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現(xian)場磁性分離器(qi)水箱改造
  • 發布日期:2019-03-14      瀏覽次數:1114
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      現場(chang)平面磨(mo)的過濾水(shui)箱,原(yuan)先(xian)使(shi)用兩臺日本生產的大型(xing)磁性(xing)分離器(qi)串聯(lian)過濾磨(mo)屑,多年來使(shi)用效果不盡人意:

      第一,過(guo)濾精度無法保證(zheng)和提高(始終(zhong)在70-80微米)。

      第二(er),下部箱體隔半月清(qing)理.沉(chen)積(ji)物內(nei)的砂輪(lun)粘結物凝固(gu)結塊,清(qing)理時(shi),需人員下到底部鑿開(kai)沉(chen)積(ji)物,費工費時(shi)。

      第三,冷卻液半(ban)年更換一次,對成本和(he)環境不(bu)利。

      經討論多種方案,終選取緩沖沉淀刮排過濾系統替代原先現場磁性分離器水箱。
        首先采用格欄和隔板對來的臟液進行阻隔緩沖,用隔板將箱體分為左右兩個腔體,兩套刮板機構并用一個驅動機構,臟液從過濾設備的尾部進入右腔體,到右腔體前頸部位置溢水方式進入左腔體,終從左腔體尾部再溢水進入中轉腔體。左右腔體再使上隔欄和下隔欄分段阻隔,讓臟液以一上一下方式流動,使臟液中的顆粒加速沉淀,經過此道粗過濾可去除臟液中大部分
      較大(da)的顆(ke)粒(li),臟液在中轉(zhuan)腔中用管道泵打入濾袋式過濾器,進一(yi)步提升精度達20微米(mi),隨后(hou)進入凈(jing)液箱(xiang)供(gong)平(ping)臺磨床隨時使用。

      其次在左右腔(qiang)體底部各安裝一套間隔(ge)600毫米(mi)的刮(gua)板和鏈條.刮(gua)板采用滲炭處理(li)以(yi)增加表面硬度(du),鏈條(tiao)采用(yong)大滾(gun)子鏈,由于臟液中(zhong)的磨粒較(jiao)多,普通(tong)鏈條(tiao)使用(yong)易磨聯接片(pian),所以改滑動(dong)摩擦為滾(gun)動(dong)磨擦運行。腔體(ti)沉積(ji)的磨屑被刮板帶到箱(xiang)體(ti)前(qian)端向上頸部并脫(tuo)(tuo)離液面,在脫(tuo)(tuo)離液面和掉入集渣(zha)車之間,泥渣(zha)中(zhong)的液隨頸部流回水(shui)箱(xiang)中(zhong),達到脫(tuo)(tuo)液效果,并解決(jue)人(ren)員定期清理問題。

      采用扭力(li)(li)控制器,時刻監控刮板排屑機主(zhu)軸的負載力(li)(li),以防止(zhi)異物(wu)和(he)沉積結塊物(wu)卡住(zhu)刮板鏈條機構(gou)。同時過濾濾筒中設置了壓(ya)力(li)(li)發(fa)訊器,防止(zhi)濾袋堵塞流(liu)量(liang)下降,供液不足(zu)。
         過濾系統流(liu)程分(fen)析
         對于整個過(guo)濾系統流程(cheng),其從機(ji)床流出(chu)的(de)臟切削液(ye)(ye)通(tong)過(guo)出(chu)液(ye)(ye)槽流入(ru)(ru)配套的(de)回(hui)液(ye)(ye)箱,然后(hou)由(you)回(hui)液(ye)(ye)泵將切削液(ye)(ye)連同切屑(xie)一起抽(chou)(chou)送(song)并向上打入(ru)(ru)架空回(hui)液(ye)(ye)管,送(song)回(hui)刮排渦旋(xuan)過(guo)濾機(ji)進行(xing)過(guo)濾。過(guo)濾后(hou)的(de)干凈液(ye)(ye)體由(you)供液(ye)(ye)泵抽(chou)(chou)出(chu)、通(tong)過(guo)供液(ye)(ye)管送(song)入(ru)(ru)機(ji)床重新使(shi)用。

      供液(ye)系(xi)(xi)統(tong)由(you)供液(ye)泵和供液(ye)管路組成(cheng),回液(ye)系(xi)(xi)統(tong)由(you)回液(ye)箱(xiang)、回液(ye)泵與管路組成(cheng)。過濾機和回液(ye)箱(xiang)全部安(an)放(fang)在地面上,供回液(ye)管道全部架空布置。

