矿用磨机技术 MILL

公司概况 COMPANY PROFILE

上海同力重型机械制造有限公司，主要从事水泥建材、矿山、环保、冶金、化工机械成套设备的技术研发、工程咨询、设备供货、安装调试，工程总承包及相关的技术服务。同力重机创建于1958年，是中国建材机械工业协会成员单位，中国水泥机械龙头企业，中国煤炭工业机电设备定点生产企业，以及ISO9001:2008标准质量管理体系认证企业、浙江省高新技术企业，国家级守合同重信用企业，全国水泥粉磨系统十佳技术与装备示范企业，位列浙江省水泥装备制造业第一位。

公司生产基地占地面积153800㎡，其中车间建筑面积85000㎡，单台行车最大起吊能力200t。公司拥有φ5.3×18m（承载200t）数控卧式车床、φ5.5×18m筒体车床、φ8m重型数显立式车床、φ8.0m重型滚齿机、14×5m数控落地镗铣床、3.4×10m数控龙门镗铣床、120mm数控卷板机、φ6.5×20m大型退火炉、φ6.5×20m喷砂房、1800t四柱液压机、10t电弧炉等重型机械制造设备100多台（套），是综合机械加工能力最强的企业之一。

Shanghai Tongli Heavy Machinery Manufacturing Co.,ltd, is specialized in technology R&D, engineering consultation ,

equipment debugging, engineering contracting and related technical services for manufacturing cement, building material,

mining, environmental protection, metallurgy, chemical equipment. Tongli Heavy Machinery Co .,,ltd established in

1958year, is a member of the China Building Material Machinery Association, a leading enterprise of China Cement

Machinery, on the vendor of designated manufacturers for coal industry mechanical and electrical equipments,

ISO9001:2008 accredited and accredited as a high-tech & new technology enterprise of Zhejiang Province, national

designated “defend the contract heavy credit enterprise”, modern enterprise of national top ten cement grinding system of

technologies and equipment , at the top of cement equipment manufacturing in Zhejiang Province.

The Tongli Co.,ltd occupies 153800m2 and the construction area of the workshop is 85000㎡，the maximum lifting

capacity of a single head crane is 200t. The company is equipped with more than 100 sets of heavy machinery

manufacturing equipments such asφ5.3×18m（The lifting capacity is 200t）digital control horizontal lathe, φ5.5×18m

lathe for machining shell, φ8m heavy digital display vertical lathe, φ8.0m heavy hobing machine, 14×5m CNC vertical

milling & boring machine, 3.4×10m CNC gantry milling & boring machine, 120mm digital control plate bending rolls,

φ6.5×20m large size annealing furnace, φ6.5×20m sand blasting room, 1800t four columns hydraulic press, 10t electric

arc furnace, etc, the integrated machinery processing ability is very strong.

公司概况

COMPANY PROFILE

经过56多年的长足发展，在众多经验丰富的技术专家和高素质管理人才的共同努力下公司拥有一流的科技研发中心和

工程团队，拥有自主知识产权的矿渣立磨、生料立磨、水泥立磨、矿用球磨机、煤立磨及回转窑、水泥磨、风扫煤磨、烘

干机等水泥机械系列主机设备；同时公司还生产复合肥、矿山、发电、污泥（垃圾）焚烧系统等设备及大型结构件，产品

产品出口德国、俄罗斯、巴西、埃及、伊朗、孟加拉、巴基斯坦、土耳其、缅甸、越南、哥伦比亚、玻利维亚、南非等六

十多个国家和地区，全球近1000余家用户。

After working hard for more than 56 years, the company has the first-class science and technology development centers

and craftsmen team who have much experience and skilled technology, specially manufactures series of cement

machinery main equipments with independent intellectual property such as slag vertical mill, raw material vertical mill,

cement vertical mill, coal vertical mill and rotary kiln, cement mill, wind swept coal mill, dryer, etc; in the meantime,

manufactures the equipments and large- sized structural workpieces such as compound fertilizer, mining, power

generating, sewage sludge (waste)incineration systems, etc, the products are exported widely to over 1000 companies

from sixty or more countries such as Germany, Russia, Brazil, Egypt ,Iran, Bangladesh, Pakistan, Turkey, Myanmar,

