超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)是優質(zhi)(zhi)(zhi)金(jin)屬(shu)加(jia)工(gong)(gong)用(yong)油(you)(you)(you)(you),適用(yong)于表面(mian)光潔度(du)要(yao)求較高(gao)的(de)(de)研磨(mo)、珩(heng)磨(mo)、超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)研等工(gong)(gong)藝(yi),適合材質(zhi)(zhi)(zhi)為黑色金(jin)屬(shu),如鑄(zhu)鋼、軸承(cheng)鋼、碳素鋼、中(zhong)(zhong)低(di)合金(jin)鋼等,能明顯降(jiang)低(di)工(gong)(gong)件(jian)表面(mian)粗(cu)(cu)糙度(du),確保加(jia)工(gong)(gong)精(jing)(jing)(jing)度(du)。軸承(cheng)超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)是與軸承(cheng)套圈加(jia)工(gong)(gong)專業設備~超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)研機配套使(shi)用(yong)的(de)(de)冷卻(que)油(you)(you)(you)(you),在精(jing)(jing)(jing)密(mi)軸承(cheng)加(jia)工(gong)(gong)過(guo)程(cheng)中(zhong)(zhong)起到冷卻(que)、潤滑、防銹、清洗的(de)(de)作(zuo)用(yong),尤(you)(you)其在生產高(gao)精(jing)(jing)(jing)度(du)、低(di)噪音軸承(cheng)方面(mian)起到關(guan)鍵作(zuo)用(yong)。由(you)于超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)在使(shi)用(yong)過(guo)程(cheng)中(zhong)(zhong)混(hun)入細切屑、油(you)(you)(you)(you)石(shi)末和(he)灰(hui)塵(chen)等雜質(zhi)(zhi)(zhi),油(you)(you)(you)(you)質(zhi)(zhi)(zhi)劣化會嚴重(zhong)影響工(gong)(gong)件(jian)的(de)(de)精(jing)(jing)(jing)度(du)及表面(mian)粗(cu)(cu)糙度(du),并使(shi)機床和(he)循環(huan)泵的(de)(de)磨(mo)損加(jia)快,所以超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)的(de)(de)過(guo)濾(lv)顯得尤(you)(you)為重(zhong)要(yao)。在超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)既定壽命(保質(zhi)(zhi)(zhi)期)條件(jian)下,提高(gao)超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)的(de)(de)利用(yong)率和(he)延長超(chao)(chao)(chao)(chao)(chao)精(jing)(jing)(jing)油(you)(you)(you)(you)的(de)(de)使(shi)用(yong)周(zhou)期可以降(jiang)低(di)軸承(cheng)加(jia)工(gong)(gong)成本、提高(gao)軸承(cheng)加(jia)工(gong)(gong)質(zhi)(zhi)(zhi)量。
傳統過濾工藝及裝備
傳統的超精油過濾系統由油箱、過濾器和泵組成,而且是單個超精機自帶過濾系統。油箱一方面用來儲油,一方面用來過濾比較粗大的金屬切屑,采用多格的結構,有利于金屬雜質的沉淀,過濾器多為筒式結構,內裝過濾介質濾芯。
濾芯由纖維材料、編織物或多孔介質加工制成。大部分濾芯供一次性使用,不可清洗。過濾精度一般1-10微米。如果濾芯的過濾精度較高,則更換頻繁,成本高。
傳統過濾工藝的缺點
由于車間內的超精機各自分散供應超精油,工人對超精油的濃度、pH值及菌數難以控制;而且單獨配備的過濾系統大都比較簡陋,即使油質未發生變化,大量的鐵屑及油石末也會很快填滿油箱,使超精油在使用過程中腐臭變質,損傷設備,難以保證零件的加工質量。須經常更換超精油,既降低生產效率,又給工人帶來繁重的勞動,同時也增加了生產成本;而這些更換下來的超精油一般都沒經過處理就被排放,對環境造成了很大污染。另外,由于超精油過濾系統是超精機自帶的,在生產車間中,超精油的蒸發和滲漏也會對生產車間的環境造成污染,直接影響工人的健康。
集中循環過濾系統
近年來,制造業對環境保護和生產集約化程度的要求越來越高,集中過濾系統得以快速發展和廣泛應用。
集中循環過濾系統主要由多級過濾分離配置組成
其中磁(ci)性(xing)分(fen)(fen)離器主要(yao)吸附過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)金(jin)屬雜(za)(za)質(zhi),對(dui)超精油(you)進行初級粗(cu)過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)。一般(ban)的磁(ci)分(fen)(fen)器能過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)80%的金(jin)屬雜(za)(za)質(zhi),這不能滿足(zu)加工精密軸承的要(yao)求(qiu),但(dan)能大大減少過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)機濾(lv)(lv)(lv)(lv)布(亦稱(cheng)濾(lv)(lv)(lv)(lv)紙)的消(xiao)耗量。