球磨机 φ1500X4500

Ball Mill φ1500X4500

使用说明书 
 
Operation Instruction 

上海西芝矿山工程机械有限公司
Shanghai Zenith Mining and Construction Co., LTD
地址：上海浦东新区川沙建业路 416 号
No, 416 Jianye RD, Pudong New District, Shanghai, China.

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 目录
Catalogue

1. 概述 Overview

2. 性能 Parameter

3. 主要结构及工作原理
Main parts and operating principle

4. 安装要求
Installation guidelines

5. 试机, 使用与维修
Test run,operating instruction and maintenance

6. 衬板件明细 Liner lists

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1. 概述 Overview
本机主要用于选矿、陶瓷、化工、水泥等行业，有干、湿两种。近年来新开发出来轴承传动
节能球磨机，节约能源 25-30%。球磨机的主要部件都是一个缓慢旋转的筒体，筒体内装有
磨碎介质，由于球磨机结构简单坚固、操作可靠、维护管理简单、能长期连续运转、对物料
适应性强、破碎比大和生产能力大，所以能满足现代化大规模工业生产的需要。
This machine is mainly used for ore dressing, ceramics, chemical and cement industries
with dry grinding and wet grinding types, energy-saving ball mill has been invented in
recent years and it can save 25% to 30% energy, compared with others. The main parts of
ball mill is a slowly rotating cylinder with grinding medium inside, due to features of simple
and firm structure, easy operation and maintenance, and continuously working, so the
ratio of reduction is big and high capacity to meet needs of modern construction.

2. 性能 Parameter
规格型号 Model φ1500X4500
进料粒度 Feeding size 0-25mm
出料粒度 Discharging size 0.074-0.4mm
产量 Capacity 10-20t/ h
电动机型号 Model of motor JR117-6 115KW
频率 Frequency 50Hz
电压 Voltage 380V
筒体转速 Rotary speed 26.7r/min
填充率 Filling ratio 27%
减速机型号及速比
Model and velocity ratio of reducer ZD40-9-Ⅱ i=5

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3. 主要结构及工作原理
Main parts and operating principle
1) 主要结构 Main parts
本机为边缘传动,中心卸料,开流式球磨机。主要由圆柱形筒体、进、出料装置
中空轴、轴瓦、传动小齿轮、大齿圈、减速机、电动机等部件组成。
It is a open circuit ball mill of edge transmission and center discharging, which contains
cylinderical barrel, feeding and discharging device, hollow shaft, main bearing, pinion, gear
rim, reduction gear, motor, etc.
a. 回转部分（筒体）Rotary shell
回转部分是由钢板卷制焊接而成的筒体，两端用螺栓分别与进、出料、中空轴相连接，并
水平地支撑在两个轴瓦上。进出料中筒内装有进出料螺旋。筒体的回转由电动机、减速机、
小齿轮、通过固定在筒体一端的大齿圈来实现的。筒体的内部设有衬板，它既可以保护筒
体，又可以把球带到适宜的高度，以提高粉磨效率。筒体上设有人孔门，用于装卸磨体、
修理更换筒体内部的零件之用。
Rotating barrel of which the two ends is connected with feeding and discharging device is
formed by welding curved steel plate and supported on two self-aligning bearing flatly.
There are some spiral in the feeding and discharging device. Rotating is achieved by
motor, reduction gear, pinion and the fixed gear rim at one end of the barrel. There are
lining plate inside to protect the barrel and get the medium-steel ball to appropriate height
to improve crushing efficiency. There is an access hole in the barrel for maintenance and
unloading grinding medium.
b. 进、出料装置 Feeding and discharging device
进料装置主要用于进料和添加钢球；出料装置用于输出成品物料及磨损的钢球、硬物等。
Feeding device is used to feed material and add steel ball. discharging device is used to
discharge processed material and wearing steel ball.

c. 支撑装置 Supporting device

轴瓦支撑着回转部分、磨球、物料等全部质量，是保证磨机正常运转的主要部件之一。轴
瓦能自动调心，以适应制造、安装的误差。
Rotating barrel, steel ball and material are all supported by the supporting device which
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 plays an essential role. The main bearing is self-adjusting to adapt tiny operating and
installation mistakes.
d. 传动装置 Transmission device
由电动机通过弹性联轴器、减速机、小齿轮、大齿圈形成传动链。
特别提示：球磨机传动装置的布置，不允许随意变动。如需变动，必须要保证小齿轮对大
齿轮的作用力垂直向上，并由此决定球磨机的回转方向，同时必须改变所有带方向性的零、
部件结构。通常情况下，这是不允许的。
Transmission device is made up of elastic coupling, reduction gear, pinion and gear rim.
please note that the transmission device could not be moved as will. if the position is
changed ,then we have to make the acting force from pinion to gear rim is vertical and up.
Generally the position of transmission device is unallowed to change.

