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Planetary Ball Mill Manual
Date:2017-03-30

QM0.4L Planetary Ball Mill

 Manual

Ⅰ. General Situations

1.       Purpose

QM series planetary ball mill could grind or mix solid particles of different granularities and materials, suspension and paste with dry and wet methods. If a vacuum ball milling tank is used, it will be possible to grind and mix samples in vacuum or inert gases. Through the application of many scientific research and enterprise units, it is proved that the QM series planetary ball mills manufactured by our plant have a granularity of grinding materials fully meeting nano level, which has already reached up to about 30 nano (0.03 um) according to feedback of users. In addition, this series of ball mills is widely applied to the fields such as geology, metallurgy, soil, building materials, chemical industry, light industry, medicine, electronics, porcelain, battery and environmental protection and so on.

Along with the high-speed development of science and technologies, and the wide application of nano materials, the mechanical alloying (MA) discovered in 1980s endows QM series planetary ball mills with new missions. The basic process of mechanical alloying is that the powder and particles of several kinds of metallic and non-metallic elements are repeatedly mixed, crashed and cold welded in ball mill, gradually refined to nano level in the process of ball milling, and form a nucleus of alloy phase in solid state, which has made some substances difficult to realize alloying with traditional melting process actually materialize alloying in the process of milling, and made many units using the ball mills manufactured by our plant realize many kinds of alloy powder, such as nano crystalline hard alloy, Nd60Fe20Al10CO10 non-crystalline alloy powder, and Al2O3/Al compound powder and so on.

2.       Operational Principle

QM series planetary ball mill has four ball milling tanks on a big tray, and when this big tray circumvolve (revolution), it will drive ball milling tanks to circumvolve (rotation) surrounding its rotor axis to form epicyclic motion. The drive ratio of revolution and rotation is 1:2 (one circle of revolution will make two circles of rotation). As for the functions of epicyclic motion, the milling ball and milling materials inside the tanks impact with each other under the functions of eccentricity, and break up, grind and mix testing samples.

3.       Characteristics

A.     QM0.4L gear drive planetary is manufactured with self-lubricating reinforced engineering plastics by our plant, which ensures mechanical strength and reduces noises at the same time.

This product is a patented product of our plant with a patent number

B.      Interval operation function: To prevent the property and quality of milling materials from being affected by overheating generated by ball milling, this machine could automatically control the time of each state as per the circulating mode of “operation – shutdown – reoperation”.

4.       Technical Parameters

Model: QM0.4L

Matchable ball milling tank: Capacity (capacity of single tank, unit: ml): 50, 100

                        Material: Stainless steel, agate, nylon, polyurethane, polytetrafluoroethylene, hard alloy (YG8) and porcelain and so on.

                        Type: Ordinary tank, stainless steel vacuum tank, stainless steel vacuum cover (used together with ball milling tanks of agate, nylon and porcelain etc. for pumping vacuum).

Maximum charge of ball milling tank: three fourths of the cubage of the tank (including milling ball).

Granularity of materials fed: Short materials 10 mm; other materials 3 mm.

Granularity of materials reclaimed: The minimum could be up to 0.1 um.

Rated rotating speed: Revolution (big tray) 300 turns / min ± 10%; rotation (ball milling tank): 600 rotations /min ± 10%.

Operational mode: Ball mill is controlled with frequency converter, and has five operational modes in total:

1.       Unilateral operation with shutdown at non-fixed time;

2.       Unilateral operation with shutdown at fixed time;

3.       Positive and negative alternate operation with shutdown at fixed time;

4.       Unilateral interval operation with shutdown at fixed time;

5.       Positive and negative alternate interval operation with shutdown at fixed time;

Mode of speed control: Frequency converter: 0~50Hz; resolution: 1 Hz; and limited speed of this machine: 0~50Hz.

Control method: 0~50Hz (0~600turns / min): make manual adjustments at any time, 1~999min operation at fixed time, 1~300min positive and negative revolution at fixed time, 1~999min interval operation at fixed time, and 0~100 times of restarting operation.

Motor: SIEMENS / Three-phase AC/ 220V/ 0.75KW

External size of ball mill: 50 X 70 X 50 mm.

