球磨(mo)機是選礦(kuang)廠主要(yao)生(sheng)產設備，某鐵(tie)礦(kuang)選礦(kuang)廠的(de)兩(liang)臺球磨(mo)機因為(wei)已經運行(xing)工作30余(yu)年(nian)，陸續(xu)出現各種問題(ti)，其中比較(jiao)嚴(yan)重(zhong)的(de)就是球磨(mo)機啟(qi)動困(kun)難的(de)問題(ti)。該廠球磨(mo)機啟(qi)動需要(yao)借助外力，并且伴隨產生(sheng)的(de)問題(ti)有：高(gao)壓電動機定子(zi)(zi)線(xian)圈和轉子(zi)(zi)線(xian)圈噴火花、高(gao)壓開關柜(ju)的(de)少(shao)油(you)斷(duan)路(lu)器(qi)噴油(you)情況(kuang)、頻敏電阻器(qi)燒(shao)壞等狀(zhuang)況(kuang)不(bu)斷(duan)。以上(shang)狀(zhuang)況(kuang)不(bu)但存在嚴(yan)重(zhong)的(de)安全隱患，并且也嚴(yan)重(zhong)影(ying)響到了(le)選礦(kuang)廠的(de)正(zheng)常運營，所以必須對球磨(mo)機進行(xing)局部改造。

一、選礦廠球磨機改造

1、一次改造

首先是(shi)(shi)對(dui)球磨機高(gao)壓(ya)(ya)控(kong)(kong)(kong)制(zhi)部分(fen)的(de)改(gai)造，更(geng)新兩臺鎧(kai)裝(zhuang)中置式(shi)高(gao)壓(ya)(ya)開(kai)關(guan)柜(ju)。經(jing)過(guo)實地考察、多(duo)方面論證，決(jue)定采用鎧(kai)裝(zhuang)磁閥式(shi)高(gao)壓(ya)(ya)固態軟啟動裝(zhuang)置，兩臺高(gao)壓(ya)(ya)電(dian)動機由原(yuan)來的(de)繞線(xian)式(shi)改(gai)為鼠(shu)籠式(shi)，就是(shi)(shi)對(dui)電(dian)動機滑(hua)環去除(chu)，把轉子(zi)繞組(zu)短接成Y接法。其工作原(yuan)理為采用高(gao)壓(ya)(ya)磁閥式(shi)可(ke)(ke)控(kong)(kong)(kong)電(dian)抗(kang)(kang)器(qi)(qi)技(ji)術(shu)，高(gao)壓(ya)(ya)磁閥式(shi)可(ke)(ke)控(kong)(kong)(kong)電(dian)抗(kang)(kang)器(qi)(qi)的(de)繞組(zu)分(fen)為高(gao)壓(ya)(ya)繞組(zu)和低(di)壓(ya)(ya)直(zhi)流(liu)繞組(zu)，該技(ji)術(shu)以西門(men)子(zi)PLC-200控(kong)(kong)(kong)制(zhi)低(di)壓(ya)(ya)晶閘(zha)管的(de)導通，通過(guo)控(kong)(kong)(kong)制(zhi)晶閘(zha)管的(de)導通角來改(gai)變控(kong)(kong)(kong)制(zhi)高(gao)壓(ya)(ya)磁閥式(shi)可(ke)(ke)控(kong)(kong)(kong)電(dian)抗(kang)(kang)器(qi)(qi)低(di)壓(ya)(ya)直(zhi)流(liu)繞組(zu)中直(zhi)流(liu)部分(fen)，根據直(zhi)流(liu)電(dian)流(liu)的(de)大(da)小改(gai)變高(gao)壓(ya)(ya)磁閥式(shi)可(ke)(ke)控(kong)(kong)(kong)電(dian)抗(kang)(kang)器(qi)(qi)鐵芯的(de)導磁率大(da)小，從而(er)改(gai)變高(gao)壓(ya)(ya)磁閥式(shi)可(ke)(ke)控(kong)(kong)(kong)電(dian)抗(kang)(kang)器(qi)(qi)高(gao)壓(ya)(ya)繞組(zu)的(de)阻抗(kang)(kang)大(da)小，從而(er)達(da)到降壓(ya)(ya)限流(liu)的(de)目(mu)的(de)，實現(xian)無(wu)級(ji)級(ji)調速。

