0430-YQP36预加水盘式成球机设计【全套13张CAD图】
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任务书课题: YQP36预加水盘式成球机设计一、设计内容结合生产实际,完成预加水盘式成球机的设计。二、设计依据 生产能力Q=25t/h。三、技术要求所有结构及其零部件设计后考虑技术性、加工工艺性、经济性,并保证安装、使用、经济方便。要保证预加水成球盘的运转平稳,节能高产。四、毕业设计物化成果的具体内容及要求1、设计说明书1份,达1万字以上,且要符合规范要求。2、中文摘要不少于400字。并有对应英文摘要(电子文档)。3、设计图样总的绘图量折合A0不少于3平方米(CAD);具体设计的图样有:(1)预加水盘式成球机总装图一张;(2)机架部件图一张;(3)传动部件图一张;(4)机架及传动部件相关零部件图若干张。4、翻译3000以上汉字的课题相关外文资料。5、实习小结(电子文档)。五、毕业设计进度计划起讫日期工作内容备 注06.03.0606.03.07布置任务下达任务书06.03.0606.03.17调查研究,收集资料,熟悉课题,毕业实习06.03.1806.03.31总体设计,方案论证06.04.0106.05.10部件、零件设计阶段06.05.1106.06.04编写说明书06.06.0506.06.07毕业设计预答辩06.06.0806.06.11修改整理毕业设计材料06.06.1206.06.13材料评阅06.06.1406.06.16毕业答辩06.06.1706.06.18材料整理装袋六、主要参考文献:1、许林发.建筑材料机械设计(一)M.武汉:武汉工业大学出版社,1990.8.2、褚瑞卿.建材通用机械与设备M.武汉:武汉理工大学出版社,1996.9.3、 朱昆泉,许林发.建材机械工业手册M.武汉:武汉工业大学出版社,2000.7.4、徐灏.机械设计手册M.北京:机械工业出版社,1991.9.5、胡家秀.机械零件设计实用手册.北京:机械工业出版社,1999.10.6、赵忠.金属材料与热处理M.北京:机械工业出版社,1991.5.7、甘永立.几何量公差与检测M.上海:上海科学技术出版社,2001.4.8、钱志锋,刘苏.工程图学基础教程M.北京:科学出版社,2001.9.9、阎瑞敏,常敏.水泥工业自动控制预加水成球技术及装备M.江苏科学技术出版社,1990.10.10、黄有丰.预加水成球技术及其应用M.北京:中国建筑工业出版社,1991.9.11、彭常皓.对老式成球盘的改造J.四川水泥,1996.No.2:3234.12、马正先.合理调整成球盘 降低爆球率J.水泥技术,1994.No.6:5051,32.13、王振宇,孟德忠.清理成球盘边挂泥的办法J.水泥,1996.No.12:59.14、李国权.成球盘减速机的选型J.水泥,1996.No.12:43.15、徐双龙.成球盘减速机漏油的处理J.四川水泥,2001.No.6: 32.16、黄胜.成球盘减速器输入轴的改进J.水泥,2001.No.1:49.17、侯义杰.成球盘孔与轴键联接失效的修复及改进J.工程师园,2000.No.4:27.18、孙德隆,姜勇.成球盘扩径改造的实践及论证J.四川水泥,1998.No.2:2325.19、梁东武.3.6m成球盘传动机构的改造J.水泥,1996.No.3:23.20、郝志东.3.2m成球盘传动装置的改进J.水泥,1998.No.12:4950.21、李银锋.预加水成球盘传动装置的现状及改进J.水泥,1994.No.4:3234.22、黄金平.3.2m预加水成球盘成球刮刀机的改进J.中国建材装备,2001.No.3:1617.23、张贵春.3.2m 成球盘曲柄滑块式刮刀装置J.水泥,2000.No.5:39.24、李升朝.成球盘边刮刀的改进J.水泥,1996.No.12:41.25、赵文涛.