2) 工作原理 Operating principle

当电动机通过联轴器、减速机、小齿轮、大齿圈带动筒体旋转，装在筒体内的破碎介质（钢
球）与不断进入筒体内的物料在离心力和摩擦力的作用下，随着筒体上升到一定高度，然后
脱离筒壁自由落下。物料的破碎主要是靠介质落下时的冲击力和运动时的磨剥作用来实现。
物料是从进料段的中空轴内不断地输入，而磨碎以后的产品经筒体的另一端的中空轴不断排
出。湿磨时，成品被水的流动而带走。球磨机分左、右旋磨矿。客户可根据自己的现场决定，
需要在采购合同中注明。
When the rotating barrel is rotating by the action of transmission device, steel ball inside

and the feeding material will rise highly under the centrifugal force and frictional force, then

steel ball hit the material fiercely. during the grinding process, material is feeding constantly
while grinded material is discharging with water flow simultaneously. Ball mill has
sinistrogyration and dextrorotation kinds. Customers could decide which one to choose, but
it should be noted in purchasing contract.

4.安装要求 Installation requirements

球磨机安装要求除按图纸的技术要求外，同时要按下述要求进行。
Beside the requirments written in the drawing, other requirements below should be paid
attention.
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1) 安装前，应对筒体、齿轮、中空轴、轴承座、传动轴承、减速机等重要零件进行检查，如
有损伤和变形应事先修复。
Beside the requirments written in the drawing, other requirements belowing should be paid
attention. The barrel, gear, hollow shaft, bearing block, drive bearing and reduction gear
should be checked before installation.
2) 安装时应先将要装的零件清洗干净（特别注意结合面和滑动面），设备上已装好的零件，
在试运转前应检查其清洁度，不合要求时应予清洗。带有方向性的零部件，如蓖板、螺旋
筒等，应按图纸要求安装，不得装反。
All parts should be tidy, especially the faying and sliding surface. and parts like grinding
plate should be installed in the right direction. before test run, make sure ball mill is tidy.
3) 根据实测尺寸，修正两个主轴承的中心距，然后根据此进行基础划线（带整体支架时不需
要）
Adjust the distance of two main bearings center according to actual measurement data
on which the groundsill design is based.(this step could be omitted when there is a
support device.
4) 基础划线的质量要求如下（不带整体支架设备）：
Requirements of groundsill design are as follows (not overall support equipments):

a)两基础墩上的纵横向中心线距离的误差≮±3mm；

two piers on the basis, the error of vertical and horizontal distance to the center line ≮
± 3mm
b)标高的误差为±5mm（指一次浇注的混凝土表面）
Elevation error of ± 5mm (mean pouring the concrete surface one time)
5) 二次灌浆Secondary grouting
设备的二次灌浆应在设备粗校后进行。设备在安装前，应彻底清除地脚螺栓孔中
垃圾，被油污染的混凝土应予凿除，需要灌浆的表面要做拉毛处理。设备的底座、底面应
保持清洁。
Secondary grouting should be conducted after calibration. Bolts hole should be cleared
concrete polluted by oil should be eliminated. The grouting surface should receive
treatment. Base and bottom of ball mill should be clean.
灌浆一般宜采用细碎石混凝土（或水泥砂浆），其标号应比基础的混凝土标号高一级，

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 灌浆时，应捣固密实，捣固时不得撞动设备、垫铁、地脚螺栓等，以免影响设备的安装精
度，当灌浆层的耐压强度达到设计强度的 75%以上后，方可对设备进行精校。
Crushed stone concrete, a grade higher than general concrete, should be used to
groute. Keep equipment, mat iron, anvhor bolts stationary to insure installation
accurancy when tamping. Secondary calibration is proceeded after compression
strength has been up to 75% of designed compression strength.
6) 主轴承的安装 Installation of main bearing
轴承装配前应进行检查，调整间隙。
Check the main bearing before installation. heat the bearing by oil till the inner hole
become bigger enough to be installed.
7) 回转部分的安装(设备散装运输时) Installation of rotating barrel
筒体与中空轴组装时，，结合面应清除干净，涂以铅油，结合应紧密，不得加入任何调整
垫片。回转部分应符合以下规定：设备放置后，应检查两端标高，在中空轴颈的母线上测
量，相对标高差、（进料端的标高高于出料端 20mm）。两中空轴的轴线应在同一轴线上
（对散装件），大齿圈与筒体，齿圈端面与中空轴端面之间不得大于 0.15mm 的间隙，大
齿圈与小齿轮装配时的齿侧间隙应为 0.4-1.5mm，轮齿的接触面积在齿高方向≥45%、齿
宽方向≥60%。
Faying places should be clean and applied lead oil when barrel and hollow shaft is
connected. During the process, nothing is allowed to added in the faying place.