Net weight of ball mill: 60KG.

 

1.       Examination

After tearing open the container, check if the machine is lacked of some accessories according to packing list, and if the ball mill, power pack and ball milling tank are damaged in transportation.

2.       Reading

Read the User’s Manual carefully, carry out non-load test running of the ball mill as per the steps described in the Manual, and check if the operation of frequency converter and ball mill is normal.

3.       Loading Tank

It’s possible to load tank if the above items are checked and proved qualified.

a. Loading milling tank: To enhance the efficiency of ball milling, milling balls of different sizes are loaded into the tank, with big balls for breaking up coarse milling materials, and small ones for milling and grinding such materials to make them reach required fineness.

In the following table are number of balls equipped for ball milling tanks of various specifications (only for reference).

Cubage of Tank (ml)

50

100

150

250

300

400

500

Ball

(Piece)

φ6

50

100

150

250

280

320

400

φ10

8

16

24

40

48

80

100

φ20

 

 

 

2

3

6

8

Note: The optimal numbers of balls equipped are the experience data obtained by users from practice according to the nature of milling materials and the required fineness.


b. Loading milling materials

Requirements on granularity of milling materials before ball milling: The granularity of short materials shall be no bigger than10mm, and that of the other materials shall be less than3mmgenerally. The loading of materials shall be no higher than three fourths of the cubage of the tank (including milling balls).

4.       Loading Ball Milling Tank

Immediately after loading of tank, we could install ball milling tanks inside the puller cover of ball mill. It is possible to install 4 ball milling tanks at the same time, or install 2 ball milling tanks symmetrically, and it’s forbidden to install only 1 or 3 ball milling tanks. After installation, make use of two force-applying bushing (accessory of this machine) to tighten V-type bolt and lock nut in succession to prevent milling tanks from loosening in the process of ball milling.

Note: It’s forbidden to knock at bolts and nuts with hammer when tightening them.

After loading of ball milling tanks, put on the protection cover and turn on the safety switch to make the ball mill operate normally. If any unexpected accident occurs in the process of ball milling, the protection cover will loosen or fall off, the safety switch will be off, and the ball mill will stop running immediately. In such conditions, it’s necessary to eliminate accidents first, put on the protection cover again, and then restart up the machine.

After completion of ball milling, loosen the lock nut and V-type bolt with force-applying bushing successively, and pour the testing samples and milling balls into the sieve (accessory of this machine) at the same time to make balls separate from milling materials.

Before ball milling over again, please check if the puller cover is loosened first, if it is, it’s a must to tighten the screws to avoid any accident.

Attention shall be paid to the unloading of ball milling tank. Due to the mutual impact between milling balls and between milling balls and ball milling tank in the process of ball milling, the temperature and pressure inside the tank after long-time ball milling will be very high. So, it’s necessary to cool down the ball milling tank before unloading it after completion of ball milling, so as to prevent milling powder from being blown out by high pressure. Some metal powder has ultrafine granularity after ball milling, and inside the tank is nearly vacuum state. In such conditions, if the tank cover is opened abruptly and the milling materials are poured out, such materials will be oxidized drastically and combusted. Therefore, after ball milling of active metal powder, it’s a must to open the tank slowly after sufficient cooling, pause for a moment, and then pour out the milling materials. And reclaiming materials inside vacuum glove box will exert better effects.

Ⅲ. Power Setting

 

1.       Electric machine selected: SIEMENS three phase, and 220V. Please see the wiring diagram of electrical appliance as shown in figure 5 for details. The wiring of this machine has already been conducted before it leaves the factory, so it shall not be changed at random.

2.       Transmission system: speed regulation by frequency variation is adopted with the scope of frequency variation between 0~50Hz.

3.       Rated rotating speed: Revolution 0~300turns / min; rotation: 0~600 turns / min; corresponding frequency: 0~50Hz. The frequency converter displays the speed of rotation.


