第十一章 常見故障分析及排除
Chapter 11 Common Fault Analysis and Troubleshooting
一、主電機(jī)控制系統(tǒng)過電流
1. Overcurrent of the main motor control system
1、兩磨輥間有較大的鐵塊或其他異物，處理方法入如下：
1. There is a large iron block or other foreign matter between the two grinding rollers. The treatment method is as follows:
1）卸掉液壓系統(tǒng)高壓，使用液壓將移動(dòng)輥退回來，檢查確認(rèn)是否有異物存在；
1) Disconnect the high pressure of the hydraulic system, use hydraulic pressure to return the moving roller, and check whether there is any foreign matter;
2）若因鐵塊進(jìn)入而造成的電流，則應(yīng)仔細(xì)檢查鐵塊混入原因，檢查除鐵器的工作性能。
2) If the current is caused by the entry of iron, you should carefully check the reason for the iron mixing, and check the working performance of the iron separator.
2、進(jìn)料系統(tǒng)調(diào)節(jié)插板調(diào)得過高，調(diào)節(jié)插板端部過度磨損，斷裂致使料餅厚度過厚，造成過負(fù)荷。處理方法：
2. The feed system adjustment insert is adjusted too high, the end of the adjustment insert is excessively worn, and the fracture causes the thickness of the cake to be too thick, causing overload. Approach:
1）檢查調(diào)節(jié)插板調(diào)節(jié)的位置，重新調(diào)整好插板，并用鎖緊螺母定好；
1) Check the adjustment position of the plug-in board, readjust the plug-in board, and fix it with lock nut;
2）拆卸檢修調(diào)節(jié)插板。
2) Remove the overhaul adjustment board.
3、主傳動(dòng)系統(tǒng)零、部件損壞，傳動(dòng)阻力加大，查找的方法：
3. The main driving system is damaged and its components are damaged, and the driving resistance is increased. How to find:
1）檢查傳動(dòng)系統(tǒng)各零、部件的工作溫度確定損壞的零部件；
1) Check the working temperature of the parts and components of the driving system to determine the damaged parts;
2）根據(jù)停車前設(shè)備發(fā)出的異常聲音，確定損壞的零部件；
2) Determine the damaged parts according to the abnormal sound made by the equipment before stopping;
3）將各部分拆開，分別用手盤動(dòng)，確定損壞的部位。
3) Disassemble each part and turn it by hand to determine the damaged part.
4、出料設(shè)備發(fā)生故障，物料堵塞輥壓機(jī)出料口，造成磨輥驅(qū)動(dòng)阻力加大，解決方法：
4. The discharging equipment fails, and the material blocks the discharge port of the roller press, causing the driving resistance of the grinding roller to increase. Solution:
1）排除出料設(shè)備故障；
1) Troubleshoot the discharge equipment;
2）清理被堵塞的出料口。
2) Clean the blocked discharge port.
5、主電機(jī)的主回路或出現(xiàn)短路、斷路，接觸不良或元件損壞，造成過電流。
5. The main circuit of the main motor may have the short circuit, open circuit, poor contact or damaged components, resulting in overcurrent.
1）檢查主回路的接線情況及導(dǎo)線發(fā)熱情況；
1) Check the wiring of the main circuit and the heating of the wires;
2）檢查元器件的工作情況及發(fā)熱情況；
2) Check the working conditions and heating conditions of components;
3）檢查控制回路各主要元、器件的工作點(diǎn)；
3) Check the operating points of the main components and devices of the control loop;
4）更換損壞的元、器件和導(dǎo)線，重新調(diào)整控制回路主要元、器件的工作點(diǎn)。
4) Replace damaged components, devices and wires, and readjust the operating points of the main components and components of the control loop.
二、系統(tǒng)工藝設(shè)備按程序自動(dòng)停車
2. System process equipment automatically shuts down according to the program
系統(tǒng)工藝設(shè)備沒有任何人操作的情況下，由計(jì)算機(jī)控制,順序停車.出現(xiàn)此情況可能是由如下原因造成的:
The system process equipment is controlled by the computer and stopped in sequence without anyone operating. This situation may be caused by the following reasons:
1.系統(tǒng)工藝設(shè)備中有一設(shè)備過負(fù)荷,檢查各系統(tǒng)工藝設(shè)備的工作情況,排除設(shè)備故障。
1. One of the system's process equipment is overloaded. Check the working conditions of the system's process equipment and troubleshoot the equipment.
