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Cause Analysis And Treatment Of Common Troubles In Extrusion Granulator
Apr 19, 2017

Extrusion granulator set machine, electricity, instrument integration, high level of automation control. Therefore, in the actual operation there will be more difficult to diagnose the fault, resulting in processing time is too long, thus affecting the normal operation of the whole set of polypropylene unit, greatly reducing the economic benefits of production. The author combines the theoretical knowledge granulation extrusion process and more than ten years of actual production operation management experience, analyzing the reasons of the common faults in operation, and the resolving measures and the corresponding treatment methods, so as to ensure the stable operation of long period.

Analysis of common failures and Solutions

1, the main motor torque is too high

Cause analysis: oil lubrication system failure, the main motor output shaft and the gear box in the middle of the bad, motor and clutch vibration and other reasons will damage the main motor bearing, resulting in high torque. In addition, the excessive load of the material or the poor melt will lead to the high torque of the main motor.

Solution: check and clean the lubricating oil system regularly, measure the main motor bearing with the vibration measuring instrument and infrared thermometer, and form the trend chart. If the value of the super trend, then determine whether the main motor idling current value or power value exceeds the specified value, to determine whether the replacement of bearings. Regularly check the main motor output shaft and the gear box input shaft between the situation, the first drive or replacement of bearings after three months of operation must check the situation. Conduct electrical test and check to determine the cause of the unbalance of the rotor, and test the vibration speed of the clutch. Periodically check the heating and cooling system to ensure that the material is heated evenly. If the compressor is driven for a moment, the power curve of the main motor and the melt pressure curve increase instantly, which indicates that the feeding quantity of the feeding system is too large, and the feeding quantity should be reduced.

2, the main motor torque is too low

Cause analysis: feeding system failure will cause the main motor torque is too low.

Solution: check the judgment or the raw material feed additive system whether the system is faulty, the blockage cleaning point.

3, friction clutch fault

Cause analysis: the main motor instantaneous start voltage is too low, friction disc, friction plate overheating, friction disc and friction plate aging, friction disc air pressure is too low and other reasons can lead to the clutch off.

Solution: the main motor startup, should avoid peak electricity, reduce the load, restart the shortest time interval is 30 minutes; in the summer, repeated two times to start the main motor, should extend the interval of time or forced cooling fan. With the instrument wind blowing and wiping with a cloth wipe the friction plate and the friction plate surface ash trace, if the wear is heavier or the surface of the "glass" phenomenon, should replace the friction plate, friction plate. Confirm whether the air pressure value can make the friction disc and the friction plate.

4, high melt pressure

Cause analysis: the filter mesh is high, low melt index polypropylene powder and feeding a large amount of each cylinder low temperature causes the material to melt completely, because template opening rate is low so that the nose blocked material extrusion can lead to melt pressure is too high.

Solution: the production of low melting index products, should use low filter mesh, increase the throttle to reduce the back pressure; timely replacement of filters, ash content and quality of polypropylene powder and various additives in monitoring. Reduce feed load. Under the condition of not affecting the quality of extruded products, the temperature of each cylinder is increased, the temperature of the melt is increased, and the fluidity of the material is increased. After the extruder stops, raise the temperature of the head and keep it for a period of time.

5, underwater cutting system failure

Cause analysis: cutter blade damage or excessive wear particles, water flow rate is too low, cutter vibration is too large, the cutter and the template fitting is not tight, the material melt index fluctuation is relatively large discharge velocity is inconsistent, particles can lead to high temperature through the under water pelletizing system stop causing the entire unit chain parking.

Solution: after parking, visual inspection of the cutting edge of the mouth is worn over or damaged, if any, should be replaced with a knife. Check and confirm whether the internal leakage of water particles, particle filter and water cooler is blocked, if the plug should be manually cleaned; check the entry and exit of the particle pump pressure is normal, if not normal, should repair the water pump and pump line valve particles. Check whether there is a difference between the cutter shaft and the cutting motor, whether the bearing assembly of the cutter shaft is damaged or not. Check whether there is a gap between the four moving wheels and the guide rail in the cutting trolley. Control the volatile of polypropylene powder and eliminate the vibration of the cutter and the cutter shaft when it flows through the template hole. Reduce the template check cylinder and oil temperature, template temperature distribution, flow rate, pressure and temperature of the cylinder cooling water is normal; confirm the "water knife" arrived at the time of setting the template, prevent the particles arrive early water freezing holes of the template template. Close the cutter head, should quickly put the feeding amount to the preset load extrusion machine