Ⅳ. Description of Frequency Converter

 

(One) Technical Indexes of Frequency Converter

1.       Model: LB60G-2S0007BER;

2.       Input: Single phase 220V ± 10%, 50/60Hz;

3.       Output: Voltage three phase 0~240V, frequency 0~50Hz, rated current 4.5A, power 0.75KW, allowed overload 150% per minute;

4.       Indication: Frequency, rotating direction, rotating speed, voltage, current (digital display), abnormal indication (character indication), state display (light emitting diode red display);

5.       Requirements on ambient environment: The indoor altitude of the use place shall be below 1000 meters and free of corrosive gases, dust and direct sun shining; ambient temperature: -10 –40°C; humidity: 20 – 90% (without phenomenon of water bead coagulation); vibration: below0.6G.

6.       Function code table of frequency converter:

Function Code

Function Description

Set Scope

Exfactory Value

Cd01

Number of poles of electromotor

02 ~ 14

04

Cd02

Operating method

Note: “0”indicates unilateral operation, and “1”indicates alternative operation.

0 ~ 1

0

Cd03

Operating timing control

Note: “0”indicates non-fixed time (continuous), and “1”indicates fixed time.

0 ~ 1

0

Cd04

Time setting for alternative operation

Note: Take  min  as the unit.

1300.0

5

Cd05

Upper limit frequency

Note: Take Hz as the unit.

0.01 ~ 50

45

Cd06

Lower limit frequency

Note: Take Hz as the unit.

0 ~ 50

1

Cd07

Accelerating time

Note: The time from starting 0.5Hz to 50Hz with second as the unit.

0.1 ~ 3600

10

Cd08

Decelerating time

Note: The time from 50Hz to stopping 0.5Hz with second as the unit.

0.1 ~ 3600

15

Cd09

Setting of the drive ratio of coefficient dragged

0.10 ~ 200.00

0.43

Cd10

Display method

Note: “0”display frequency with power switched on, and “1”display rotating speed with power switched on.

0 ~ 1

0

Cd11

Operational method

Note: “0”indicates positive rotation, and “1”indicates reverse rotation.

0 ~ 1

0

Cd12

Fixed operating time

Note: Take  min  as the unit.

1999.0

10

Cd13

Current display correction

Note: Take A as the unit.

0.1 ~ 10

9

Cd14

Interval shutdown time of alternative operation

Note: The interval time of negative and reverse alternative rotations with  min  as the unit.

0.0999.0

10

Cd15

Operational interval shutdown time

Note: Circulating startup time in unilateral operation with  min as the unit.

0.0999.0

10

Cd16

Number of restarting for operation

0 ~ 100.

0











































Other description: Frequency converter will operate normally when X1-COM on the row of frequency converters of free stop and operation is short connected. When X1-COM is broken off, the frequency converter will stop freely.


7. Explanation on the operation and functions of contact panel 


Explanation on each serial number of contact panel:

1.       LED digital tube display zone: Display frequency, positive and reverse rotating direction, rotating speed, voltage, current and failure code, and function code etc..

2.       MENU/ESC menu selection and switching button: A switching button in the state of programming and monitoring, for switching between parameter display and programming menus. If this button is operated in the state of programming menu, it will return to the previous menu.

3.       ENTER/DATA function selection and saving button: Enter into the next menu in the state of programming, and finish the saving operation of parameters in the state of third-level menu.

4.   Up button: Increase by degrees of function code, menu group, or set parameter values.

5.  RUN Operation order button: To be used for starting frequency converter in the mode of panel control.

6.  ▼ Down button: Decrease by degrees of function code, menu group, or set parameter values.

7.  Unit indicator light: Green light indicates the state of rotating direction (F/R), frequency (Hz), rotating speed (Hz, v), voltage (v), and current (A) etc. respectively.

8.  ◣◣ Shift button: Shift the display of rotating direction, frequency, rotating speed, voltage and current and so on.

Change the modification digit of the set data, including from kilodigit to the two digits behind decimal point.

9.   JOG Inching button: This frequency converter has no such function.

10.  Operation indicator light: This light appears green when the frequency converter operates.

11.  STOP/RESET Stop order/ failure reset button: Press this button to stop the operation of frequency converter, and reset operation starts in the state of failure alarm. 