過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)機主要(yao)過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)非金(jin)屬雜(za)(za)質(zhi);過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)精度由(you)過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)介質(zhi)—無(wu)紡布決定,根(gen)據加工精度要(yao)求(qiu)選擇不同的無(wu)紡布,一般(ban)過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)精度能達(da)到10~20微米;在上(shang)述過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)的基礎上(shang),精密過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)器對(dui)超精油(you)進行精過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv),從而得(de)到加工過(guo)(guo)(guo)程(cheng)中所需(xu)的軸承超精油(you),過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)精度可達(da)0.5微米,能夠(gou)滿足(zu)加工特種軸承的要(yao)求(qiu)。系統(tong)的各個組成部分(fen)(fen)分(fen)(fen)擔了過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)任務,實現了集中、多(duo)級、自動(dong)、循環過(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)。
集中循環過濾系(xi)統的性能(neng)特點
超(chao)(chao)精(jing)(jing)油集(ji)中(zhong)(zhong)過(guo)(guo)(guo)(guo)濾(lv)(lv)系(xi)統與單(dan)機(ji)(ji)配備(bei)、分散過(guo)(guo)(guo)(guo)濾(lv)(lv)系(xi)統相(xiang)比具有明(ming)顯(xian)的優點。它可(ke)以對超(chao)(chao)精(jing)(jing)油進行集(ji)中(zhong)(zhong)過(guo)(guo)(guo)(guo)濾(lv)(lv),實(shi)(shi)現(xian)對其(qi)濃度(du)、pH 值和(he)菌數的控制,從而保(bao)證超(chao)(chao)精(jing)(jing)油在較長(chang)(chang)時間內(nei)不發(fa)生變質(zhi),延長(chang)(chang)超(chao)(chao)精(jing)(jing)油的使(shi)(shi)(shi)用壽命(ming)。超(chao)(chao)精(jing)(jing)油實(shi)(shi)際(ji)使(shi)(shi)(shi)用壽命(ming)約為(wei)(wei)超(chao)(chao)精(jing)(jing)油保(bao)質(zhi)期的80%,大(da)(da)大(da)(da)降(jiang)低了(le)軸承加工(gong)成本。系(xi)統中(zhong)(zhong)的各個(ge)裝(zhuang)置對超(chao)(chao)精(jing)(jing)油的過(guo)(guo)(guo)(guo)濾(lv)(lv)實(shi)(shi)現(xian)了(le)多(duo)級過(guo)(guo)(guo)(guo)濾(lv)(lv),精(jing)(jing)度(du)更高,成本更低,節省人力(li)(li)物力(li)(li)。過(guo)(guo)(guo)(guo)濾(lv)(lv)機(ji)(ji)油池內(nei)的高液位(wei)及負(fu)壓式的設計可(ke)為(wei)(wei)超(chao)(chao)精(jing)(jing)油穿透過(guo)(guo)(guo)(guo)濾(lv)(lv)層提(ti)供很高的壓力(li)(li),使(shi)(shi)(shi)其(qi)穿透能力(li)(li)和(he)速度(du)大(da)(da)大(da)(da)提(ti)高,過(guo)(guo)(guo)(guo)濾(lv)(lv)效率明(ming)顯(xian)提(ti)高。過(guo)(guo)(guo)(guo)濾(lv)(lv)機(ji)(ji)流量大(da)(da),可(ke)達20t/h 以上。
過濾機的工作原(yuan)理
超(chao)精油(you)(you)(you)集(ji)中(zhong)(zhong)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)系統(tong)(tong)的(de)(de)(de)重(zhong)要(yao)部(bu)(bu)件—過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji)在集(ji)中(zhong)(zhong)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)過(guo)(guo)(guo)(guo)(guo)(guo)程中(zhong)(zhong)起到(dao)舉足輕重(zhong)的(de)(de)(de)作(zuo)(zuo)用,故有必要(yao)對其(qi)進(jin)行說(shuo)明。出于安全和(he)改善車間(jian)工作(zuo)(zuo)環(huan)境(jing)因素的(de)(de)(de)考慮(lv),可將過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji)安置在廠房外部(bu)(bu)的(de)(de)(de)一(yi)個泵(beng)房內(nei)。