Vietnam, Columbia, Bolivia, South Africa, etc

我们的重型装备

OUR HEAVY EQUIPMENT

Ø5.3*18m 全数控卧式车床

Ø5.3*18m all-digital-controlled horizontal lathe Ø10m 滚齿机

Ø10m hobbing machine

俄罗斯制造的ø8m重型数显立式车床 Ø8m heavy digital display vertical made in Russia

Ø5.8*18m 筒体车床 Ø5.8*18m lathe machining shell

我们的重型装备

OUR HEAVY EQUIPMENT

10*3.4m数控龙门镗铣床

10*3.4m CNC gantry boring & milling machine

两台14*5m 数控落地镗铣床

14*5m CNC vertical boring & milling machine two set

我们的重型装备

OUR HEAVY EQUIPMENT

6.5*20m 大型退火炉

6.5*20m large annealing furnace

16*5m 数控切割机 16*5m CNC cutting machine

16*5m 数控切割机 16*5m CNC cutting machine

16m 刨边机

16m beveling machine

6.5*20大型喷砂房

6.5*20 large sandblasting room

我们的重型装备

OUR HEAVY EQUIPMENT

我们的质控体系

OUR QUALITY CONTROL SYSTEM

我们的质控体系

OUR QUALITY CONTROL SYSTEM

我们的质控体系

OUR QUALITY CONTROL SYSTEM

大型筒体热处理

Large heat treatment of cylinder

碎矿设备 Crushing equipment

磨矿设备 Grinding equipment

选矿设备 Beneficiation equipment

输送设备 Conveying equipment

采矿设备 Mining equipment

矿山设备成套服务能力 THE COMPLETE SET SERVICE CAPABILITIES OF MINING EQUIPMENT

磨矿设备选型

HOW TO CHOOSE THE MILL？

试验（实验室与半工业试验） Tests (laboratorial and semi-industrial test)

选型（流程设计与功率选择） Selection (process design and power selection)

产品设计 Product Design

产品制造 Manufacturing

设备安装、调试 Equipment installation & test

1

2

3

4

5

工艺与技术支持 Technology and technical support

6

破碎粉磨成套服务能力 CRUSHING AND GRINDING OF THE COMPLETE SET OF SERVICE CAPABILITIES

高效

节能 环保

目标 GOALS OR THE DIRECTION OF DEVELOPMENT

矿物加工工艺典型总体流程 TYPICAL OVERALL PROCESS OF MINERAL PROCESSING

矿物加工工艺典型碎磨流程

Typical overall process of mineral processing

破碎粉磨流程

Crushing & grinding processes

发展趋势： 多碎少磨

(Development trend ：crushing more，

grinding less）

适用：中小型选矿

Apply to：small or middle size ore

Dressing

(belwo 10000t/d, one series）

（单系列日处理1万吨以下）

半自磨流程

Semi-autogenous grinding process

发展趋势：设备大型化

Development trend ：large-scale

equipment

适用：大中型选矿

Apply to：middle or big size ore

Dressing

(over 10000t/d, one series）

（单系列日处理1万吨以上）

破碎粉磨流程 CRUSHING & GRINDING PROCESS

半自磨流程 SEMI-AUTOGENOUS GRINDING MILL PROCESS

半自磨流程——典型范例 TYPICAL EXAMPLE OF SAG MILL PROCESS

破碎粉磨试验 CRUSHING & GRINDING TESTS

工艺流程设计及设备选型 PROCESS DESIGN AND EQUIPMENT SELECTION

常规破碎粉磨流程设备选型 Equipment selection for conventional crushing & grinding process

容积法 Volumetric method

功耗法 Power method

工艺流程设计及设备选型 PROCESS DESIGN AND EQUIPMENT SELECTION

半自磨流程设备选型Equipment selection for Semi-Autogenous Grinding

process

JKSimMet Simulation（ JKTech company of the University of

Queensland, Australia ）

磨矿设备

MILL

矿用磨机典型结构概况 TYPICAL STRUCTURE OVERVIEW OF MINE MILL

进料部 Feed

轴承部 Bearin

g

回转部 Shell

传动部 Drive

出料部 Discharg

e

主电机 Moto

r

空气离合器 Air clutch

起重装置 Jacking device 慢速传动装置

Inching drive

润滑油站 Lubrication station

喷射润滑装置 Spray lubrication device

低压控制系统 PLC system

励磁柜 Excitation device

高压开关柜 High Voltage Switchgear

软起动装置 Soft-start device

磨机回转体——构成 ROTARY BODY STRUCTURE

磨机回转体——中空轴、端盖 TRUNNION & HEAD

• 整体式（通常用于中小型磨机）integral type (for middle or small size Mill)