2.系統(tǒng)控制柜元、器件接觸不良.仔細(xì)檢查系統(tǒng)控制柜的各元、器件,尤其是接觸器的接點(diǎn),其工作狀況是否正常。
2. Poor contact of system control cabinet elements and devices. Carefully check each element and device of the system control cabinet, especially the contacts of the contactor, whether their working conditions are normal.
3.系統(tǒng)控制計(jì)算機(jī)本身出現(xiàn)故障,應(yīng)請(qǐng)專業(yè)人員對(duì)其進(jìn)行檢修和更換。
3. The system control computer itself fails, and professionals should be asked to repair and replace it.
三、主傳動(dòng)系統(tǒng)工作異常
3. Abnormal operation of the main drive system
1.行星減速器運(yùn)轉(zhuǎn)出現(xiàn)異常聲音;
1. The planetary reducer has abnormal sounds when it is running;
1)減速器內(nèi)齒輪齒面過度磨損或折斷.應(yīng)拆卸減速器更換齒輪;
1) The tooth surface of the internal gear of the reducer is excessively worn or broken. The reducer should be disassembled to replace the gear;
2)減速器內(nèi)軸承損壞,應(yīng)更換新軸承;
2) If the bearing in the reducer is damaged, a new bearing should be replaced;
3)潤(rùn)滑油過少或潤(rùn)滑油變質(zhì),更換或補(bǔ)充潤(rùn)滑油。
3) Too little lubricating oil or lubricating oil deterioration, replace or supplement the lubricating oil.
2.萬向節(jié)傳動(dòng)軸工作聲音異常
2. The working sound of the universal joint drive shaft is abnormal
1)“+”字軸斷裂,更換“+”字軸;
1) The "+" axis is broken, replace the "+" axis;
2)軸承座和底盤聯(lián)接螺栓松動(dòng),重新按規(guī)定擰緊;
2) The connecting bolts of the bearing seat and the base plate are loose, and re-tighten according to the regulations;
3)“+”字軸軸承損壞,更換軸承;
3) "+" shaft bearing is damaged, replace the bearing;
4)“+”字軸軸承斷油,應(yīng)補(bǔ)充潤(rùn)滑脂。
4) If the "+" shaft bearing is cut off, grease should be added.
3、扭矩支承工作異常
3. The torque support works abnormally
1)蝶形彈簧發(fā)生疲勞斷裂或塑性變形,重新更換蝶形彈簧;
1) If the butterfly spring has fatigue fracture or plastic deformation, replace the butterfly spring;
2)關(guān)節(jié)軸承損壞,應(yīng)更換;
2) The joint bearing is damaged and should be replaced;
3)軸承磨損過度或損壞, 應(yīng)更換;
3) The bearing is excessively worn or damaged and should be replaced;
4、主軸與減速器的輸出軸產(chǎn)生相對(duì)轉(zhuǎn)動(dòng)。
4. The main shaft and the output shaft of the reducer rotate relative to each other.
1)在設(shè)備安裝時(shí)未按規(guī)定要求進(jìn)行,重新清理主軸軸頸和減速器輸出軸,重新按規(guī)定安裝;
1) If the equipment is not installed in accordance with the specified requirements, re-clean the main shaft journal and the output shaft of the reducer, and reinstall according to the regulations;
2)若仍不能運(yùn)轉(zhuǎn),則應(yīng)與制造單位聯(lián)系，商討解決辦法。
2) If it still does not work, you should contact the manufacturer to discuss solutions.
5、主軸承運(yùn)轉(zhuǎn)聲音異�；蜉S承溫度過高。
5. The running sound of the main bearing is abnormal or the bearing temperature is too high.
1）主軸承過度磨損或滾柱斷裂，此時(shí)應(yīng)更換主軸承；
1) The main bearing is excessively worn or the roller is broken, and the main bearing should be replaced at this time;
2）潤(rùn)滑系統(tǒng)供油不正常，應(yīng)檢查潤(rùn)滑系統(tǒng)；
2) The lubrication system is not normally supplied with oil, and the lubrication system should be checked;
3）軸承內(nèi)部混入異物，應(yīng)考慮清洗軸承，更換密封圈。
3) If foreign matter is mixed into the bearing, cleaning the bearing and replacing the sealing ring should be considered.