成球盘底刮刀传动系统的改进J.水泥,1998.No.11:48.26、杨军.成球盘刮刀的改造J.水泥,2004.No.2:65.27、郭红军.成球盘刮刀系统的改造技术J.水泥,1996.No.12:4243.28、邓清华.成球盘刮料装置的改进J.江西建材,1998.No.1:3132.29、王树华.成球盘无动力刮刀的改进J.四川水泥,1998.No.1:31,25.30、郝志东.预加水成球盘底刮刀装置简介J.水泥工程,1999.No.4:2930.七、其他5开题论证报告课题名称:YQP36预加水盘式成球机设计一、 课题来源、课题研究的主要内容及国内外现状综述 本课题来源于江苏海建集团股份有限公司。课题研究的主要内容是设计盘径为3.6m、产量为25t/h的预加水成球盘。目前我国水泥企业,正向着大型化迅速发展,以海螺集团为首的一批年产1000万吨以上的大型水泥集团发展势头迅猛,海螺在2002年形成年产4000万吨的生产能力,跻身于世界10强之列。基础条件较好的立窑水泥企业,通过推广应用20项适用技术,正在向现代立窑企业和经济规模化发展,以塔牌集团为首一批年产100万吨以上大型立窑水泥企业,已加入发展经济规模新型干法之列。我国水泥2002年年产总量虽然已经达到7亿多吨,但立窑水泥仍占70%,在现阶段,现代立窑还是一种比较符合国情的适用技术。立窑生产工艺由于它的单机生产能力小,劳动生产率低和难以实现自动化生产等缺点,难以与大型新型干法企业竞争,逐步被新型干法或更新的技术所取代,是我国水泥工业发展的历史必然。但由于国民经济的持续高速发展的拉动,水泥的市场需求仍处在上升期,这就给立窑水泥的发展提供了空间,这也是为什么在新型干法快速发展和淘汰了近1亿吨立窑生产能力的情况下,立窑水泥的增量仍然大于旋窑水泥增量的原因所在。可以预言,今后相当长的历史时期,我国水泥工业还少不了立窑水泥的支撑。因此有生存发展条件的立窑水泥企业,要不失时机的逐步与新型干法接轨和发展新型干法生产线,这是立窑水泥企业实现可持续发展的历史选择。生料制备、水泥粉磨系统等与新型干法技术的接轨,为立窑水泥企业的产品质量提供了生料质量的保证,但窑的煅烧水平最终决定熟料质量的优劣。通过我国广大立窑水泥工作者长期不断地技术创新,在立窑煅烧技术上,取得了前所未有的技术进步和发展。由于这些新技术的推广应用,使立窑生产工艺,至今还能作为我国水泥生产工艺中的一种经济实用的技术方式,与新型干法生产技术共存。 当前立窑煅烧系统,应该进一步重点抓好两项技术的推广和粉尘治理。其中预加水小料球快速煅烧技术,小料球快速烧成技术是立窑煅烧的一项重要技术进步,目前应用十分成功的企业并不多,主要原因是前几年预加水成球系统的控制技术和设备还不太过关,小料球的操作控制要点还没完全掌握,目前预加水成球技术已经发展到第六代产品,设备及控制系统基本过关。小料球快速煅烧技术的核心是减小料球平均粒经和大小球的差异,也就是将成球的粒度由原来的812mm,降低为37mm。由于粒球平均直径大大减小,对加快煅烧速度、提高窑的产量和降低fCaO含量都产生了积极的影响,应用成功的企业都取得明显效果。二、本课题拟解决的问题1盘底平面和侧平面有出现变形,增加主电机运转负荷,影响成球质量;2支架刚度和强度不够,出现变形;3采用行星减速机出现传动扭矩不足及漏油现象;4采用圆柱齿轮减速机出现的漏油以至缺油、磨损现象;5盘体转动扭矩大以至减速机输入轴端键和键槽的变形与孔轴的磨损现象;6采用的伞齿轮副传动不稳定与断齿现象;7固定式无动力边刮刀磨损及所成球质量差和无法保证生产连续性的现象;8动力轴承出现轴承烧坏、键槽损坏甚至电机烧坏和小立轴失效的现象;9盘式6爪电动刮刀的动力消耗大,成球质量低,清盘阻力大、周期长,结构复杂、不易维修等问题;10圆柱形刮刀杆的五爪无动力刮刀中,存在刀杆不易夹紧,彻底清盘一次的周期长,清料阻力大,成球盘动力消耗高等缺陷。