In order to make the complete set of pellet feed processing equipment operate normally, prolong its service life, reduce failures, and improve economic benefits, the author puts forward some opinions for reference. 1 Installation and commissioning of equipment
1.1 Before installation, check whether the dimensions of each installation foundation meet the requirements of the drawings according to the equipment plan and foundation plan. If there is any discrepancy, it should be repaired until the dimensions are correct before installation.
1.2 The installer should be familiar with the installation requirements of each equipment first, and carry out construction in strict accordance with the technical requirements.
1.3 The equipment may be deformed, damaged or lost during transportation, so before installation, check and accept the equipment against the detailed list of equipment, and take corresponding measures to make the equipment in good condition before installation.
1.4 Before entering the installation site, each equipment should be numbered, and the installation process card and schedule should be formulated. According to the requirements of the installation process sequence, the equipment should be transferred to the site for installation one by one.
1.5 Installation sequence: from top to bottom, first place the host equipment and the rack in place, and then install the connecting pipes and electrical equipment.
1.6 Tools required for installation: Equipment and village materials must be available.
1.7 After installation, each rotating part of the equipment must rotate flexibly, without jamming, bumping and impact sound, and each connecting part must be firm and sealed, and there must be no leakage of powder, air or oil.
1.8 The installation of electrical equipment should comply with the relevant national regulations, the direction of each line should be clear, and there should be no leakage or leakage of electricity. The wires and cables should have protective casings to prevent mice from being bitten.
1.9 After the installation of all the equipment, each single machine should be tested with empty car, and can be put into load test after normal operation.
1.10 Before the load test, the electronic batching scale and packing scale should be calibrated, and the specified accuracy is required.
1.11 After the load runs for 8 hours, it can be handed over to the manufacturer for production and use after there is no fault. 2 Operation and use
2.1 The equipment shall be checked by the on-duty personnel of each post before driving.
2.1.1 Whether foreign objects fall into the equipment; whether each rotating part is flexible, whether there is jamming or bumping; whether each connecting part is firm; whether there is powder leakage, air leakage, oil leakage, etc. If there is a fault, it should be eliminated in time.
2.1.2 Whether there is lubricating oil for each gear; whether the tension of the transmission belt is appropriate; whether the hammer of the pulverizer, the die and the roller of the granulator need to be replaced; whether the specifications of the screen meet the requirements.
2.2 The on-duty personnel in the control room should master the daily production schedule and the storage volume of main and auxiliary materials in order to schedule production.
2.3 Sequence of operations
2.3.1 Turn on the main power switch first, and then place each system switch to the working position.
2.3.2 Turn on the audio signal switch to notify the staff to enter the workplace.
2.3.3 After completing all the preparatory work, the on-duty personnel in the control room determine the entry number of each material, assign each three-way valve to each corresponding position, start the dust removal fan first, and then turn on the switches according to the processing sequence.
126.96.36.199 The starting sequence of the raw material system: dust removal fan→pulverizing elevator→horizontal conveyor→raw material pulverizer→cleaning screen→raw material elevator. If the raw material system is shut down, it should be carried out in the reverse process of its start-up.
188.8.131.52 The stop and start of the auxiliary material system is roughly the same as that of the original grain system.
184.108.40.206 Batching and mixing system: The system has two control modes: manual and automatic. Manual batching can be carried out according to the pre-specified formula and mixing time, while automatic computer is used for automatic weighing batching and mixing time and other control work.
220.127.116.11 Granulation system: operated and started by a special control cabinet.
2.4 The duty personnel in the control room should always pay attention to observe the various signal lights on the analog screen. If the batching warehouse sends out a signal of empty warehouse or full warehouse, they should notify the relevant feeding personnel in time to operate the warehouse gate.
2.5 The staff should call out and input the required material formula according to the production arrangement, and use the computer and its auxiliary devices to operate correctly.
2.6 When operating the feeding device of the pulverizer and granulator, it should be ensured that the main motor works under the rated current without clogging.
2.7 Various trace elements, vitamins, etc., are input in proportion from the additive feeding port of the mixer. The mixer mixes a batch of materials once, and the input time is given by the control room when each batch of materials is first mixed. Put in the signal, put in in time. 3 Maintenance and Repair
3.1 Carry out maintenance and maintenance according to the requirements of each equipment instruction manual. If there are no special requirements, use ZG-3 calcium-based lubricating oil for bearing lubricating oil, HJ-60 mechanical oil for reducer lubricating oil, and HJ-20 mechanical oil if the room temperature is lower than -10℃ in winter.
3.2 The equipment should be repaired once in half a year and overhauled once in a year. During minor repairs, it is necessary to replace the lubricating oil, clean the bearings, and replace the damaged parts.