• 分体式（通常用于大中型磨机）separated type ( for big or middle size

Mill）

型式 Type

• ZG20Mn[σs=295MPa；σb=510MPa]

• ZG35CrMo[σs=510MPa；σb=740MPa]

• 设备满负荷运行，应力幅值不超过100MPa

• Full load operation: stress amplitude ≤100MPa

材料 Material

• 为便于运输，端盖可采取分体结构

• The Head could be separated type for convenience of transportation

• 采用专用高强度螺栓联接

• Special high tension bolts are used for connection

• 采用过盈配合，保证整体同轴度

• Interference fit to ensure overall coaxiality

结构 Structure

分体式 separate

d

整体式 Integra

l

磨机回转体——中空轴、端盖 TRUNNION & HEAD

磨机回转体——筒体 SHELL

材料选用 Material selection

筒体钢板一般选用Q235A、Q235B或Q345B Shell plate (normally used): Q235A,Q235B or Q345B

法兰一般选用16Mn、ZG20Mn或Q345B Flange plate (normally used): 16Mn, ZG20Mn, or Q345B

质量要求 Quality requirements

采用超声波探伤，符合GB/T11345-1989标准规定B级,检验1级 Ultrasonic inspection used, according to GB/T11345-1989 B class,

grade 1

焊接后进行消除应力处理（退火/振动） Stress relief treatment: heat treatment or vibration

外观 Appearance

涂漆前进行喷丸处理 Sand blasting before painting

磨机回转体——筒体 SHELL

磨机回转体——有限元分析 FINITE ELEMENT ANALYSIS

磨机回转体——衬板 LINER

•锰钢衬板——用于强冲击磨矿设备

• Manganese steel liner：for strong impact

•橡胶衬板——常用于细磨

• Rubber liner: for fine grinding

•磁性衬板——仅用于细磨含导磁性矿物

• Magnetic liner: for fine grinding with magnetic permeability mine

种类types

•采用EDEM离散元平台模拟

• EDEM Discrete Element simulation is used

模拟验证

•大型磨机须配备专用机械手

• Specialized mechanical arm should be used for big size Mill.

•一般采用RME 或 Mclellan产品

• Brand RME or Mclellan will normally be used.

