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Analysis of Common Faults of Small Combined Milling Units
Flour processing units, which consist of multiple small-scale counter-roll mills along with wheat cleaning and conveying systems, are widely used in rural areas due to their efficiency, automation, and ability to produce high-quality flour. These systems are popular among users because they offer high productivity, strong labor capacity, and good grinding quality. However, during operation, these units can experience various malfunctions. Below is an analysis of the common causes of such failures:
1. **Motor Failure**
The entire system contains over 10 motors of different sizes, making motor failure a frequent issue. High temperatures are a major cause, often resulting from insufficient bearing lubrication, dirt entering the bearings, damaged bearings, or motor overload.
2. **Cleaning Screen Failure**
- **Loose screen or frame**: This is usually caused by loose bolts or wooden wedges.
- **Wheat particles in sand**: This occurs when the internal damper of the stone nozzles is too small or the screen slope is not properly adjusted.
- **Excessive wheat breakage**: This happens when the gap between the tooth plate and sieve in the wheat-making device is too narrow, or the mesh is too large or damaged.
3. **Spiral Stirrer Failure**
- **No grain discharge**: This may be due to improper motor rotation, a blocked outlet, or a broken stirrer blade.
- **Stirrer shaft not rotating**: This could result from excessive feeding or belt slippage.
4. **Pulverizer Failure**
- **Body shaking**: Tighten the bolts connecting the grinding head and rack.
- **Reduced production**: Adjust the spring to ensure even roller gaps and repair or replace worn grinding teeth.
- **High flour temperature**: Loosen the roll and consider replacement if wear is severe. In summer, turn off the heat source.
- **No bran**: This may be caused by misaligned spindles, poor screen sealing, or broken screens.
- **Little or no flour**: Usually due to clogged screens.
5. **Winder Malfunction**
When the air is closed, the bag may be sucked in. Common causes include leaks at joints or impeller wear. If the impeller is worn, a rubber plate can be installed on its outer edge.
6. **Filter Cartridge Issues**
- **Dust in the room**: This can occur due to a loose dust collector, unsealed cloth tubes, or air leakage in the ducts.
- **Excess flour in the filter**: Caused by excessive airflow, leaks in the lower end of the powder collector, or large clearance between the impeller and shell.
7. **Electrical Faults**
- **Unit won’t start**: Possible reasons include low voltage, missing phase, poor wiring contact, broken control loops, or blown fuses.
- **Single machine won’t start**: This might be due to poor contact in the control loop, burned-out AC contactor coil, or similar issues.
By understanding these potential problems, operators can better maintain and troubleshoot flour processing equipment, ensuring smooth and efficient operation. Regular inspections and timely repairs are essential for prolonging the lifespan of the system and maintaining product quality.
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