Double-Bearing Vertical Grinding Mill Vibration Reduction
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Solution Overview
Problem
Conventional industrial grinding mills are energy-intensive, inefficient, and plagued by high vibration, high power consumption, noise, and heavy metal pollution, with complex maintenance requirements and low energy utilization rates, particularly in the cement industry.
Innovation Solution
An energy-saving double-bearing vertical grinding mill with a permanent magnet variable frequency motor, double-spiral rotor, and rolling bearings at both ends of the rotating shaft, eliminating the need for special couplings and simplifying maintenance by allowing the rotor to remain in place during maintenance, while using corundum materials and ventilation openings for efficient grinding and dust management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single bearing is used to support the rotating shaft, then the device complexity is reduced, but the vibration of the rotor increases significantly and manufacturing requirements become too high
Solution Approach 1:
The single bearing support is segmented into two separate bearings: an upper bearing (50) positioned above the grinding chamber and a lower bearing (60) positioned below the grinding chamber. This segmentation allows each bearing to independently support specific sections of the rotating shaft, reducing vibration in critical areas while maintaining overall structural simplicity.
2Device complexity
If a variable frequency motor with reducer and single bearing is used, then the device complexity is reduced, but special couplings with power higher than 630 Kw must be imported from European companies, prolonging the manufacturing cycle by 4-6 months
Solution Approach 1:
The traditional mechanical transmission system (variable frequency motor + reducer + special coupling) is replaced with a permanent magnet variable frequency motor that integrates the motor and reducer functions. This substitution eliminates the need for special imported couplings, reducing the manufacturing cycle by 4-6 months while maintaining the required power transmission capability.
3Ease of repair
If the rotor is designed to be removable for maintenance, then the ease of repair is improved, but the device complexity increases and maintenance becomes laborious and difficult
Solution Approach 1:
The double-spiral rotor (40) is extracted as a separate, independently replaceable component from the grinding mill system. The rotor can be removed through the feeding port without disassembling the entire mill, allowing maintenance personnel to service or replace the rotor independently while leaving the bearing support structure and other components in place.
4Power
If conventional grinding mills are used for wet grinding, then the energy consumption is high, but the energy utilization rate is merely 2-3% with 95% converted into waste heat and noise
Solution Approach 1:
The grinding process parameters are changed from wet grinding to dry grinding, and the energy conversion pathway is modified by using a permanent magnet variable frequency motor that directly drives the rotor without a reducer. This changes the energy transmission efficiency, reducing waste heat and noise while improving the overall energy utilization rate from 2-3% to significantly higher levels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces vibration, lowers manufacturing costs, increases grinding efficiency, reduces noise and resource consumption, and shortens manufacturing cycles by 4-6 months, achieving a 30% cost savings and doubling the functional life of bearings, while promoting eco-friendliness by reducing lubricant and cooling water usage.
Implementation Method 1
a permanent magnet variable frequency motor arranged above the shell
Implementation Method 2
an upper bearing and a lower bearing are both sleeved on the rotating shaft and are respectively located at the upper end and the lower end of the rotating shaft
Implementation Method 3
a grinding medium is filled in the grinding chamber, and the inner side wall of the shell and the side wall of the access door are respectively provided with a first lining plate and a second lining plate
Implementation Method 4
the lower end surface of the shell is arranged in an air blowing port in communication with the interior of the grinding chamber
Data Source
AI summary
An energy-saving double-bearing vertical grinding mill for dry grinding and shaping, comprising a shell, a permanent magnet variable frequency motor arranged above the shell, a rotating shaft connected with the output end of the permanent magnet variable frequency motor, and a double-spiral rotor arranged on the rotating shaft, wherein a grinding chamber is formed in the shell, wherein an upper bearing and a lower bearing are respectively arranged at top and bottom of the grinding chamber, wherein the upper bearing and the lower bearing are both sleeved on the rotating shaft and are respectively located at upper end and lower end of the rotating shaft, wherein the upper bearing and the lower bearing are both rotatably connected with the rotating shaft, wherein the grinding chamber is filled with a grinding medium.