安装

磨机回转体——衬板安装与拆卸 INSTALLATION AND REMOVAL OF THE LINER

•中小型磨机通常采用整体铸造结构

•材料一般选用ZG35CrMnSi或QT600

•使用寿命：进料衬套约2年，出料衬套约5年

•大型磨机通常采用可拆分结构

•耐磨件常采用耐磨橡胶或铸钢衬板

类型与材料选用

•衬套与中空轴之间采用长锥面密封

密封

•依靠长锥面配合并承载

•避免了法兰螺栓承受循环载荷断裂

定位与承载

磨机回转体——进、出料衬套 TRUNNION LINER

磨机回转体——大型磨机进、出料衬套 TRUNNION LINER

进料衬套 出料衬套

出料衬套组装结构

滚动轴承

滑动轴承

单块瓦

多块瓦

动静压润滑

全静压润滑

类型 Type

结构 Structure

润滑 Lubricating

磨机主轴承 MAIN BEARING

推荐采用 Recommendation

磨机主轴承——静压滑动轴承 MAIN BEARING —— HYDROSTATIC SLIDING BEARING

装备 Equipped with

温度检测

temperature detection

流量监测

flow detection

油压检测

oil pressure detection

配备专用油站

Equipped with special

lubrication oil station

断电保护

power-off protection

磨机主轴承——轴瓦材质 MAIN BEARING —— BEARING BUSH MATERIAL

巴氏合金（铅锑轴承合金、锡锑轴承合金）

• 需与轴承衬体浇铸后加工

• 适用于中小型磨机及大型滑履轴承

铅铜合金

• 单体加工

• 适用于大中型磨机单片瓦轴承

锌合金

• 单体加工

• 适用于大中型磨机单片瓦轴承，可替代进口铜瓦

磨机主轴承——轴承密封 TRUNNION BEARING SEALING

轴承密封

活塞环式密封

适用于轴径小于2.6m轴承

优点：结构紧凑、使用寿命长、维护简单

缺点：制造难度大、拆卸较困难

三舌橡胶密封

适用于轴径大于2.0m轴承

优点：安装拆卸方便、可调整

缺点：使用寿命短、结构复杂

Bearing cooling

轴瓦内部通冷却水冷却

动静压轴承 全静压轴承 全静压轴承 （高温工作环境）

磨机主轴承——轴承冷却 MAIN BEARING —— COOLING

双圆弧面支撑调心结构 The double arc surface support

aligning structure 适用于中小型磨机 Apply to: middle or small size

ball mill 特点：摩擦阻力小、调心灵活 Features: small friction resistance, flexible aligning

球面支撑调心结构 Spherical support aligning

structure 适用于大型磨机 Apply to: big size ball mill 特点：承载能力大、球面需润滑 Features: huge load carrying capacity, lubrication need to be done on spherical surface.

磨机主轴承——轴承调心结构 BEARING ALIGNING STRUCTURE

磨机主轴承——滑履轴承 MAIN BEARING —— PAD BEARING

因加工精度所限，单片瓦承载区域随轴承直径增大无显著提升，由此出现了多片瓦结构轴承。

By the reason of machining accuracy, load bearing area of single bearing bush does not enlarge with the diameter increasing. Then multi-bush bearing is bore:

配置：Equipped with 温度检测 temperature detection 流量监测 flow detection 油压检测 oil pressure detection 环形称重传感器 ring weight sensor

用于大型耳轴支撑 或用于筒体支撑 Apply to: big trunnion support or shell support 配备专用油站 Equipped with special oil station