其一步改造完成后，球(qiu)磨(mo)機(ji)(ji)高(gao)壓電(dian)(dian)控安全(quan)運行(xing)近兩年，球(qiu)磨(mo)機(ji)(ji)電(dian)(dian)動(dong)(dong)機(ji)(ji)運行(xing)電(dian)(dian)流(liu)突然增大約(yue)8A，并(bing)且啟動(dong)(dong)困難，不敢(gan)停車，停車后需多次(ci)啟動(dong)(dong)，才(cai)能(neng)正常(chang)運行(xing)。由于(yu)電(dian)(dian)動(dong)(dong)機(ji)(ji)本身(shen)因(yin)使用年限(xian)已久，效率低(di)下，老化嚴重，由于(yu)高(gao)壓電(dian)(dian)動(dong)(dong)機(ji)(ji)經(jing)過(guo)了(le)多次(ci)反復(fu)修理，各項性能(neng)指(zhi)標急劇(ju)下降，且JR1410-8型號電(dian)(dian)動(dong)(dong)機(ji)(ji)屬于(yu)高(gao)能(neng)耗淘汰(tai)產(chan)品，不能(neng)繼續使用，對此(ci)進行(xing)了(le)第二步改造。

2、二次改造

二(er)次改造(zao)方(fang)案(an)為對兩臺JR1410-8型三(san)相異步高(gao)壓(ya)電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)重(zhong)新(xin)(xin)選型，進行更換。經過實地考察，多(duo)方(fang)面(mian)論證，決定(ding)(ding)(ding)采(cai)用(yong)(yong)(yong)西安電(dian)(dian)(dian)機(ji)(ji)(ji)廠鼠籠式YHP500-8A三(san)相異步高(gao)壓(ya)電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)，此型號電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)滿足(zu)球(qiu)磨機(ji)(ji)(ji)重(zhong)載啟動(dong)、啟動(dong)能(neng)矩很(hen)大(da)(da)的特點，滿足(zu)使用(yong)(yong)(yong)要求。電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)額(e)定(ding)(ding)(ding)功率為315kW、額(e)定(ding)(ding)(ding)電(dian)(dian)(dian)壓(ya)6kV、額(e)定(ding)(ding)(ding)電(dian)(dian)(dian)流46.6A、效(xiao)率93%；堵轉電(dian)(dian)(dian)流/額(e)定(ding)(ding)(ding)電(dian)(dian)(dian)流為7.5、堵轉轉矩/額(e)定(ding)(ding)(ding)轉矩為2.0。JR1410-8型電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)機(ji)(ji)(ji)身短、高(gao)，聯軸(zhou)(zhou)器(qi)安裝軸(zhou)(zhou)軸(zhou)(zhou)徑(jing)、定(ding)(ding)(ding)位(wei)尺寸均小，YHP500-8A型電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)機(ji)(ji)(ji)身細、長，聯軸(zhou)(zhou)器(qi)安裝軸(zhou)(zhou)軸(zhou)(zhou)徑(jing)、定(ding)(ding)(ding)位(wei)尺寸均偏大(da)(da)，造(zao)成(cheng)新(xin)(xin)舊電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)中(zhong)心(xin)高(gao)不一(yi)致，T3型膠板彈性(xing)聯軸(zhou)(zhou)器(qi)不能(neng)通用(yong)(yong)(yong)，新(xin)(xin)電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)中(zhong)心(xin)高(gao)偏低、地腳(jiao)螺栓安裝尺寸不一(yi)致，為了保證不動(dong)原有基(ji)礎，利用(yong)(yong)(yong)原來的地腳(jiao)螺栓，需重(zhong)新(xin)(xin)設計制作專用(yong)(yong)(yong)電(dian)(dian)(dian)動(dong)機(ji)(ji)(ji)底座及專用(yong)(yong)(yong)半(ban)聯軸(zhou)(zhou)器(qi)。