(A) Test running of frequency converter --- non-load operation of ball mill (with no ball milling tank installed)

1.       Connect three-phase and 380V alternative current to the ball mill.

2.       Turn on the power supply switch, and LED will display “P. OFF”, and will display in a flicker way “50.00”, Hz indicator light turns on.

3.       Press menu selection and switching button MENU/ESC, LED will display the function code “Cd01”.

4.       Press function selection and saving button ENTER/DATA, LED will display the current value of the function code “Cd01”, such as “04”(digit in ones place flickers). If modification is necessary, it’s possible to press or ▼ to set the value required. After setting, press the button ENTER/DATA once again, the value set will be confirmed and saved, and the next function code “Cd02”will be displayed at the same time. If this button is not pressed, the value already set will not be recognized by the frequency converter, and the previous value will remain effective.

5.       According to the demands of ball milling techniques, set each function code one by one as per the abovementioned method.

As for data setting, it’s possible to press shift button ◣◣ to make LED flicker display corresponding to the digit of data already set, so as to finish the data setting quickly.

6.       After setting Cd16, press the button ENTER/DATA to confirm and display “-b—“; after pressing the down button ▼, LED displays “Cd16”. If you continue pressing the button ▼, function code will decrease from Cd16 to Cd01 one by one.

Note: In the process of setting, if LED displays the symbols such as “-b— ”, “-R—”, “-P—”, “-H—”, “-d--”, and “-c--” etc., these are all the other functions of frequency converter and have nothing to do with the functions of ball mill, and you only need to press the button ▼ continuously to return to “Cd16”.

7.       Explanation on function code: Cd01, Cd05, Cd06, Cd07, Cd08, Cd09 and Cd13 are fixed exfactory values and shall not be changed, or the correctness of such parameters as rotating speed and current etc. will be affected.

Setting Cd07 and Cd08 is to keep a delaying interval between the positive and reverse alternative operation of electric machinery. Over mall setting value will possibly affect the life of electric machinery.

When Cd10 setting is “0”, LED display shows the frequency after the frequency converter is started up; and when the setting is “1”, LED display shows the rotating speed after the machine is started up.

When Cd11 setting is “0”, LED display shows positive rotation (ball mill operates deasil) after the frequency converter is started up; when the setting is “1”, LED display shows reverse rotation (ball mill operates widdershins) after the machine is started up.

8.       The start-up temperature of cooling axial fan of the frequency converter is43. When the working temperature of the frequency converter is over43, the axial fan will turn on automatically; on the contrary, when the working temperature is lower than43, it will turn off automatically.

9.       If the frequency converter is confirmed to work normally after the abovementioned operations, it’s possible to continue the non-load test running of ball mill.

10.   Put on the protection cover of ball mill, switch on the safety switch, and press the operation order button RUN, the operation indicator light will turn on and the ball mill will begin test running.

11.   Press the up button and down button ▼ for accelerating and decelerating testing of the ball mill.

12.   Adjust the rotating speed of the ball mill to the maximum rated rotating speed, and make it operate for some time before judging if the operation sound of the ball mill is normal.

13.   After everything is proved normal, press the stop order button STOP/RESET to make ball mill stop freely, and LED will restore its flicker display.

14.   About 5 seconds after the power switch is switched off, “P. OFF” will appear and then disappear.

 

(B) Test running of installing ball milling tank to ball mill

1.If the frequency converter and ball mill are proved fully normal after all of the above operations, it’s possible to install the ball milling tank with milling materials and milling balls inside it to the ball mill according to section II “Operational Procedures” of this manual.

2. Put on the protection cover, switch on the electric power source, and carry out the test running of ball mill.

 

(C) Practical examples of operation

Example 1: Unilateral operation with shutdown at non-fixed time.

Ball mill some testing sample with non-fixed long-time unilateral operation at the rotating speed of 400 turns / minute.

Setting: 1. cd02, set the operational method as unilateral operation “0”.

       2. cd03, set the control in operation as non-fixed time “0”.