3.3 Adjust the tightness of the belt in time. When the machine is running, the belt must not have serious slippage.
3.4 The wearing parts such as hammers and sieves of the pulverizer, die and pressure rollers of the pelletizing system should be repaired, adjusted and replaced in time. The time of replacement, maintenance and adjustment depends on the productivity or product quality of the feed processing products. Generally, when the productivity drops significantly, the pellet forming rate and surface quality fail to meet the requirements, it should be adjusted or replaced in time.
3.5 After the hammers of the pulverizer are worn, they should be reversed or turned around, and the original arrangement of the hammers should be maintained when turning around. When all four corners are worn and new hammers need to be replaced, each group of new hammers should be weighed. The weight difference of each group of hammers should not exceed 5g. When installing, it must be assembled according to the hammer arrangement diagram to avoid strong shock.
3.6 After the electronic scale has been used for half a year, its accuracy should be checked and calibrated.
3.7 After each shift, the bean cake powder should be used in the pellet machine cavity to punch out the residue in the die hole.
3.8 The computer control room is often kept clean and quiet 4 General faults and troubleshooting methods
4.1 The pulverizer vibrates strongly and makes a lot of noise. The reasons may be:
4.1.1 If the arrangement of the hammers is wrong, the hammers should be re-installed according to the arrangement diagram of the hammers;
4.1.2 If the individual hammers are stuck in the pins and are not thrown away, they should be dealt with in time;
4.1.3 If the fixing bolts of the pulverizer bearing seat are loose or the bearing is damaged, it should be repaired or replaced in time.
4.1.4 After the hammer of the pulverizer or the impeller of its own fan is worn, the balance of the rotor is destroyed, and the relevant parts should be replaced in time.
If the inspection is not for the above reasons, it may be that the weight difference between the two groups of hammers on the corresponding pin shaft of the pulverizer rotor is too large, and the corresponding two groups of hammers should be re-selected so that the weight difference does not exceed 5g.
4.2 The ash returning from the feeding port of the pulverizer is generally due to the excessive feeding amount, which causes the insufficient lifting capacity of the pulverizer fan and blocks the screen and suction pipe. At this time, it is necessary to stop the machine in time to remove the accumulated material in the upper and lower cavities of the pulverizer screen, clear the suction pipe, and readjust the feeding amount of the pulverizer.
4.3 Abnormal noise in the pulverizer is generally caused by large pieces of hard objects entering the pulverizer, or parts in the machine falling off and flowing water in the pulverizing chamber. When this situation is found, the machine should be stopped immediately, the crushing chamber should be checked and foreign objects should be excluded.
4.4 The particles of finished batch materials are too coarse, which is generally due to the occurrence of holes in the sieve after abrasion or the impact of foreign objects, or the improper installation of the sieve, and the poor fit between the sieve edge and the sieve. should be dealt with accordingly.
4.5 The fluidity of the mixer is poor and the mixing uniformity is not enough. It may be due to the damage of the broken arch plate in the mixer or the looseness of the transmission belt. Check the position of the broken arch plate or the tightness of the transmission belt in time.
4.6 Excessive dust in the operation area is mainly due to the fact that the mouth of the dust removal cloth bag is not fastened tightly, the joints of the feeding pipe and the upper cover of the mixer are not tightly sealed, resulting in dust leakage. In addition, the fan casing, the elbow of the feeding pipe, and the suction pipe use a section After time, there may also be holes and holes caused by wear and tear. Therefore, if too much dust is found, the above parts should be checked and dealt with in time.
4.7 Weakness and overheating of the motor The weakness of the motor may be due to the open circuit of one phase in the three-phase circuit of the motor, and the overheating of the motor may be due to the short circuit of the internal circuit of the motor or the long-term overload operation. At this time, stop the machine in time, and ask an electrician to check the electrical equipment or adjust the workload.
4.8 The pellet machine does not produce material The reasons may be:
4.8.1 If the feeding port and agitator are blocked, the blockage should be removed in time;
4.8.2 If the die hole is blocked, the die hole should be opened;
4.8.3 If the moisture content of the raw material is too high or too low, the amount of steam should be adjusted;
4.8.4 If the gap between the die and the roller is too large, the gap should be adjusted to meet the requirements.
4.9 The signal light on the analog screen does not light up. The reasons may be:
4.9.1 If the level device is damaged, it should be replaced with a new one;
4.9.2 If the circuit of the level controller is in poor contact, the circuit should be checked and dealt with;
4.9.3 The bulb is broken and should be replaced.
4.10 Significant decline in productivity may be due to:
4.10.1 If the hammer is worn, the hammer should be replaced or the angle should be adjusted;
4.10.2 If the sieve hole is blocked, the sieve hole should be cleaned;
4.10.3 The pressing roller is worn, repair or replace the pressing roller;
4.10.4 The voltage drops to avoid the peak of electricity consumption;
4.10.5 If the steam supply is insufficient, check the pressure gauge and increase the steam volume and pressure;
4.10.6 If the feeding amount is too small, check the feeding device and adjust it;
4.10.7 Part of the die holes are blocked, remove the blockage.