5. 试车、使用和维修保养
Test run, operating instruction and maintenance
1) 球磨机安装完毕并符合安装要求后，才能进行试车运转工作，试运转程序如下
Test run could be started after all installation requirements are met. Below are steps for
test run:
a. 将减速机内按要求加注润滑油，齿轮护罩内加入齿轮油；
Add lubrication oil to reduction motor and gear oil to gear cover.
b. 球磨机空运转24小时（不加研磨体）
Ball mill runs 24 hours without anything inside.
c. 加入 1/3 研磨体并喂料，运转 8 小时；
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 Add one third medium and run for 8 hours with feeding raw material inside.
d. 加入 2/3 研磨体并喂料，运转 72 小时；
Add two third medium and run for 72 hours with feeding raw material inside.
设备试运转过程中，要注意转动部位的温度，主轴承、传动轴承的温度不得超过 70℃。
减速机在试运转期间应密切注意个润滑点的供油情况是否正常，电动机的负荷、大、小齿
轮及减速机声音是否有异常等。每次试运转中的震动情况应严格注意。停机后，要检查轴
颈与轴承的情况、传动齿轮的啮合情况、检查地脚螺栓、中空轴螺栓、衬板紧固螺栓、大
齿圈螺栓等紧固情况，检查各处有无漏水、漏料等情况。
Check oil sites once at least per hour to insure the temperature of the main bearing, drive
bearing and reduction motor not more than 70 ℃ and 55 ℃ respectively, check whether
the gear rim and pinion working sound is normal. And Check any leakage phenomenon
around sealed places.
2) 试运转合格后，允许正式使用，用户可根据具体情况，制订操作、维护、检修制度，以保
设备的正常运转。
If the test run is qualified, then the ball mill could be put into use.
a. 球磨机操作的知识 Operating guidelines
判断球磨机运转是否正常有两种常用的办法：第一种办法是检查物料的出料粒度，
若合乎要求，，且跳动不大，就说明球磨机的运转正常，说明加料恰当、物料的进料粒度、
水分都合适，钢球级配合适。第二种办法是听球磨机的声音，设备运转正常时应该是“哗
哗”夹杂着轻微的冲击声。如果声音变的暗哑，发出“轰轰”的声音，冲击声听不到，说明仓
内物料过多，严重时出现满磨现象，这时应立即停止喂料，待设备正常运转后在继续喂料；
如停止喂料后，正常的声音仍然听不到，物料很难喂入，而且出料很少，对于干式球磨机
说明筒体内有严重粘磨现象，应立即进行处理，一般来说可用以下办法解决：若是入磨物
料水分过高，则应降低入磨物料水分在 2%以内，也可以加入部分干物料，研磨能消除上
述现象，湿式球磨机不会出现此现象。钢球的冲击声很强，说明筒体内物料少，应增加喂
料，喂料量不可过强，应逐步的调整过来。
There are two ways to judge whether ball mill runs normally. The first way is check
whether discharging size meets required standard, if the answer is positive then we
judge ball mill is normal. The second way is listening to the ball mill, if it sounds like "hua
hua" and lightly impact sound, then we could judge ball mill is normal. If the sound
becomes heavy or no more impact sound then generally we can judge material inside is
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too much, which suggest us stop feeding. What is worse, if we can't hear normal sound
and discharging material is less than normal, it may suggest material inside is stuck
together if it is dry grinding type. Generally the problem could be solved by declining
moisture of raw material to 2% or lower, else adding dry material is another choice. Wet
grinding ball mill won't occur such problems. If the impact sound is too strong, it means
material inside is too less that we should add more material individually.