      整個過濾系統的(de)電氣(qi)控(kong)制箱(xiang)面板有(you)工況指(zhi)示燈、故(gu)(gu)障指(zhi)示燈,箱(xiang)頂(ding)有(you)閃光燈,在閃光報警的(de)同(tong)時有(you)提示信(xin)號(hao)(hao)或(huo)(huo)故(gu)(gu)障信(xin)號(hao)(hao)輸出,用作預(yu)警或(huo)(huo)緊急操作干預(yu)。提供液位監測以(yi)及泵機過載報警、故(gu)(gu)障自診等必要的(de)安(an)全運(yun)行保障。
          刮(gua)板排(pai)屑過濾裝(zhuang)置工(gong)作(zuo)原理與(yu)主要結構
          刮(gua)板(ban)(ban)排屑裝(zhuang)置主要(yao)由(you)箱(xiang)體(ti)、刮(gua)板(ban)(ban)減(jian)速(su)(su)電機、鏈(lian)輪驅(qu)(qu)動裝(zhuang)置、供液泵以(yi)及電氣控制等功(gong)能(neng)部件組成,其工作原(yuan)理如下(xia):臟(zang)切削液通過(guo)回液管道直接流入過(guo)濾裝(zhuang)置內,由(you)于物質(zhi)(zhi)重力的(de)原(yuan)因,臟(zang)液中體(ti)積較大的(de)顆粒雜(za)質(zhi)(zhi)在(zai)流動中逐漸沉(chen)淀(dian)到箱(xiang)體(ti)底部以(yi)達到沉(chen)淀(dian)分(fen)離的(de)過(guo)濾效果,排屑機內的(de)鏈(lian)式刮(gua)板(ban)(ban)在(zai)減(jian)速(su)(su)電機的(de)驅(qu)(qu)動下(xia)緩慢平移,將不斷(duan)沉(chen)淀(dian)在(zai)箱(xiang)底的(de)大量雜(za)質(zhi)(zhi)刮(gua)上來(lai),后排入接渣車(che)中。

      刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)排(pai)屑(xie)裝置對臟切削液進行(xing)預處理,過濾、分離(li)出液體(ti)中(zhong)大(da)量(liang)雜質,從而提高后面渦旋分離(li)效果。刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)排(pai)屑(xie)過濾裝置主(zhu)要由帶(dai)提升斜坡(po)的箱(xiang)體(ti)、鏈(lian)(lian)式刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)、刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)鏈(lian)(lian)驅(qu)動減速電(dian)機(ji)、液位控制開關(guan)等功(gong)能(neng)部件(jian)組成(cheng)。刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)排(pai)屑(xie)機(ji)構由刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)鏈(lian)(lian)和刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)組成(cheng),減速電(dian)機(ji)與刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)鏈(lian)(lian)軸是通過扭矩限止(zhi)器聯接的,如果有(you)物(wu)體(ti)卡住,刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)一(yi)般能(neng)越過物(wu)體(ti)繼(ji)續行(xing)走。如果被大(da)物(wu)體(ti)卡死不能(neng)越過,扭矩限止(zhi)器的安全銷會斷裂,保(bao)護刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)鏈(lian)(lian)驅(qu)動電(dian)機(ji)和刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)排(pai)污機(ji)構相(xiang)應零部件(jian)不受損壞。刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)軸的一(yi)端(duan)安裝有(you)刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)運行(xing)監測(ce)傳感器,監視刮(gua)(gua)(gua)(gua)(gua)(gua)板(ban)(ban)(ban)工作,向主(zhu)機(ji)發岀故障警報信號。
          渦旋分離裝置(zhi)工作原(yuan)理(li)與主要結(jie)構
          經刮板排屑預過(guo)濾后的(de)(de)切削液(ye)隨著液(ye)位的(de)(de)升高溢(yi)流到(dao)凈液(ye)箱內(nei),由(you)過(guo)濾泵抽出、送入渦旋(xuan)(xuan)分(fen)離(li)器進行(xing)二次過(guo)濾。渦旋(xuan)(xuan)分(fen)離(li)裝置(zhi)是無濾材消耗的(de)(de)過(guo)濾設備。渦旋(xuan)(xuan)分(fen)離(li)器是一個上大(da)下小(xiao)的(de)(de)錐管(guan)(guan),上部有進液(ye)管(guan)(guan)沿切線方向(xiang)接入。切削液(ye)從進液(ye)管(guan)(guan)進入錐管(guan)(guan)后,沿錐管(guan)(guan)壁旋(xuan)(xuan)轉(zhuan)下行(xing)。由(you)于錐管(guan)(guan)直(zhi)徑由(you)上向(xiang)下逐(zhu)漸縮小(xiao),切削液(ye)的(de)(de)轉(zhuan)速(su)越來(lai)越高。