磨机主轴承——滑履轴承 MAIN BEARING —— PAD ASSEMBLY

设计目标 Design Objective 增大瓦面等压范围，提高瓦面承载率

increase the bush load bearing area

to enhance the load bearing rate

解决方案 Solution 采用周边四角压力区域补偿

pressure span compensation

by the around four corners

磨机驱动系统 DRIVE SYSTEM

驱动型式 drive type

•同步电机+气动离合器

•Synchronous motor+ air clutch

•异步电机+减速器

•Asynchronous motor +reducer

•环形电机驱动

•Ring motor drive

传动型式 transmission type

•齿轮传动 Gear transmission

•单驱动 Single drive

•双驱动 Double drive

•无齿传动 No gear transmission

•中心传动 Centre drive

•环形电机 Circumferential motor

传动型式 Transmission type

传递功率kW Transmitted power

单电机齿轮传动 Single motor gear rive

8000~10000

双电机齿轮传动 Twin motor gear drive

16000~20000

环形电机驱动 Circumferential motor drive

16000+

磨机驱动系统——布置形式 DRIVE SYSTEM - DRIVE ARRANGEMENT STYLE

磨机驱动系统——齿轮传动 DRIVE SYSTEM - GEAR DRIVE

设计依据： ANSI/AGMA 6114-A06 Design standard

接触系数Csf：不低于1.75 Csf≥1.75

弯曲系数Ksf：不低于2.5 Ksf≥2.5

校验方法： Method of calibration

采用ANSYS分析平台模拟

ANSYS platform simulation

探伤 FLAW RATING

热处理 HEAT TREATMENT

精度等级 ACCURACY

齿面硬度 HARDNESS

材料 MATERIA

ZG34Cr2Ni2Mo（用于大型磨机）；

采用调质处理，提高硬度、细化晶粒、 提高整体性能；

大型磨机为280~320 HB；

AGMA 10级（GB10095 7~8级）；

采用超声波及磁粉探伤， 符合2级以上中国标准；

MULTIPLE PROCESSING DUMBBELL PIN POSITIONING & TOOTH SURFACE MODIFICATION

磨机驱动系统——大齿轮 DRIVE SYSTEM - GEAR

探伤 FLAW RATING

热处理 HEAT TREATMENT

精度等级 ACCURACY

齿面硬度 HARDNESS

材料 MATERIA

17Cr2Ni2Mo（用于大中型磨机）

采用调质处理，齿面进行渗碳、 淬火、磨齿处理；

57~62HRC（ 17Cr2Ni2Mo ）

AGMA 12级（GB10095 5~6级）

采用超声波及磁粉探伤 符合2级以上中国标准

采取油、脂润滑，齿面修形等技术 TAKE OIL, GREASE, TOOTH SURFACE MODIFICATION SUCH AS TECHNOLOGY

监控 Monitor

温度检测 Temperature

流量检测 Flow

振动检测 Vibration

油位检测 Oil level

磨机驱动系统——小齿轮 DRIVE SYSTEM - PINION

磨机驱动系统——齿轮罩刚度优化 DRIVE SYSTEM - GEAR WHEEL COVER STIFFNESS OPTIMIZATION

应力云图 Stress Cloud

Chart

位移云图 Displacement Cloud Chart

磨机给料系统 FEEDING SYSTEM

种类及适用范围 Type and application scope 鼓形给料器——适用于小型溢流型球磨机

drum feeder ( small size overflow ball Mill)

联合给料器——使用于小型格子型球磨机

joint feeder ( for small grate ball Mill)

管式给料器——适用于各规格球磨机

Tube type feeder (Applicable to all kinds of ball mill)

溜槽给料器——适用于半自磨机

Chute feeder ( Applicable to SAG Mill)

新增功能 Added function 电力驱动给料车——用于大中型磨机

Electric drive feeder wagon ( for big or middle size Mill)

料位检测装置——用于检测是否堵料

Material level detection device (for check if it is blocked )

材料 Material ZG35CrMnSi/QT450/焊接+内衬 (welding + lining)

密封 Sealing 专有联合密封结构，杜绝漏矿

Special joint sealing structure to avoid leakage

磨机给料系统 FEEDING SYSTEM

小型磨机 管式给料

tube feeder for small

Mill

大中型磨机 电力驱动给料车

Electric drive feeder wagon for big or middle size Mill

磨机排料系统 DISCHARGE SYSTEM

圆筒筛型式 Types of drum screen 整体焊接式 Wholly Welded

焊接架体+把合筛网，可更换

welded frame+ bolt fastening screen cloth (Changeable)

筛孔型式 Types of screen pore 圆形孔 (circular hole)、长圆形孔（长

宽比3：1）Long round hole(length-width ratio,3:1)、条形孔 (longandnarrow hole)

筛网材料 screen cloth material 16Mn、1Cr18Ni9Ti、耐磨橡胶

(Abrasion resistant rubber) 、聚氨酯 (Polyurethane)

技术升级 Technological upgrading 增设尾部渣浆分离机构 Added tail

slurry separation device

增设矿渣料斗 Added slag hopper

增设检查筛网视窗Added monitor window for screen cloth

磨机排料系统 DISCHARGE SYSTEM

自返装置

圆筒筛

慢速驱动装置 INCHING DRIVE

人性化设计 Humanized design 操作简单、省力 Easy operation, save labour

推力放大10倍，与原结构相比提升5倍。

thrust strengh enlarged 10 times, 5 times more than the original structure

与主机互锁安全可靠 Interlock with the main body, safe

and reliable 配有限位开关，由PLC统一控制。 Equipped with limit switch

controlled by PLC 系列化离合器 Series of clutch

齿式离合器、单向爪形离合器、双向爪形离合器

Gear clutch,one-way claw form clutch,

two-way claw form clutch

磨机起重装置 LIFTING DEVICE

总体型式 Overall type 1拖2：1个液压站配带2个千斤顶 One

hydraulic station equipped with two jacks

1拖4：1个液压站配带4个千斤顶 One hydraulic station equipped with four jacks

千斤顶型式 Type of jack 单作用——常用于小型磨机 Single Acting(for small Mill) 双作用——用于大中型磨机 Double-acting(for big or middle size Mill )