四、液壓系統(tǒng)工作不正常
4. Hydraulic system is not working properly
1、液壓系統(tǒng)壓力打不上去或打上去后很短時(shí)間就降了下來，造成油泵頻繁工作。
1. The pressure of the hydraulic system can't rise or it drops down within a short time after it is hit, causing the oil pump to work frequently.
1）閥門未關(guān)到或未開到位，應(yīng)重新檢查；
1) If the valve is not closed or opened in place, check again;
2）電磁方向閥因堵塞或其他原因其閥芯未到位，應(yīng)按動(dòng)幾下電磁閥的按鈕；
2) The valve core of the solenoid directional valve is not in place due to blockage or other reasons. Press the button of the solenoid valve several times;
3）主溢流閥閥芯未完全閉合�？蓡�(dòng)閉合幾次電磁閥；
3) The main relief valve spool is not fully closed. The solenoid valve can be started and closed several times;
4）液壓泵站溢流閥失靈或未調(diào)好。應(yīng)檢修或更換；
4) The overflow valve of the hydraulic pump station is malfunctioning or not adjusted properly. Should be overhauled or replaced;
5）系統(tǒng)中有外泄露，應(yīng)停機(jī)修復(fù)；
5) There is external leakage in the system; it should be shut down for repair;
6）系統(tǒng)中油缸密封圈過度磨損或電磁方向閥、主溢流閥的閥芯過度磨損造成內(nèi)泄露，此時(shí)應(yīng)更換這些過度磨損的零部件。
6) Excessive wear of the oil cylinder sealing ring in the system or excessive wear of the valve cores of the solenoid directional valve and the main relief valve cause internal leakage. At this time, these excessively worn parts should be replaced.
2、液壓系統(tǒng)發(fā)生振蕩
2. The hydraulic system oscillates
1）壓力控制閥，主要是組合閥中的電磁換向閥和錐閥中有雜質(zhì)堵塞，使其不能動(dòng)作到位�？蓡�(dòng)幾次電磁閥，若仍不能解除，則應(yīng)拆除清洗這些閥，特別是主溢流閥；
1) The pressure control valve is mainly because the electromagnetic reversing valve and poppet valve in the combination valve are blocked by impurities, making it unable to move in place. The solenoid valve can be activated several times. If it still cannot be released, these valves should be removed and cleaned, especially the main relief valve;
2）由于液壓系統(tǒng)工作壓力與蓄能器充氣壓力相接近，造成蓄能器的頻繁啟閉產(chǎn)生震動(dòng)。
2) Since the working pressure of the hydraulic system is close to the charging pressure of the accumulator, the frequent opening and closing of the accumulator causes vibration.
五、潤(rùn)滑系統(tǒng)不能正常供油
5. The lubrication system cannot supply oil normally
1、潤(rùn)滑泵站溢流口溢流
1. Overflow at the overflow of the lubrication pump station
1）潤(rùn)滑泵站限壓閥壓力調(diào)得過低。處理方法：適當(dāng)增加所限壓力；
1) The pressure of the pressure limiting valve of the lubrication pump station is adjusted too low. Treatment method: appropriately increase the limited pressure;
2）安全片破裂，更換安全片；
2) If the safety piece is broken, replace the safety piece;
3）在潤(rùn)滑油路中，有油路被堵塞。應(yīng)從分油器檢查被堵塞的油路，清洗被堵塞的分油器，管路或進(jìn)油口。發(fā)生此種情況，一般是因?qū)λ糜推饭芾聿簧疲诮o潤(rùn)滑泵充油時(shí)，未按要求使用充填泵充油，或者油泵出口的過濾網(wǎng)已經(jīng)損壞造成的；
3) In the lubricating oil circuit, the oil circuit is blocked. Check the blocked oil passage from the oil separator and clean the blocked oil separator, pipeline or oil inlet. This situation is generally due to poor management of the oil used, when filling the lubrication pump, failing to use the filling pump to fill the oil as required, or the filter at the oil pump outlet has been damaged;
4）無論因何種原因發(fā)生溢流口溢流，都必須在處理完后，對(duì)限壓閥重新進(jìn)行調(diào)節(jié)，檢查安全片和清洗過濾網(wǎng)。
4) Regardless of the overflow of the overflow port for any reason, the pressure limiting valve must be re-adjusted after the treatment is completed, the safety disc and the filter screen must be cleaned.