      渦(wo)旋(xuan)分(fen)(fen)離器(qi)正是利用切削(xue)液(ye)(ye)在錐(zhui)管(guan)中高速流(liu)動引(yin)起下旋(xuan)轉渦(wo)流(liu)生成的(de)離心力將比重大(da)于液(ye)(ye)體(ti)的(de)雜質顆粒從(cong)旋(xuan)轉的(de)液(ye)(ye)體(ti)中分(fen)(fen)離出(chu)來,聚集到(dao)錐(zhui)管(guan)壁上(shang),隨下旋(xuan)渦(wo)流(liu)出(chu)錐(zhui)管(guan)。比重小的(de)切削(xue)液(ye)(ye)以上(shang)旋(xuan)渦(wo)流(liu)形式從(cong)錐(zhui)管(guan)上(shang)口(kou)排(pai)(pai)岀,實現了雜質與切削(xue)液(ye)(ye)的(de)分(fen)(fen)離。從(cong)渦(wo)旋(xuan)分(fen)(fen)離器(qi)下端口(kou)排(pai)(pai)出(chu)的(de)少量含雜質切削(xue)液(ye)(ye)向下落(luo)入刮板排(pai)(pai)屑機內進行再過濾(lv),干(gan)凈切削(xue)液(ye)(ye)送(song)到(dao)儲(chu)液(ye)(ye)箱內由供液(ye)(ye)泵送(song)入用戶機床。渦(wo)旋(xuan)分(fen)(fen)離器(qi)適(shi)用于雜質密(mi)度比液(ye)(ye)體(ti)密(mi)度大(da)的(de)臟液(ye)(ye)過濾(lv),密(mi)度差(cha)越(yue)大(da),分(fen)(fen)離效果越(yue)好。

      過(guo)(guo)濾(lv)(lv)(lv)(lv)裝(zhuang)置由機(ji)架、濾(lv)(lv)(lv)(lv)筒、高精(jing)度濾(lv)(lv)(lv)(lv)袋、鋼(gang)網籃、壓(ya)(ya)力表等部件(jian)組成,為用戶提供清潔、可(ke)供循環使(shi)用的(de)冷(leng)卻液(ye),如果需要(yao)更高的(de)過(guo)(guo)濾(lv)(lv)(lv)(lv)精(jing)度可(ke)增加(jia)這套(tao)過(guo)(guo)濾(lv)(lv)(lv)(lv)裝(zhuang)置。其系統工(gong)作(zuo)原理如下:袋式過(guo)(guo)濾(lv)(lv)(lv)(lv)裝(zhuang)置通(tong)常(chang)作(zuo)為過(guo)(guo)濾(lv)(lv)(lv)(lv)機(ji)的(de)末(mo)級過(guo)(guo)濾(lv)(lv)(lv)(lv),切(qie)削液(ye)被抽入過(guo)(guo)濾(lv)(lv)(lv)(lv)筒進行精(jing)過(guo)(guo)濾(lv)(lv)(lv)(lv),過(guo)(guo)濾(lv)(lv)(lv)(lv)筒內(nei)有精(jing)密濾(lv)(lv)(lv)(lv)袋,污(wu)液(ye)中的(de)細微雜質被濾(lv)(lv)(lv)(lv)袋濾(lv)(lv)(lv)(lv)除,濾(lv)(lv)(lv)(lv)凈的(de)切(qie)削液(ye)流出濾(lv)(lv)(lv)(lv)筒后被送入機(ji)床.當濾(lv)(lv)(lv)(lv)袋臟(zang)堵時,流量會逐(zhu)(zhu)漸(jian)減小,壓(ya)(ya)力逐(zhu)(zhu)漸(jian)增大,當壓(ya)(ya)力上升到一定數值(zhi)時,表示濾(lv)(lv)(lv)(lv)袋內(nei)垃(la)(la)圾(ji)很(hen)多已(yi)臟(zang)堵,此時應立即(ji)停(ting)機(ji)。打開臟(zang)堵濾(lv)(lv)(lv)(lv)筒的(de)蓋板提出濾(lv)(lv)(lv)(lv)袋倒掉濾(lv)(lv)(lv)(lv)出的(de)雜質,將袋內(nei)垃(la)(la)圾(ji)清除掉。