三、解决方案及预期效果采用可调式盘体且在盘底焊接工字钢以增加盘底的刚度和强度,在盘边焊接圆钢以加强盘的径向刚度。采用无动力边刮刀和圆钢焊接成支架以减少刮刀支架所要承受的弯矩。合理布局刮刀的位置以实现成球高质量的目的,设计盘倾角在4852的范围内,盘高在550mm600mm的范围内。在传动系统方面,将采用电机皮带ZQ减速机直齿轮副成球盘的传动结构。并且设计将高速轴端和低速轴端同布置在上侧,以减少轴对密封圈的磨损和解决漏油问题。同时采用圆柱齿轮连接也避免了因伞齿轮的刚性不足而断齿影响生产连续性。ZQ减速机高速轴端采用平键双键联接,使孔轴过盈配合,保证扭矩的正常传递而不失效。大小齿轮设计防尘罩以减轻齿轮啮合的磨损。主轴采用角接触球轴承或圆锥滚子轴承以承受主轴轴向力。电机固定在固定底架的侧面,以实现安装方便的需要。调整盘转速到11.5r/min,保证成球质量。刮刀系统中,将采用无动力底刮刀结构,以起到节能、经济的需要。无动力底刮刀采用五边形刮刀盘,另外在刮刀杆上设计成方形刀杆和设计锁紧结构以解决其轴向的锁紧问题,也有设计成十爪方刀杆无动力刮刀以减少动力磨损。在刮刀盘连接的轴的上端安装一飞轮,以实现盘体转动的调速作用。设计刀头距离盘底保持在1015mm的距离范围,以减少刮刀运行中的阻力降低主机电流,保证产量要求;在刀头部焊接小型耐磨合金块来减少刀头磨损。将采用无动力固定式边刮刀,在形状和结构上做相对调整改进,如采用可换式刀头,以解决起刀杆变形而导致的清料质量差的问题。为了保证成球盘在运转过程中的稳定性,设计中将大量采用刚度和强度好的型钢焊接成底架,增加它的承压面。在调角器方面,采用蜗轮蜗杆传动和螺纹的轴向传动的原理制成,满足盘倾角的锁定要求,另外根据客户使用要求也可采用液压装置实现调试。此次设计本着高产量、高质量成球,稳定运转的原则,实现预加水成球盘要求的节能性、经济性、环保性、可扩展性。四、课题进度安排3月6日3月17日毕业实习阶段。毕业实习,查阅资料,到多个公司实践,撰写实习报告。3月18日3月31日开题阶段。提出总体设计方案及草图,填写开题报告。4月1日5月10日 设计初稿阶段。完成总体设计图、部件图、零件图。5月11日6月4日 中期工作阶段。完善设计图纸,编写毕业设计说明书,中期检查。6月5日6月7日毕业设计预答辩。6月8日6月13日毕业设计整改。图纸修改、设计说明书修改、定稿,材料复查。6月14日6月16日毕业答辩。6月17日6月18日材料整理装袋。五、指导教师意见 年 月日六、专业系意见 年 月日七、学院意见 年 月日2Feasibility study requirements for a new cement plantR.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 ISSUEIntroductionThe 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 studyIn 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 studyMarket researchThe 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 companys 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 provingThe 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 designThe 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.
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