千斤顶特点 Characteristic of jack 机械限位 Mechanical limit 液压及机械锁紧，安全可靠 Hydraulic and mechanical lock(safe and

reliable) 技术升级 technological upgrading

增大千斤顶顶起行程 Increase jacking up trip 使托架免拆卸 avoid bracket disassembled

优化人孔、托架相对位置 Relative position of manhole and braket

optimized

起重托架 有限元分析

种类 type 稀油润滑站——用于传统小型磨机或小齿轮

轴承润滑 Thin oil lubrication station(for traditional

small size Mill or pinion bearing) 高低压润滑站——用于中小型磨机 High and low pressure lubrication

station( for middle or small size Mill) 静压润滑站——适用于各类型磨机（推荐使

用） Static pressure lubrication station(for all

kinds of Mill, recommended) 功能及能力Function and capacity

向主轴承或小齿轮轴承供油 Supply oil for main bearing or pinion

bearing 具备润滑油温度检测、压力检测、油位检测、

压差检测及流量检测等功能 Has the function of oil temperature

detection , pressure detection, oil level detection, pressure difference detection and flow detection,etc.

具备润滑油加热及冷却功能 Has the oil heating and cooling function.

润滑站 LUBRICATION STATION

静压润滑站内部设置三个润滑系统 three lubrication systems setted up in static lubrication station

高压润滑系统、低压润滑系统、内循环系统 Hign pressure system, low pressure system, internal circulation system 各润滑系统均设置2台泵，一工一备，可自动切换 Two pumps equipped for each systme, one for work and one for stand

by,automatic shift

内部关键零部件采用国外知名品牌产品 Key parts of the station are from abroad famous brand

标准配置 Standard configuration 高压泵及循环泵采用螺杆泵、低压泵采用齿轮泵 Screw pump used for high pressure pump and circulation pump , gear pump used

for low pressure pump 采用同步液压马达实现等流量分配 To use synchronous hydraulic motor for the equivalent flow distribution

润滑站——静压润滑站 LUBRICATION STATION

PLC集中控制 PLC centralized control PLC品牌：西门子、ABB、施耐德 PLC brand: Siemens, ABB,Schneider

彩色触摸屏人机交互 Color touch screen forHuman-Computer Interaction 操作界面形象易懂Vivid and easily understood operation-interface

配置 Equipped with 控制模块、通讯模块及执行模块采用进口知名品牌产品，运行可靠 Control module, communication module, and execution

module(abroad famous brand), reliable operation 功能 Function

具有机旁手动控制 Local manual control 具有机旁自动控制 Local automatic control 具有中控室远程控制功能 Remote control from central control room 具有数据存储功能 Data storage 具有故障诊断功能 Fault diagnosis

低压控制系统 LOW VOLTAGE CONTROL SYSTEM

低压控制系统 LOW VOLTAGE CONTROL SYSTEM

润滑油站

储气罐

油压信号 压差信号 温度信号

油位信号 动力电源 流量信号 油膜信号

故障信号

气压信号 液位信号

喷射润滑

振动信号

低压控制柜 PLC 中控

产品业绩

PERFORMANCE RECORD

矿用磨机生产业绩 PERFORMANCE EXAMPLE

the first Φ5500×8500mm overflow ball mill of China (2 sets)

2台Φ5500×8500mm溢流型球磨机 功率：4500kW (Power)

矿用磨机生产业绩 PERFORMANCE EXAMPLE

4台Φ5500×8800mm溢流型球磨机 功率：4500kW(Power) overflow type ball mill jobsite operation(Duobaoshan, copper

ore)

矿用磨机生产业绩 PERFORMANCE EXAMPLE

1台Φ5500×9500mm溢流型球磨机 功率：4800kW (Power) Overflow type ball mill jobsite operation

矿用磨机生产业绩 PERFORMANCE EXAMPLE

Φ4880×7300mm溢流型球磨机（2台）overflow type ball mill

功率：3000kW Power:3000kW

矿用磨机生产业绩 PERFORMANCE EXAMPLE

Φ5030×7500mm溢流型球磨机（5台）overflow type ball mill

功率：3100kW Power:3100kW

India Vedanta现场运行 (5 sets)

矿用磨机生产业绩 PERFORMANCE EXAMPLE

Φ6400×6400mm溢流型球磨机（1台）

功率：5500kW(Power） Overflow type ball mill

知名配套供货商 FAMOUS BRAND SUPPLIER FOR THE MILL AUXILIARIES