1. Introduction and operation analysis of the main equipment
1.1 Introduction to the main equipment
The specification is a overflow ball mill with a diameter of 2700mm × 3600mm, and the transmission method is edge single drive. The dragging motor model specification is TDM K400-326k100kW, and the rated speed of the whole body is 21.7r/min. There are a total of 5 ball mills.  
1.2 Analysis of Operation Status
The operating environment of the ball mill is harsh and the load is high. Its efficiency and service life are determined by the transmission device, which is mainly composed of large and small gears that mesh with each other. The service life of the gears is not only related to the working conditions, load, materials, heat treatment, and installation accuracy, but also closely related to the lubrication condition. The contact surface of the gear meshing surface is very small, and the operating state during meshing is relatively complex, with both sliding and rolling. In addition, the influence of machining and assembly errors and tooth surface wear causes excessive pressure per unit area of the tooth surface; In addition, although the grinding machine gears have dust covers, there are still certain sealing defects. Dust often invades, and some dust particles adhere to the meshing surface. Coupled with external conditions, it is difficult to ensure good lubrication of the gears, accelerating wear and shortening their service life. For many years, the main manifestations of gear damage and failure in grinding machines have been wear, bonding, and pitting, which are mainly caused by poor lubrication.  
The traditional lubrication methods for ball mills include: bearing oil cup lubrication, large gear ring lubrication with oil, oil tanker lubrication with oil, concentrated lubrication with thin oil, asphalt application lubrication, and manual periodic lubrication. On site, there is no reliable real-time detection and control solution, relying solely on manual visual inspection to determine, often resulting in inadequate lubrication, waste of lubricating grease, environmental pollution, increased maintenance costs for grinding machines, and reduced production efficiency
1) Gear vibration, loud noise, and unstable operation can cause an increase in the load on the transmission bearings, resulting in bearing damage and often causing faults such as shaking of the transmission motor bearings; And the vibration of the small gear exacerbates the damage to the grinder.  
2) When the grinder operates without good lubrication, the temperature of the end cover of the grinding head is prone to rise, and its diameter is heated to increase, which can easily push open the joint surface in the large gear ring, causing an opening phenomenon and resulting in unstable operation or other faults.  
3) The wear of bearings and gears intensifies, leading to rapid failure.  
4) Manual lubrication requires high labor intensity, and the amount and position of oil are difficult to control, resulting in oil waste, poor lubrication, and low residual oil pollution on site.  
In summary, good lubrication of bearings and gears is an important factor for the safe, stable, and economical operation of ball mills.  
2. Characteristics and installation requirements of ZPGR-2000 intelligent lubrication device for dry and thin oil
The ZPGR-2000 intelligent lubrication system for dry and thin oil has made significant breakthroughs in equipment configuration, working principle, and structural layout. By combining microcomputer technology with programmable controllers, it has changed the traditional lubrication method and taken equipment lubrication to a new level. The main control equipment, pneumatic high-pressure lubrication pump, electromagnetic oil feeder, flow sensor, pressure sensor and other components in the system are carefully designed and developed for intelligent lubrication systems.  
2.1 Characteristics of Intelligent Lubrication Device
The equipment adopts SIEMENS S7 series programmable controller as the main control system, providing the best solution for intelligent lubrication control requirements. The on-site PLC communication is connected with the upper computer monitoring system for real-time monitoring, making the lubrication status clear at a glance.  
1) The on-site fuel supply distribution is directly controlled by the upper computer in the main control room or the text display of the on-site programmable controller. The size of the fuel supply and the duration of the fuel supply cycle are monitored by the main control system, and the data communication is reliable.  
2) The flow sensor monitors the operating status of each lubrication point in real time. If there is a fault, it can alarm in a timely manner and accurately determine the location of the fault point. Through communication display and upper computer monitoring screen, it is convenient for the staff to timely grasp the lubrication status of the equipment and take effective maintenance measures.  
3) The operator can remotely adjust the oil supply parameters according to the different lubrication requirements of each point of the equipment to adapt to the lubrication requirements of different parts.  
2.2 Usage and Installation Requirements
1) The requirements of ball mill for ZPGR-2000 intelligent lubrication system. Using compressed air as power to drive the pneumatic oil pump, and cooperating with pneumatic components to extract lubricating oil from the oil tank, it is evenly sprayed on the working tooth surface through the nozzle in a mist form, forming a tough oil film; Use an electromagnetic oiler to supply lubricating grease into the bearings, remotely start and stop the lubrication equipment through interlocking with the site, and have a fault alarm function. Oil requirements: 680 # or 460 # extreme pressure gear oil is used for ball milling gears, and 0 #~2 # lubricating grease is used for bearings. The system adjustment is simple, and after being put into operation, the maintenance workload is small, and the work is stable and reliable.  
2) Installation requirements for ZPGR-2000 intelligent lubrication device in ball mill applications. The lubrication device should be installed as close to the grinder as possible, but not directly in a location with strong vibration. The installation location should have low dust and good ventilation conditions; There should be a certain amount of space around the main control device for maintenance and operation; Before installation, the pipeline should be treated according to relevant specifications to remove impurities; When installing pipelines, it is advisable to minimize the use of right angle elbows to reduce system resistance; The effectiveness and installation of fuel injectors are closely related. Firstly, the lubrication range of the friction parts should be fully included in the spray belt. If installing one nozzle cannot meet the requirements, several nozzles can be combined to ensure good lubrication on the surfaces that need to be lubricated. For gear lubrication, the installation position of the nozzle should be determined through calculation to determine its optimal working position, which refers to:
① All grease must be sprayed onto the surface of the teeth;  
② The minimum amount of grease sprayed on non meshing surfaces;  
③ When the compressed air pressure is 0.45MPa, the angle between the nozzle and the gear pitch circle and the nozzle centerline is 30.; The distance from the nozzle to the intersection of the gear pitch circle and the nozzle centerline is 200mm; The nozzle sprays a cone angle of 41. The optimal working state is when the oil is atomized and the particles are small and dense;  
④ After determining the working position, mark it on the gear cover;  
⑤ Drill positioning holes, adjust the angle of the nozzle, and install the fuel injection plate.  
3. Operation of ZPGR-2000 Intelligent Lubrication System in Grinding Machine Applications
3.1 Operation Status
Since its installation in 2003, this system has operated reliably, had a low failure rate, and required minimal maintenance. It plays an important role in lubricating the main equipment of the mill and ensuring its safe and stable operation. By regularly measuring vibration and the deflection of the large gear ring, it was found that the tolerance value change of the radial runout of the gear with the installation of the fuel injection device was much smaller than that of the gear ring without the installation of the fuel injection device; The vibration amplitude of the grinder installed with the fuel injection device is stable. The gear of the grinding machine without an oil injection device, even if lubricating grease is added every day, still experiences dry grinding, with a vibration amplitude difference of 0.04~0.05mm.  
3.2 Economic benefits
Good lubrication extends the operating cycle of the mill and the replacement cycle of gears, increases the actual life of the transmission bearings by 1-2 times, reduces maintenance workload, lowers the frequency of shutdown maintenance, and improves production efficiency. Due to the regular and quantitative spraying of lubricating grease in mist form by the device, the quantity is small, the efficiency is high, and the fuel saving effect is significant. Before using Zhuang, each machine required 15kg of open gear grease per day. Calculated based on the daily operation of 5 grinding machines and 75kg of oil consumption, it is estimated that 27375kg of oil will be used annually, equivalent to RMB 191615/a (calculated at 7 yuan/kg of grease). After use, using 8kg of grease per unit per day will cost RMB 102200 per year, saving RMB 89415 per year.