由于過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji)體(ti)積比較大(da),一(yi)般將泵(beng)房做成地(di)坑的(de)(de)(de)結(jie)構。過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji)是真空式(shi)紙帶過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji),通(tong)過(guo)(guo)(guo)(guo)(guo)(guo)PLC實現自動控(kong)制(zhi),過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji)的(de)(de)(de)容(rong)量與(yu)流量根(gen)據(ju)車間(jian)超(chao)精機(ji)(ji)的(de)(de)(de)臺數進(jin)行設(she)計。過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji)的(de)(de)(de)外殼通(tong)過(guo)(guo)(guo)(guo)(guo)(guo)焊接而(er)成,防滲漏(lou)性強(qiang)。主油(you)(you)(you)箱由不銹(xiu)鋼(gang)柵板(ban)(ban)分成兩部(bu)(bu)分:上(shang)(shang)部(bu)(bu)為污油(you)(you)(you),下部(bu)(bu)為凈(jing)油(you)(you)(you)。無(wu)紡布(bu)搭(da)在主油(you)(you)(you)箱上(shang)(shang)部(bu)(bu)的(de)(de)(de)刮(gua)板(ban)(ban)上(shang)(shang)。刮(gua)板(ban)(ban)通(tong)過(guo)(guo)(guo)(guo)(guo)(guo)角鋼(gang)焊接在特(te)(te)種鏈條(tiao)(tiao)上(shang)(shang)而(er)成,從(cong)而(er)實現電機(ji)(ji)帶動刮(gua)板(ban)(ban)走布(bu)。特(te)(te)種鏈條(tiao)(tiao)(即刮(gua)板(ban)(ban))在主油(you)(you)(you)箱內(nei)的(de)(de)(de)上(shang)(shang)部(bu)(bu)(包括(kuo)斜(xie)臂(bei))依次(ci)(ci)排列。不銹(xiu)鋼(gang)柵板(ban)(ban)起到(dao)二(er)次(ci)(ci)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)的(de)(de)(de)作(zuo)(zuo)用。工作(zuo)(zuo)時(shi),從(cong)機(ji)(ji)床回流的(de)(de)(de)污油(you)(you)(you)由回油(you)(you)(you)管道進(jin)入(ru)(ru)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)機(ji)(ji),在重(zhong)力及負壓(ya)作(zuo)(zuo)用下,超(chao)精油(you)(you)(you)經(jing)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)層(ceng)進(jin)入(ru)(ru)下部(bu)(bu)凈(jing)油(you)(you)(you)箱內(nei),雜質滯(zhi)留在無(wu)紡布(bu)上(shang)(shang)。隨著(zhu)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)的(de)(de)(de)不斷(duan)(duan)進(jin)行,超(chao)精油(you)(you)(you)中(zhong)(zhong)的(de)(de)(de)雜質由于過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)層(ceng)的(de)(de)(de)截(jie)止(zhi)在過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)層(ceng)上(shang)(shang)表面形成一(yi)層(ceng)濾(lv)(lv)(lv)(lv)(lv)餅,濾(lv)(lv)(lv)(lv)(lv)餅自身參與(yu)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)而(er)成為新(xin)的(de)(de)(de)致密(mi)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)層(ceng)。 隨著(zhu)濾(lv)(lv)(lv)(lv)(lv)餅的(de)(de)(de)不斷(duan)(duan)增厚和(he)致密(mi),過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)層(ceng)被堵(du)塞,致使(shi)凈(jing)油(you)(you)(you)箱內(nei)的(de)(de)(de)壓(ya)力不斷(duan)(duan)上(shang)(shang)升。當壓(ya)力上(shang)(shang)升到(dao)設(she)定(ding)值(zhi)時(shi),由控(kong)制(zhi)系統(tong)(tong)發令,氣動閥門打開(kai),將小(xiao)油(you)(you)(you)箱和(he)凈(jing)油(you)(you)(you)箱連通(tong),補充凈(jing)油(you)(you)(you)箱內(nei)的(de)(de)(de)凈(jing)油(you)(you)(you),使(shi)壓(ya)力下降。同(tong)時(shi),刮(gua)板(ban)(ban)電機(ji)(ji)通(tong)過(guo)(guo)(guo)(guo)(guo)(guo)大(da)鏈輪帶動特(te)(te)種鏈條(tiao)(tiao),使(shi)臟布(bu)走出過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)區,從(cong)而(er)走入(ru)(ru)新(xin)布(bu),形成新(xin)的(de)(de)(de)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)面,繼續保持額定(ding)的(de)(de)(de)過(guo)(guo)(guo)(guo)(guo)(guo)濾(lv)(lv)(lv)(lv)(lv)能力,開(kai)始新(xin)的(de)(de)(de)工作(zuo)(zuo)循環(huan)。
