第十一章   常见故障分析及排除

Chapter 11 Common Fault Analysis and Troubleshooting

一 、主电机控制系统过电流

1. Overcurrent of the main motor control system

1 、两磨辊间有较大的铁块或其他异物 ，处理方法入如下 ：

1. There is a large iron block or other foreign matter between the two grinding rollers. The treatment method is as follows:

1）卸掉液压系统高压，使用液压将移动辊退回来 ，检查确认是否有异物存在；

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）若因铁块进入而造成的电流 ，则应仔细检查铁块混入原因 ，检查除铁器的工作性能 。

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 、进料系统调节插板调得过高 ，调节插板端部过度磨损 ，断裂致使料饼厚度过厚 ，造成过负荷 。处理方法 ：

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）检查调节插板调节的位置 ，重新调整好插板 ，并用锁紧螺母定好 ；

1) Check the adjustment position of the plug-in board, readjust the plug-in board, and fix it with lock nut;

2）拆卸检修调节插板 。

2) Remove the overhaul adjustment board.

3 、主传动系统零 、部件损坏 ，传动阻力加大 ，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）检查传动系统各零 、部件的工作温度确定损坏的零部件 ；

1) Check the working temperature of the parts and components of the driving system to determine the damaged parts;

2）根据停车前设备发出的异常声音 ，确定损坏的零部件 ；

2) Determine the damaged parts according to the abnormal sound made by the equipment before stopping;

3）将各部分拆开 ，分别用手盘动 ，确定损坏的部位 。

3) Disassemble each part and turn it by hand to determine the damaged part.

4 、出料设备发生故障 ，物料堵塞辊压机出料口 ，造成磨辊驱动阻力加大 ，解决方法 ：

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）排除出料设备故障 ；

1) Troubleshoot the discharge equipment;

2）清理被堵塞的出料口 。

2) Clean the blocked discharge port.

5 、主电机的主回路或出现短路 、断路 ，接触不良或元件损坏 ，造成过电流 。

5. The main circuit of the main motor may have the short circuit, open circuit, poor contact or damaged components, resulting in overcurrent.

1）检查主回路的接线情况及导线发热情况 ；

1) Check the wiring of the main circuit and the heating of the wires;

2）检查元器件的工作情况及发热情况 ；

2) Check the working conditions and heating conditions of components;

3）检查控制回路各主要元 、器件的工作点；

3) Check the operating points of the main components and devices of the control loop;

4）更换损坏的元 、器件和导线 ，重新调整控制回路主要元 、器件的工作点 。

4) Replace damaged components, devices and wires, and readjust the operating points of the main components and components of the control loop.

二 、系统工艺设备按程序自动停车

2.  System process equipment automatically shuts down according to the program

系统工艺设备没有任何人操作的情况下 ，由计算机控制,顺序停车.出现此情况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.系统工艺设备中有一设备过负荷,检查各系统工艺设备的工作情况,排除设备故障 。

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.系统控制柜元 、器件接触不良.仔细检查系统控制柜的各元 、器件,尤其是接触器的接点,其工作状况是否正常 。

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.系统控制计算机本身出现故障,应请专业人员对其进行检修和更换 。

3. The system control computer itself fails, and professionals should be asked to repair and replace it.

三 、主传动系统工作异常

3. Abnormal operation of the main drive system

1.行星减速器运转出现异常声音;

1. The planetary reducer has abnormal sounds when it is running;

1)减速器内齿轮齿面过度磨损或折断.应拆卸减速器更换齿轮;

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)减速器内轴承损坏,应更换新轴承;

2) If the bearing in the reducer is damaged, a new bearing should be replaced;

3)润滑油过少或润滑油变质,更换或补充润滑油 。

3) Too little lubricating oil or lubricating oil deterioration, replace or supplement the lubricating oil.

2.万向节传动轴工作声音异常

2. The working sound of the universal joint drive shaft is abnormal

1)“+”字轴断裂,更换“+”字轴;

1) The "+" axis is broken, replace the "+" axis;

2)轴承座和底盘联接螺栓松动,重新按规定拧紧;

2) The connecting bolts of the bearing seat and the base plate are loose, and re-tighten according to the regulations;

3)“+”字轴轴承损坏,更换轴承;

3) "+" shaft bearing is damaged, replace the bearing;

4)“+”字轴轴承断油,应补充润滑脂 。

4) If the "+" shaft bearing is cut off, grease should be added.

3 、扭矩支承工作异常

3. The torque support works abnormally

1)蝶形弹簧发生疲劳断裂或塑性变形,重新更换蝶形弹簧;

1) If the butterfly spring has fatigue fracture or plastic deformation, replace the butterfly spring;

2)关节轴承损坏,应更换;

2) The joint bearing is damaged and should be replaced;

3)轴承磨损过度或损坏, 应更换;

3) The bearing is excessively worn or damaged and should be replaced;

4 、主轴与减速器的输出轴产生相对转动 。

4. The main shaft and the output shaft of the reducer rotate relative to each other.

1)在设备安装时未按规定要求进行,重新清理主轴轴颈和减速器输出轴,重新按规定安装;

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)若仍不能运转,则应与制造单位联系 ，商讨解决办法 。

2) If it still does not work, you should contact the manufacturer to discuss solutions.

