Equipment startup and operation failures
1. The motor cannot start
Possible reasons: The power supply is not connected or the voltage is unstable; The thermal relay tripped due to overload; The cutterhead is stuck, causing a protective shutdown of the motor.
Solution: Check the power lines, switches, and fuses to ensure stable voltage (it is recommended to configure a voltage regulator); Press the reset button of the thermal relay and investigate the cause of overload (such as excessive material or foreign object blockage); Manually reverse the cutter head to try to remove the jam. If it fails, stop the machine and clean up any foreign objects.
2. Sudden shutdown during operation
Possible reasons: Motor overheating triggers protection mechanism; Belt slippage or breakage; Control system components (such as contactors, sensors) malfunction.
Solution: Stop the cooling motor, check if the cooling fan is working properly, and clean the dust accumulation on the motor casing; Adjust the tension of the belt or replace the worn belt (it is recommended to stock spare belts); Contact the manufacturer to test the parameters of the PLC or frequency converter and replace faulty electrical components.
Abnormal crushing effect
1. Decreased crushing efficiency
- Phenomenon: Decreased processing capacity per unit time; The particle size of the discharged material is uneven.
- Possible reasons: blade wear, notches, or installation angle deviation; The sieve aperture is blocked or damaged; The material hardness exceeds the equipment design range.
- Solution: Regularly check the sharpness of the blade and replace it if the wear exceeds 30%; Calibrate the blade clearance (refer to the standard value in the instruction manual); Clean up the residue of the screen mesh and replace the deformed/damaged screen mesh; Avoid breaking high hardness impurities such as metal and glass, and install magnetic separation devices if necessary.
2. The discharge contains unbroken whole material
- Possible reasons: Excessive feeding speed leading to material accumulation; The gap between the blade and the sieve is too large; The material size exceeds the capacity of the crushing chamber.
- Solution: Adjust the feeding speed and adopt a uniform feeding method; Adjust the gap between the blade and the sieve to 1-3mm (fine tune according to the material type; pre cut large pieces of material to ensure that the size meets the equipment requirements).
Equipment abnormal noise and vibration
1. Metal friction sound appears in the line
(1) Possible reasons: The blade comes into contact with the sieve or crushing chamber wall; Bearing oil shortage or damage; Loose fixing bolts cause component displacement.
(2) Solution: Immediately stop the machine and check the position of the blade, then re tighten the fixing bolts of the blade shaft; Add high-temperature lubricating grease to the bearings. If the noise persists, replace the bearings; Regularly use a torque wrench to check the bolts in various parts of the equipment.
2. Abnormal vibration of the whole machine
(1) Possible reasons: Loose anchor bolts or uneven foundation; Rotor dynamic balance imbalance (common after long-term use); The material distribution inside the crushing chamber is uneven.
(2) Solution: Flatten the foundation and reinforce the bolts. It is recommended to install the equipment on a concrete base; Contact the manufacturer to perform dynamic balance calibration on the rotor; Optimize the feeding method to avoid material accumulation on one side.
Overheating and wear of equipment
1. The bearing temperature is too high
(1) Possible reasons: Insufficient or deteriorated lubricating grease; Bearing seal failure leads to dust intrusion; Tightening the belt increases additional load.
(2) Solution: Add lubricating grease every 8 hours of operation, thoroughly clean the bearings every quarter, and replace the grease; Replace the sealing ring and install a dust cover; Adjust the belt to the appropriate tension (press the middle to sink 5-10mm).
2. Rapid wear and tear of blades
(1) Possible reasons: The material does not meet the standard (such as not using SKD11/D2 tool steel); Crushing materials containing fibers or reinforcing agents (fiberglass); The cooling system malfunction caused the blade to undergo high-temperature annealing.
(2) Solution: Choose high hardness blades treated with nitriding and regularly flip the blades to extend their lifespan; Purchase specialized wear-resistant blades for special materials; Check the operation status of the water cooling system pipeline or air cooling fan.
Daily maintenance and preventive measures
1. Daily mandatory inspection items
- Clean the residual plastic debris from the sieve and crushing chamber.
- Check if the hydraulic system pressure (if any) is within the standard range of 20-25MPa.
- Monitor the running sound and immediately investigate if any abnormal noise is found.
2. Weekly maintenance focus
- Fully tighten all bolts (especially the blade shaft area).
- Check if the wiring terminals of the electrical cabinet are oxidized or loose.
- Clean the filter cartridge of the dust removal system and maintain normal negative pressure.
3. Precautions for long-term shutdown
- Drain the water from the cooling pipeline to prevent rusting.
- Apply rust proof oil to the blade and wrap it with plastic film.
- Disconnect the main power supply and cover the equipment to prevent dust.
Principles for handling emergency situations
1. Immediate shutdown scenario: The equipment emits smoke or a burnt smell; Metal parts turn red (overheated); The safety cover has come off.
2. Prohibited operating behavior: reaching into the crushing chamber before completely stopping the machine; Replace key components with non original parts; Adjusting the rated parameters of the frequency converter without authorization.
Conclusion
By using the above troubleshooting and maintenance methods, the efficiency of equipment use can be significantly improved. It is recommended to keep the equipment manual and manufacturer's service hotline, as complex faults still require professional engineers to handle. Reasonable usage habits combined with preventive maintenance can extend the lifespan of equipment by 3-5 years, truly achieving cost reduction and efficiency improvement.