      濾(lv)(lv)(lv)袋(dai)由(you)鋼網籃(lan)和(he)濾(lv)(lv)(lv)袋(dai)組成,不同(tong)精度(du)(du)的濾(lv)(lv)(lv)袋(dai)可以達到(dao)不同(tong)的過(guo)(guo)濾(lv)(lv)(lv)精度(du)(du)。該(gai)裝置(zhi)的過(guo)(guo)濾(lv)(lv)(lv)精度(du)(du)由(you)不同(tong)的濾(lv)(lv)(lv)袋(dai)保證,用(yong)戶可在100-10微(wei)米范圍內選(xuan)擇。
         更(geng)高精度也(ye)可(ke)(ke)以實現(xian),但在相同(tong)的(de)流量下(xia)體積要增大許多。濾(lv)(lv)(lv)(lv)(lv)袋可(ke)(ke)以從鋼(gang)網(wang)籃上(shang)(shang)取下(xia)調(diao)換(huan),清洗后可(ke)(ke)反(fan)復使用(yong),如(ru)果有(you)破損則(ze)應更(geng)換(huan)新濾(lv)(lv)(lv)(lv)(lv)袋。濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)上(shang)(shang)蓋和筒(tong)(tong)(tong)(tong)(tong)身(shen)之間裝(zhuang)有(you)可(ke)(ke)靠的(de)密封圈。在過(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)裝(zhuang)置兩個過(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)的(de)進液管道(dao)上(shang)(shang)安裝(zhuang)有(you)三通(tong)切(qie)(qie)換(huan)閥,供液輸出(chu)管道(dao)各(ge)自獨立。當一只(zhi)濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)臟堵(du)時,用(yong)戶只(zhi)要通(tong)過(guo)(guo)調(diao)整濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)進液管道(dao)上(shang)(shang)的(de)切(qie)(qie)換(huan)閥,即可(ke)(ke)把污(wu)液切(qie)(qie)換(huan)到另(ling)一只(zhi)干凈的(de)過(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)中進行過(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)。這樣既(ji)不影響用(yong)戶設備的(de)正常(chang)運行,也(ye)方便臟堵(du)濾(lv)(lv)(lv)(lv)(lv)袋的(de)清洗或更(geng)換(huan)。同(tong)時兩個過(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)的(de)進液管道(dao)還安裝(zhuang)有(you)壓力(li)表(biao),用(yong)戶可(ke)(ke)通(tong)過(guo)(guo)觀察壓力(li)表(biao)數值(zhi)了(le)解過(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)筒(tong)(tong)(tong)(tong)(tong)內壓力(li),并(bing)由(you)此判斷濾(lv)(lv)(lv)(lv)(lv)袋是否發生臟堵(du)。

      配套過濾(lv)器(qi)(qi)的(de)水泵實際流(liu)量和(he)工(gong)作壓力要與過濾(lv)器(qi)(qi)對應,建議過濾(lv)筒的(de)大工(gong)作壓力不大于0.2-0.4Mpa
          上述方案(an),可以有效(xiao)地解決下(xia)部箱體隔(ge)半月清理(li)(li),沉(chen)積(ji)物內(nei)的(de)(de)(de)砂輪凝(ning)固結塊等問(wen)(wen)題,消除了(le)清理(li)(li)過程中(zhong)人員下(xia)到底部鑿開沉(chen)積(ji)物的(de)(de)(de)問(wen)(wen)題,提(ti)(ti)高(gao)了(le)系統的(de)(de)(de)工作效(xiao)率。同(tong)時使其過濾(lv)精度(du)得到了(le)保(bao)證(zheng)和提(ti)(ti)高(gao),繼而終降(jiang)低(di)了(le)冷(leng)卻液半年更換次數(shu),在降(jiang)低(di)成本的(de)(de)(de)同(tong)時也(ye)改善了(le)社(she)會環(huan)境。
       

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