b. 球磨机的操作程序 Operating procedures of ball mill：

b-1 启动前的准备 Preparation before starting ball mill

(1) 清除球磨机周围有碍运转的杂物，检查安全设施；
Remove other unconcerned things
(2) 检查球磨机内及危险地点是否有人；
Check whether there is anybody inside of ball mill
(3) 检查研磨体表面至蓖板中心距离（及填充率）是否符合要求；
Check whether the distance between ball mill surface and lining plate and the
filling ratio is as required
(4) 将人孔盖可靠封闭和紧固；
Close and seal the access hole
(5) 润滑点、润滑油是否充足；
Whether lubrication oil and oil sites is enough
(6) 第一次试运转或长时间停止运行时，在启动前，必须向中空轴颈上加润滑油，人工
手动盘磨至少一周，确认无碰撞和卡滞现象后，才能由电机启动。
Operator should add oil lubrication on the hollow shaft neck when first test run or
ball mill hasn't run for a long time. and start the electrical motor when there is no
collision and stagnation phenomenon
(7) 在启动球磨机前，还应和有关工作岗位取得联系，允许后启动。
Start the ball mill after getting permission.

b-2 球磨机的启动顺序 Start sequences:

(1)启动出料输送设备；
Turn on conveying device
(2)启动球磨机电动机；
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 Turn on electrical motor
(3)启动磨机的喂料装置。
Turn on feeding equipment

b-3 停机顺序 Turn off sequences

(1) 停止向球磨机喂料的喂料设备的运行；
Turn off feeding equipment
(2) 停止球磨机的运转；
Turn off electrical motor
(3) 关闭出料输送系统。
Turn off conveying equipment

b-4 注意事项 Matter needing attention

(1)当球磨机准备长时间停止运行时，要将研磨体从筒体内取出，避免筒体弯曲；
When the ball mill wouldn't run for a long time, take out grinding medium inside in
case of barrel deformation.
(2)要经常检查主轴承的润滑情况；
Check lubrication condition of main bearing frequently.
(3)在球磨机停止之后，每隔 5-10 分钟将筒体转动半圈，直到球磨机充分冷却为止。
Make barrel take a turn every 10 to 20 minutes after ball mill stops running till it
cools off.

3) 球磨机的维护和保养 Maintenance of ball mill

a. 定期检查地脚螺栓、衬板螺栓、磨门螺栓等重要螺栓是否松动；
Regularly check the anchor bolts, lining plate bolts, grinding door bolts and other
important bolts to know whether bolts become loose.
b. 各润滑点的润滑情况至少每小时检查一次，主轴承、传动轴承温度不允许超过 70℃，减
速机的温度不允许超过 70℃。
check oil sites once at least per hour to insure the temperature of the main bearing,
drive bearing and reduction motor not more than 70℃ and 55℃ respectively.
c. 检查各处密封有无漏油、漏料等情况。
Check any leakage phenomenon around sealed places.
d. 记录电动机电流值的变化，若发现电流有异常变化，应停车进行检查。

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 Record the changes of motor current value. if abnormal changes occures, stop running
and check
e. 大、小齿轮转动的声响是否正常。
Whether the gear rim and pinion working sound is normal.
f. 为了及时发现设备的故障隐患，除了正常的维护外，必须定期停机，对重要部件的连接
情况、磨损情况做仔细的检查，并针对发现的缺陷作正确处理，同时作好详细的检查、
修理记录。
In addition to normal maintenance, operators should examine joint places and fraying
degree of main parts periodically in case of breakdown.

4) 设备使用的润滑油应根据气候、润滑点的不同，按下表选用润滑油
Refer to the following table when choose lubricating oil of which the application is based on
different climate and oil sites.
序号 润滑位置 润滑油牌号 气候情况 备注
NO. Oil Site Brand of Oil Climate Note
轴承 机械油 NT40 或 2#锂基润滑脂 冬季
1
Bearing Automobile oil NT40 or 2# lithium lubricating grease winter

齿轮 齿轮油恩氏粘度 130E 冬季
2
Gear Gear oil with 130E Engler viscosity winter
减速机 机械油 NL20 冬季
3
Reduction gear Automobile oil NL20 winter
轴承 机械油 NT50 或 2#锂基润滑脂 夏季
4
Bearing Automobile oil NT50 or 2# lithium lubricating grease Summer

齿轮 齿轮油恩氏粘度 250E 夏季
5
Gear Gear oil with 250E Engler viscosity Summer
减速机 机械油 NL30 夏季
6
Reducer Automobile oil NL30 Summer

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6.衬板件明细  Liner lists
序号 名称  材料 

No.  Name  Material 

1  大波纹衬板 ZGMn13 

Big corrugated liners 

2  小波纹衬板 ZGMn13 

Small corrugated liners 

3  磨头衬板  ZGMn13 

Mill head liners 

4  隔仓衬板 ZGMn13 

Partition screen plates 

5  隔仓板固定环 ZGMn13 

Fixing ring  for 

partition screen plates 

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