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The cause of the failure is in the extrusion granulation unit, which causes the friction cleavage unit to disengage during operation. The reasons for the interlocking of the unit can be divided into four categories:
Main motor system failure 1. Main motor torque is too high or too low; 2. Main motor speed is too low; 3. Main motor bearing temperature is too high; 4. Main motor winding temperature is too high; 5. Main motor water-cooled cooler inlet and outlet The temperature is too high; 6, the main motor bearing lubricant pump outlet flow is too low; 7, the main motor bearing lubricant pump outlet pressure is too low; 8, the main motor water-cooled cooler water leakage is too high.
Transmission system failure 1. Gearbox shift lever position deviation; 2. Friction clutch instrument wind pressure is too high; 3. Friction clutch speed difference is too large; 4. Gearbox lubricating oil pump outlet pressure is too low; 5. Gearbox lubricating oil pump outlet The oil temperature is too high; 6, the internal friction of the friction clutch.
Extrusion granulator screw process section failure 1. The melt pressure before and after the throttle valve is too high; 2. The melt pressure of the machine head is too high; 3. The melt pressure difference before and after the change of the screen is too large; 4. The rotation of the driving valve is faulty. Wait.
Underwater pelletizing system failure 1. The temperature of the pelletizing motor winding is too high; 2. The speed of the pelletizer is too low; 3. The torque of the pelletizer is too high; 4. The automatic switching of the particulate water bypass is faulty; 5. The water pressure of the pellet is too high. Or too low; 6, the particle water flow is too low; 7, the pelletizer clamping bolt is not tight; 8, the pelletizing chamber bypass water valve is not closed; 9, the pelletizer hydraulic clamping pressure is too low; The pelletizing motor is faulty; 11. The axial cutting pressure of the hydraulic cutter is too low.
Among the above-mentioned fault causes, the frequency of occurrence is more: the main motor torque of the main motor system is too high or too low; the friction clutch of the transmission system is faulty; the melt pressure of the system of the extrusion granulator screw process section is high; Granulator system failure, etc. The following is a detailed analysis of these common causes of failure, and the corresponding solutions are given.
Analysis of common fault causes and solutions for the main motor torque is too high:
In the case of oil lubrication system failure, the main motor output shaft and the gearbox inlet and outlet shafts are poorly aligned, and the motor and clutch vibrations will damage the main motor bearings, resulting in excessive torque. In addition, too much feed load or poor material melting can cause excessive torque in the main motor.
solution:
The lubricating oil system is inspected and cleaned regularly, and the main motor bearing is measured with a vibration measuring instrument and an infrared thermometer to form a trend graph. If the trend value is exceeded, determine whether the main motor idle current value or power value exceeds the specified value to determine whether the bearing should be replaced. Regularly check the alignment between the main motor output shaft and the gearbox input shaft. The alignment must be checked after three months of initial or replacement bearing operation. Perform an electrical test to determine the cause of the rotor imbalance; perform a vibration speed test on the clutch and re-adjust the dynamic balance if the specified value is exceeded. Regularly check the heating and cooling system of the cylinder to ensure that the material is evenly melted by heat. If the extruder motor starts instantaneously, the main motor power curve and the melt pressure curve increase instantaneously, indicating that the feeding amount of the feeding system is too large, and the feeding amount should be reduced.
Analysis of the main motor torque is too low:
Failure of the feed system causes the twin-screw idle to cause the main motor torque to be too low.
solution:
Check to see if the additive system or main material blanking system is faulty and clean the plugging point.
Analysis of the cause of friction clutch failure:
The instantaneous starting voltage of the main motor is too low, the friction disc and the friction plate are overheated, the friction disc and the friction disc are aging, and the air pressure of the friction disc is too low, which can cause the clutch to disengage.
solution:
When the main motor starts, avoid the peak of power consumption and reduce the feeding load. The interval between restarts is shorter than 30 minutes. In the summer, when the main motor is restarted more than twice, the interval should be extended or the fan should be used. Forced cooling. Use the instrument wind to sweep and wipe the surface of the friction plate and the friction plate with a rag. If the wear is heavy or the surface is “vitrifiedâ€, the friction plate and friction plate should be replaced. Check if the air pressure value matches the friction disc to the friction plate.
High melt pressure analysis:
The filter mesh has a high mesh number, the polypropylene powder has a low melt index and a large feed amount, and the low temperature of each cylinder causes the material to be incompletely melted, and the template opening ratio is low, so that the extrusion of the head material is hindered, etc., which can cause melt pressure. Too high.
solution:
When producing low melt index products, use a low mesh filter to increase the throttle opening to reduce back pressure; replace the filter in time, monitor the quality of various additives and the ash content of the polypropylene powder. Reduce the feed load. Under the condition that the quality of the extruded product is not affected, the temperature of each barrel is increased, the temperature of the polypropylene melt is increased, and the fluidity of the material is increased. After the extruder has stopped, increase the temperature of the head and keep it constant for a period of time, then rinse the template thoroughly.
Analysis of the causes of underwater pelletizing system failure:
Excessive cutter wear or cutting edge damage, particle water flow is too low, the pelletizer vibration is too large, the cutter is not tightly attached to the template, the material melt index fluctuates greatly, the discharge flow rate is inconsistent, the particle water temperature is too high, etc. It can cause the underwater pelletizing system to stop and cause the entire unit to interlock and stop.
solution:
After parking, visually inspect the cutting edge for excessive wear or damage, and if so, replace the cutter. Check and confirm whether the granule water leaks inside, whether the granule water tank filter and the cooler are blocked. If the clogging should be cleaned manually; check whether the inlet and outlet pressure of the granule water pump is normal. If it is not normal, check the valve on the granule water pump and the pump line. Check whether the alignment between the cutter shaft and the pelletizing motor is out of tolerance, whether the bearing assembly of the cutter shaft is damaged, and whether the rotor balance of the cutter rotor is out of balance. During operation, check whether there is a gap between the four moving wheels of the pelletizing cart and the guide rail. Controls the volatiles in the polypropylene powder to eliminate vibrations on the cutter and cutter shaft as it flows through the die orifice. Reduce the temperature of the hot oil at the template, check the temperature distribution of the cylinder and the template, whether the flow, pressure and temperature of the cooling water of the cylinder are normal; confirm the time setting of "water, knife and material" reaching the template to prevent the pellet water from prematurely Arriving the template freezes the template holes. After the pelletizer is closed on the machine head, the feed rate should be quickly increased to the set load of the extruder.
If the above fault cause points can be combined with the logical relationship of the interlock to be compiled into fault diagnosis software, it can provide quick and intuitive reference and help for the operation, maintenance and management of the unit.
About the common failure and treatment of extrusion granulator
The extrusion granulator unit is highly integrated with the machine, electricity and instrument, and the level of automation control is high. Therefore, in the actual operation, there will be more faults that are difficult to diagnose, resulting in too long processing time, which affects the normal operation of the whole polypropylene plant and greatly reduces the production economic benefits. Combining the theoretical knowledge of extrusion granulation production process and the management experience of actual production operation for more than ten years, the author analyzes and judges the common causes of failures in the operation of the unit, and has formulated corresponding solutions and treatment methods to ensure its Long-term stable operation.