       3. Press MENU/ESC button to make the display conduct flicker display.

       4. Press RUN button to make ball mill begin to work.

       5. Press ◣◣ button till two red lights turn on and display the rotation speed of ball mill.

       6. Press or ▼ button to adjust the speed to 400 turns / minute.

       7. After long time operation, press STOP/RESET button to shut down the machine manually.

       8. Switch off the power supply and the ball milling is completed.

 

Example 2: Unilateral operation with shutdown at fixed time.

Ball mill some testing sample with shutdown after 10h unilateral operation at the frequency of 40Hz.

Setting: 1. cd02, set the operational method as unilateral operation “0”.

       2. cd03, set the control in operation as fixed time “1”.

       3. cd12, set the operating time as “600.0”.

       4. cd16, set the number to operation and restarting times as “0”.

       5. Press MENU/ESC button to make the display conduct flicker display.

       6. Press RUN button to make ball mill begin to work.

       7. Press ◣◣ button till red light Hz turns on, and the display shows the frequency.

       8. Press or ▼  button to adjust the frequency to 40Hz.

       9. The machine will stop automatically after 10h ball milling.

       10. The ball milling is completed, switch off and disconnect the power supply.

 

Example 3: Positive and reverse alternative operation with shutdown at fixed time.

Carry out positive and reverse alternative operation of some testing sample every 1.5h, and the machine will shut down automatically 15h later.

Setting: 1. cd02, set the operational method as alternative operation “1”.

       2. cd03, set the control in operation as fixed time “1”.

       3. cd04, set the alternative operating time as 90

       4. cd12, set the operating time as 900

       5. cd14, set the interval time of alternative operation as “0.0”.

       6. cd16, set the number to operation and restarting times as “9”.

       7. Press MENU/ESC button to make the display conduct flicker display.

       8. Press RUN button to make ball mill begin to work.

       9. Same as the previous example, set the rotating speed or frequency as per related requirements.

       10. The machine will stop automatically 15h later, switch off and disconnect the power supply.

Note: In operation, the function code cd16 displays countdown, such as the countdown 9~0 displayed in this example.

 

Example 4: Unilateral interval operation with shutdown at fixed time.

Some testing sample requires 0.5h operation before 1h shutdown, and then continues 0.5h operation in the same direction before further 1h shutdown. Repeat such operation for 10 times before shutdown of the machine.

Setting: 1. cd02, set the operational method as unilateral operation “0”.

       2. cd03, set the control in operation as fixed time “1”.

       3. cd12, set the operating time as 30

       4. cd15, set the interval shutdown time as “60”.

       5. cd16, set the number to operation and restarting times as “9”.

       6. Press MENU/ESC button to make the display conduct flicker display.

       7. Press RUN button to make ball mill begin to work.

       8. Same as the previous example, set the rotating speed or frequency as per related requirements.

       9. The machine will stop automatically after 10 times of repeated operation, and then switch off and disconnect the power supply.

Note: In operation, the function code cd16 displays countdown, such as the countdown 9~0 displayed in this example.

 

Example 5: Positive and reverse alternative interval operation with shutdown at fixed time.

Some testing sample requires 0.8h operation in positive direction before 0.5h shutdown, and then 0.8h operation in reverse direction, and finally shutdown of the machine after 20 times of repeated operation.

Setting: 1. cd02, set the operational method as alternative operation “1”.

       2. cd03, set the control in operation as fixed time “1”.

       3. cd04, set the alternative operating time as 48.

       4. cd14, set the interval shutdown time of alternative operation as 30

       5. cd16, set the number to operation and restarting times as “19”.

       6. Press MENU/ESC button to make the display conduct flicker display.

       7. Press RUN button to make ball mill begin to work.

       8. Same as the previous example, set the rotating speed or frequency as per related requirements.

       9. The machine will stop automatically after 20 times of alternative circulation, and then switch off and disconnect the power supply.

 

(Three) Failure elimination of frequency converter

If any abnormal situation occurs to the frequency converter, its protection functions will work, LED will display the function code in a flicker way, failure output relay will work, frequency converter will stop output, and ball mill will stop automatically. After such failures are eliminated, press MENU/ESC button and then restart up the ball mill for operation.

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