5 、主轴承运转声音异常或轴承温度过高 。

5. The running sound of the main bearing is abnormal or the bearing temperature is too high.

1）主轴承过度磨损或滚柱断裂 ，此时应更换主轴承 ；

1) The main bearing is excessively worn or the roller is broken, and the main bearing should be replaced at this time;

2）润滑系统供油不正常 ，应检查润滑系统 ；

2) The lubrication system is not normally supplied with oil, and the lubrication system should be checked;

3）轴承内部混入异物 ，应考虑清洗轴承 ，更换密封圈 。

3) If foreign matter is mixed into the bearing, cleaning the bearing and replacing the sealing ring should be considered.

四 、液压系统工作不正常

4. Hydraulic system is not working properly

1 、液压系统压力打不上去或打上去后很短时间就降了下来 ，造成油泵频繁工作 。

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）阀门未关到或未开到位 ，应重新检查 ；

1) If the valve is not closed or opened in place, check again;

2）电磁方向阀因堵塞或其他原因其阀芯未到位 ，应按动几下电磁阀的按钮 ；

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）主溢流阀阀芯未完全闭合 。可启动闭合几次电磁阀 ；

3) The main relief valve spool is not fully closed. The solenoid valve can be started and closed several times;

4）液压泵站溢流阀失灵或未调好 。应检修或更换 ；

4) The overflow valve of the hydraulic pump station is malfunctioning or not adjusted properly. Should be overhauled or replaced;

5）系统中有外泄露 ，应停机修复 ；

5) There is external leakage in the system; it should be shut down for repair;

6）系统中油缸密封圈过度磨损或电磁方向阀 、主溢流阀的阀芯过度磨损造成内泄露 ，此时应更换这些过度磨损的零部件 。

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 、液压系统发生振荡

2. The hydraulic system oscillates

1）压力控制阀 ，主要是组合阀中的电磁换向阀和锥阀中有杂质堵塞 ，使其不能动作到位 。可启动几次电磁阀 ，若仍不能解除 ，则应拆除清洗这些阀 ，特别是主溢流阀 ；

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）由于液压系统工作压力与蓄能器充气压力相接近 ，造成蓄能器的频繁启闭产生震动 。

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 、润滑系统不能正常供油

5. The lubrication system cannot supply oil normally

1 、润滑泵站溢流口溢流

1. Overflow at the overflow of the lubrication pump station

1）润滑泵站限压阀压力调得过低 。处理方法 ：适当增加所限压力 ；

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 ，更换安全片 ；

2) If the safety piece is broken, replace the safety piece;

3）在润滑油路中 ，有油路被堵塞 。应从分油器检查被堵塞的油路 ，清洗被堵塞的分油器 ，管路或进油口 。发生此种情况 ，一般是因对所用油品管理不善 ，在给润滑泵充油时 ，未按要求使用充填泵充油 ，或者油泵出口的过滤网已经损坏造成的 ；

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）无论因何种原因发生溢流口溢流 ，都必须在处理完后 ，对限压阀重新进行调节 ，检查安全片和清洗过滤网 。

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 、润滑泵正常工作 ，但分油器不动作

2. The lubrication pump works normally, but the oil separator does not work

1）由于润滑油泵贮油筒空油 ，而空油警报装置失灵造成 ，重新充填润滑脂 ，检修警报系统 ；

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）因润滑泵活塞杆或活塞套过度磨损 ，失去功能 。此时应更换润滑泵 ；

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）穿在机器内部的输送油管或管接头漏油 。此时应仔细检查各油路和管接头 ，更换已损坏的油管和管接头 。

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 、挤压出的物料质量下降或粗颗粒增多

6. Quality of the extruded material decreases or the coarse particles increase

该种情况将会使整个磨粉产量降低 ，后续粉磨状况变差 。

This situation will reduce the overall milling output and the subsequent grinding conditions will become worse.

1 、挤压出的物料质量下降

1. The quality of the extruded material is reduced

1）液压系统压力过低 ，达不到预定的粉碎效果 。重新调节液压系统工作压力 ；

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）进料装置调节插板调得过低 ，使液压系统施加的挤压粉碎力未完全作用于挤压的物料上 ，其表现是 ：移动辊只是偶然做水平移动 。液压系统压力正常 ，但主电动机电流较小 ；

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）两轴承的轴承座之间被物料堵塞 ，造成两磨辊间原始辊缝加大 。同样会使液压系统所施加的挤压力未完全作用于被挤压的物料上 ，其表现与上相同 。

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 、挤压出的物料中粗颗粒增多

2. Increased coarse particles in the extruded material

1）上述的1） 、2）两条均使挤压的物料中颗粒增多 ；

1) Both 1) and 2) of the appeal increase the particles in the extruded material;

2）因侧挡板下端衬板过度磨损 ，使磨辊边缘影响区加大 ，造成大量物料未经挤压 ，通过磨辊 。此时应更换挡板下端衬板 。通过观察挤压出物料的颗粒组成和磨辊工作情况 ，可以判断是否应该更换侧挡板下端衬板 。

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.