二、改造前后電控及電動機情況對比

改造(zao)(zao)(zao)之前球磨(mo)機存(cun)在(zai)重(zhong)大的(de)安全隱患。高(gao)(gao)(gao)(gao)壓電(dian)控(kong)經(jing)常(chang)(chang)(chang)出(chu)(chu)現故障，不是繞線(xian)(xian)(xian)式(shi)高(gao)(gao)(gao)(gao)壓電(dian)動(dong)(dong)機的(de)線(xian)(xian)(xian)圈接地就是匝間(jian)短路，造(zao)(zao)(zao)成(cheng)(cheng)繞線(xian)(xian)(xian)式(shi)高(gao)(gao)(gao)(gao)壓電(dian)動(dong)(dong)機的(de)導磁率急劇下降，使(shi)繞線(xian)(xian)(xian)式(shi)高(gao)(gao)(gao)(gao)壓電(dian)動(dong)(dong)機輸出(chu)(chu)轉矩達不到(dao)額(e)定轉矩，使(shi)繞線(xian)(xian)(xian)式(shi)高(gao)(gao)(gao)(gao)壓電(dian)動(dong)(dong)機啟(qi)動(dong)(dong)非常(chang)(chang)(chang)困(kun)難，需要(yao)借助外力進行(xing)盤車，有(you)時需要(yao)連續啟(qi)動(dong)(dong)好幾次才(cai)能正常(chang)(chang)(chang)運行(xing)，這樣就造(zao)(zao)(zao)成(cheng)(cheng)繞線(xian)(xian)(xian)式(shi)高(gao)(gao)(gao)(gao)壓電(dian)動(dong)(dong)機的(de)定子(zi)線(xian)(xian)(xian)圈的(de)溫(wen)度急劇上升，在(zai)啟(qi)動(dong)(dong)過程中(zhong)線(xian)(xian)(xian)圈有(you)火(huo)花噴出(chu)(chu)，繞線(xian)(xian)(xian)式(shi)高(gao)(gao)(gao)(gao)壓電(dian)動(dong)(dong)機經(jing)常(chang)(chang)(chang)燒壞定子(zi)線(xian)(xian)(xian)圈和轉子(zi)線(xian)(xian)(xian)圈，造(zao)(zao)(zao)成(cheng)(cheng)高(gao)(gao)(gao)(gao)壓開(kai)關(guan)柜的(de)少油斷路器噴油，頻敏電(dian)阻器燒壞，以上問題使(shi)安全生產(chan)(chan)得不到(dao)保障，經(jing)常(chang)(chang)(chang)停產(chan)(chan)，嚴(yan)重(zhong)影響生產(chan)(chan)，造(zao)(zao)(zao)成(cheng)(cheng)維(wei)護人員的(de)維(wei)護時間(jian)長，增加維(wei)護人員的(de)勞動(dong)(dong)強度，增加生產(chan)(chan)成(cheng)(cheng)本。

改(gai)造之后球磨機能達到一次性啟(qi)動，啟(qi)動時(shi)不需要(yao)借助外力，高壓電控得到了(le)保(bao)障，生產得到了(le)保(bao)障，消除了(le)啟(qi)動工程中存(cun)在(zai)的安全隱(yin)患，減少了(le)維(wei)護(hu)量，降(jiang)低了(le)維(wei)護(hu)人員(yuan)的勞動強度。

（1）改造前(qian)平均每月(yue)處(chu)理(li)一次電控故(gu)障、事(shi)故(gu)，現在事(shi)故(gu)為零(ling)。

（2）改造在節假日(ri)期間，不影(ying)響生產(chan)、用時短。

（3）不需要重(zhong)新澆灌(guan)高壓電動(dong)機基礎，造價(jia)低、耗(hao)時短(duan)。

（4）能一(yi)次性(xing)啟動，效(xiao)果好。

（5）選(xuan)用效率(lv)高率(lv)電動機，既節能、又降耗。

總的(de)(de)來(lai)說，本(ben)次改造(zao)既(ji)消除(chu)了(le)(le)(le)安全(quan)隱患，又保(bao)(bao)障了(le)(le)(le)生(sheng)產，保(bao)(bao)證了(le)(le)(le)選(xuan)礦設備的(de)(de)正常運行，提(ti)(ti)高(gao)了(le)(le)(le)生(sheng)產效率(lv)，同時為(wei)其他類似的(de)(de)技術改造(zao)提(ti)(ti)供(gong)了(le)(le)(le)有力的(de)(de)借鑒作用。