濾(lv)(lv)(lv)渣隨使(shi)(shi)用后(hou)的臟布(bu)(bu)一(yi)同落(luo)入廢布(bu)(bu)斗中進(jin)行(xing)(xing)(xing)集中處理。濾(lv)(lv)(lv)布(bu)(bu)更新(xin)僅在過(guo)濾(lv)(lv)(lv)量(liang)減小到不能(neng)滿足(zu)供油(you)要(yao)求時進(jin)行(xing)(xing)(xing)。這種控制(zhi)方式可使(shi)(shi)濾(lv)(lv)(lv)布(bu)(bu)消耗(hao)降到低(di),保證有效(xiao)利用濾(lv)(lv)(lv)布(bu)(bu)。過(guo)濾(lv)(lv)(lv)機加長的提升斜坡和(he)很低(di)的刮板電機轉速可以給濾(lv)(lv)(lv)餅脫(tuo)(tuo)油(you)留出充足(zu)的時間,使(shi)(shi)濾(lv)(lv)(lv)渣在脫(tuo)(tuo)離過(guo)濾(lv)(lv)(lv)機前進(jin)行(xing)(xing)(xing)脫(tuo)(tuo)油(you),提高濾(lv)(lv)(lv)餅含固量(liang),不用對(dui)濾(lv)(lv)(lv)渣進(jin)行(xing)(xing)(xing)后(hou)續脫(tuo)(tuo)油(you)處理。
供油管道(dao)(dao)系(xi)統(tong)和(he)回油管道(dao)(dao)系(xi)統(tong)
超精油集中過濾系統用于整個車間甚至整個工廠的(de)供油,因此輸油管道的(de)設(she)計是否合(he)理關系到生產能否順利進(jin)行。
供(gong)油(you)(you)管(guan)道(dao)系統(tong)將(jiang)(jiang)(jiang)過(guo)濾(lv)后(hou)的(de)凈油(you)(you)供(gong)給超(chao)精(jing)研(yan)機;回油(you)(you)管(guan)道(dao)系統(tong)將(jiang)(jiang)(jiang)超(chao)精(jing)研(yan)機用(yong)過(guo)的(de)超(chao)精(jing)油(you)(you)輸送(song)至各級過(guo)濾(lv)設(she)備以(yi)進(jin)行過(guo)濾(lv)。供(gong)油(you)(you)管(guan)道(dao)系統(tong)和(he)回油(you)(you)管(guan)道(dao)系統(tong)分別由總(zong)管(guan)、支管(guan)和(he)進(jin)油(you)(you)管(guan)組(zu)成。總(zong)管(guan)道(dao)設(she)在泵房(fang)的(de)地坑內;支管(guan)可(ke)(ke)以(yi)架空固定在立(li)柱(zhu)上,也可(ke)(ke)以(yi)從地溝走;供(gong)油(you)(you)進(jin)油(you)(you)管(guan)通過(guo)閥和(he)軟(ruan)管(guan)將(jiang)(jiang)(jiang)超(chao)精(jing)油(you)(you)送(song)入機床。機床電(dian)磁閥控制供(gong)油(you)(you)或切(qie)斷供(gong)油(you)(you)。回油(you)(you)進(jin)油(you)(you)管(guan)通過(guo)軟(ruan)管(guan)與(yu)超(chao)精(jing)研(yan)機連(lian)接,將(jiang)(jiang)(jiang)污油(you)(you)回收。
供油管(guan)道系統和(he)回油管(guan)道系統分為地(di)下式(shi)和(he)地(di)面(mian)式(shi)兩種(所謂地(di)下式(shi)或(huo)地(di)面(mian)式(shi)是指支管(guan)和(he)進油管(guan)位于地(di)下或(huo)地(di)面(mian)上):
(1)地下式(shi),從(cong)機床流(liu)出的臟切削(xue)油通過地下管路或地溝連(lian)同切屑一起(qi)送(song)回過濾(lv)系(xi)統(tong);
(2)地(di)面式(shi),從機床流出的(de)臟切(qie)削油通過(guo)地(di)面上(shang)的(de)管路(lu)連(lian)同切(qie)屑送回(hui)過(guo)濾系統,這種布(bu)局會占(zhan)用廠房空間(jian),影響以后添置機床等設備(bei)。
系統清(qing)理(li)
根據生產規模定(ding)期(qi)清理(li),可利用機床供液泵和供液管(guan)實(shi)施。清理(li)系統時,關閉機床供油(you)(you)管(guan)閥門(men),開(kai)足(zu)沖(chong)洗閥門(men),用機床供油(you)(you)管(guan)送來的(de)(de)大流量凈(jing)油(you)(you)高速沖(chong)洗回油(you)(you)管(guan)路,清除回油(you)(you)管(guan)內的(de)(de)各種(zhong)雜質和污油(you)(you),清除菌類(lei)的(de)(de)滋生環(huan)境。對廢超精油(you)(you)集中處理(li),從而進一(yi)步(bu)減少對環(huan)境的(de)(de)污染。