2、潤(rùn)滑泵正常工作，但分油器不動(dòng)作
2. The lubrication pump works normally, but the oil separator does not work
1）由于潤(rùn)滑油泵貯油筒空油，而空油警報(bào)裝置失靈造成，重新充填潤(rùn)滑脂，檢修警報(bào)系統(tǒng)；
1) As the lubricating oil pump reservoir is empty and the empty oil alarm device fails, refill the grease and overhaul the alarm system;
2）因潤(rùn)滑泵活塞桿或活塞套過度磨損，失去功能。此時(shí)應(yīng)更換潤(rùn)滑泵；
2) The lubrication pump piston rod or piston sleeve is excessively worn and loses its function. At this time, the lubrication pump should be replaced;
3）穿在機(jī)器內(nèi)部的輸送油管或管接頭漏油。此時(shí)應(yīng)仔細(xì)檢查各油路和管接頭，更換已損壞的油管和管接頭。
3) The oil delivery pipe or pipe joint running inside the machine is leaking. At this time, carefully check the oil circuits and pipe joints, and replace the damaged oil pipes and pipe joints.
六、擠壓出的物料質(zhì)量下降或粗顆粒增多
6. Quality of the extruded material decreases or the coarse particles increase
該種情況將會(huì)使整個(gè)磨粉產(chǎn)量降低，后續(xù)粉磨狀況變差。
This situation will reduce the overall milling output and the subsequent grinding conditions will become worse.
1、擠壓出的物料質(zhì)量下降
1. The quality of the extruded material is reduced
1）液壓系統(tǒng)壓力過低，達(dá)不到預(yù)定的粉碎效果。重新調(diào)節(jié)液壓系統(tǒng)工作壓力；
1) The pressure of the hydraulic system is too low to achieve the predetermined crushing effect. Readjust the working pressure of the hydraulic system;
2）進(jìn)料裝置調(diào)節(jié)插板調(diào)得過低，使液壓系統(tǒng)施加的擠壓粉碎力未完全作用于擠壓的物料上，其表現(xiàn)是：移動(dòng)輥只是偶然做水平移動(dòng)。液壓系統(tǒng)壓力正常，但主電動(dòng)機(jī)電流較小；
2) The adjusting flap of the feeding device is adjusted too low, so that the crushing force exerted by the hydraulic system does not completely act on the squeezed material. Its performance is: the moving roller only moves horizontally by accident. The hydraulic system pressure is normal, but the main motor current is small;
3）兩軸承的軸承座之間被物料堵塞，造成兩磨輥間原始輥縫加大。同樣會(huì)使液壓系統(tǒng)所施加的擠壓力未完全作用于被擠壓的物料上，其表現(xiàn)與上相同。
3) The material is blocked between the bearing seats of the two bearings, causing the original roll gap between the two grinding rollers to increase. It will also cause the squeezing force exerted by the hydraulic system to not completely act on the squeezed material, and its performance is the same as above.
2、擠壓出的物料中粗顆粒增多
2. Increased coarse particles in the extruded material
1）上述的1）、2）兩條均使擠壓的物料中顆粒增多；
1) Both 1) and 2) of the appeal increase the particles in the extruded material;
2）因側(cè)擋板下端襯板過度磨損，使磨輥邊緣影響區(qū)加大，造成大量物料未經(jīng)擠壓，通過磨輥。此時(shí)應(yīng)更換擋板下端襯板。通過觀察擠壓出物料的顆粒組成和磨輥工作情況，可以判斷是否應(yīng)該更換側(cè)擋板下端襯板。
2) Due to the excessive wear of the lining plate at the lower end of the side baffle, the affected area of the grinding roller edge is enlarged, causing a large amount of materials to pass through the grinding roller without being squeezed. At this time, the bottom liner of the baffle should be replaced. By observing the particle composition of the extruded material and the working condition of the grinding roller, it can be judged whether the lower end lining plate of the side baffle should be replaced.
