusher housing.
Dismantling and installation of crushing roller

54. Picture no. 54
将整个破碎辊 （13）连同活动轴承 （8）一起，从破碎机壳体中推
出来
破碎辊的拆卸和安装

55. Picture no. 55
Assemble blind flange (Pos.14) to the crushing roll (Pos.13).
Now the complete roll can be removed.

The installation of the crushing roll takes place in reverse order.
When assembling the nuts (Pos.12) pull tight with 215 Nm.
Dismantling and installation of crushing roller

56. Picture no. 56
将盲板法兰 （14）装到破碎辊 （13）上。现在，就可以把整个破
碎辊拆卸下来了 。

安装破碎辊时 ，采用与拆卸相反的顺序即可 。只是，螺母（12）
用215Nm扭矩拧紧。
破碎辊的拆卸和安装

57. Picture no. 57
Dismantling and installation of crushing rings
Deposit cross arm (Pos.1) on crusher support frame (Pos.2) and fix
with existing pins of wearing plates (Pos. 3).
Mount large carrying strap with supporting beam (Pos.4).
Disassemble nuts on movable bearing (Pos.6) and screws (Pos.5) for
fastening the shifting plate.
Dismantle cooling air hose (Pos.7).
Remove complete movable bearing unit (Pos.8) with shifting plate
from working area.

58. Picture no. 58
破碎环的拆卸和安装
将横梁（ 1）放到破碎机支架（ 2）上面，用原有的耐磨板定位销（ 3）
固定住。
把大型挂具（ 4）安装到支撑横梁上
把活动轴承（ 6）上的螺母、活动板的紧固螺栓（ 5）拆下来
拆掉冷却风管 (7)
将整个活动轴承（ 8）连同活动板一起，搬出作业面。

59. Picture no. 59
Pull out all crushing rings (Pos.9) up to the carrying strap (Pos.4).
Dismantling and installation of crushing rings

60. Picture no. 60
将挂具（ 4）之前的全部破碎环（ 9）都拉出来。
Dismantling and installation of crushing rings

61. Picture no. 61
Secure crushing roll for shifting of carrying strap (Pos.10).
Push crushing rings (Pos.9) to the opening
mount small carrying strap on the supporting beam (Pos.11)
Dismantling and installation of crushing rings

62. Picture no. 62
固定好破碎辊 （10），以便更换吊带
将破碎环 (9)推到开口处
将小型挂具 (11)安装到横梁上
Dismantling and installation of crushing rings

63. Picture no. 63
Pull out all crushing rings (Pos.9).
The installation of the crushing rings takes place in reverse order.

When assembling the nuts of the movable bearing (Pos.6) pull tight
with 215 Nm.
Dismantling and installation of crushing rings

64. Picture no. 64
将所有破碎环拉出来 (9).
安装破碎环时 ，采用与拆卸相反的顺序即可 。

安装活动轴承的螺母 （6）时，采用215Nm扭矩拧紧 。
破碎环的拆卸和安装

65. Picture no. 65
See separate operating / installation instructions!
Dismantling of drive motor and bearing

66. Picture no. 66
阅读另外的运行 、安装说明 ！
驱动电机和轴承的拆卸