Automatic traction system failure
Traction speed fluctuation
Fault description: The speed of the plastic sheet is unstable during the traction process, sometimes fast and sometimes slow.
Possible causes:
- The drive circuit of the traction motor is faulty, resulting in unstable power supply to the motor.
- The speed sensor is faulty, and the feedback speed signal is inaccurate.
- There are jams or gaps in the mechanical transmission parts, affecting the smoothness of traction.
Troubleshooting methods:
- Check the electronic components of the drive circuit, such as capacitors, resistors, transistors, etc., and replace them if damaged. At the same time, check whether the circuit connection is loose to ensure good contact.
- Calibrate or replace the speed sensor to ensure that it can accurately measure and feedback the traction speed.
- Perform a comprehensive inspection of the mechanical transmission parts, including gears, chains, couplings, etc. Clean the oil and impurities on the surface of the parts, replace the parts with severe wear, and adjust the gap of the transmission parts to ensure smooth transmission.
Traction direction deviation
Fault description: The plastic sheet deviates from the predetermined track and deviates to one side during the traction process.
Possible reasons:
- The traction rollers are not installed in parallel, resulting in uneven force on both sides of the sheet.
- The sheet itself has uneven thickness or uneven edges, which affects the linearity of traction.
- The guide device is improperly adjusted and fails to effectively guide the sheet.
Troubleshooting method:
- Re-adjust the installation position of the traction rollers, and use tools such as a level and calipers to ensure that the traction rollers are parallel to each other and perpendicular to the sheet conveying direction.
- Check the quality of the sheet, and pre-treat or eliminate sheets with uneven thickness or uneven edges.
- Carefully adjust the guide device to match it with the width and conveying direction of the sheet to ensure that the sheet moves in a straight line under the constraint of the guide device.
Fault of the crushing system
Tool wears too fast
Fault description: The tool is obviously worn in a short period of time, affecting the crushing effect.
Possible reasons:
- The tool material is not suitable for the type of plastic sheet to be crushed, and the wear resistance is insufficient.
- The feed port of the crushing chamber is too large, resulting in excessive impact force when the sheet enters the crushing chamber, accelerating tool wear.
- The cutting parameters of the tool are set unreasonably, such as cutting speed, feed rate, etc.
Troubleshooting method:
- According to the material and characteristics of the plastic sheet, select a tool of suitable material, such as a carbide tool suitable for crushing high-hardness plastic sheets.
- Adjust the size of the feed port so that the sheet can enter the crushing chamber smoothly and reduce the impact force. A buffer device such as a rubber pad can be added at the feed port.
- Optimize the cutting parameters of the tool, determine the optimal cutting speed and feed rate through experiments, and avoid excessive tool wear due to improper parameters.
Blockage in the crushing chamber
Fault description: Plastic sheets accumulate in the crushing chamber and cannot be discharged normally, resulting in reduced crushing efficiency or even equipment shutdown.
Possible reasons:
- The screen is blocked, so that the crushed particles cannot be discharged through the screen in time.
- The feed speed is too fast, exceeding the crushing and discharge capacity of the crusher.
- The design of the crushing chamber is unreasonable, and there are dead corners where materials are retained.
Troubleshooting method:
- Clean the screen regularly. You can use compressed air or brushes to remove plastic debris and impurities on the screen. For severely clogged screens, you can remove them for soaking, cleaning or replacement.
- According to the rated processing capacity of the crusher, reasonably adjust the feed speed. You can install a feed speed control device to ensure uniform and stable feeding.
- Inspect and optimize the internal structure of the crushing chamber, such as improving the shape of the crushing chamber, adding guide plates, etc., to avoid material retention in the chamber.
Electrical system failure
Control circuit short circuit
Fault description: During the operation of the equipment, a short circuit occurs in the control circuit, causing the fuse to blow or the circuit protection device to operate.
Possible causes:
- The insulation layer of the wire is damaged, resulting in a short circuit between the wires or between the wires and the equipment casing.
- Damage to electrical components, such as internal short circuits in relays and contactors.
- Water or moisture in the equipment causes the insulation performance of the circuit to deteriorate.
Troubleshooting method:
- Carefully check the wires of the control circuit. If the insulation layer is damaged, it should be replaced or insulated in time. Use insulating tape to wrap the damaged part to ensure good insulation.
- Check the electrical components one by one, use tools such as multimeters to measure the resistance, voltage and other parameters of the components to determine whether the components are damaged. If damaged, replace the corresponding electrical components.
- Dry the equipment, such as using a hair dryer or dehumidifier to remove moisture inside the equipment. At the same time, check the waterproof measures of the equipment to prevent water from entering again.
PLC program failure
Fault description: The operation logic of the equipment is confused, such as uncoordinated traction and crushing actions, and the equipment cannot run according to the set program.
Possible causes:
- PLC program error, which may be due to improper program writing, program loss or interference.
- PLC hardware failure, such as CPU module, input and output module failure.
Troubleshooting method:
- Check the PLC program and compare it with the original program to see if there are any errors or missing instructions. If necessary, modify and improve the program. At the same time, back up the program to prevent loss again.
- Check whether the hardware connection of the PLC is loose, and use diagnostic tools to detect each module of the PLC to determine whether there is a hardware failure. If there is a hardware failure, replace the corresponding module.
Mechanical transmission system failure
Belt slippage
Fault description: The traction or transmission belt slips during operation, resulting in poor power transmission.
Possible causes:
- The belt tension is insufficient, and the friction between the belt and the pulley is insufficient.
- There are oil stains or impurities on the belt surface, which reduces the friction coefficient between the belt and the pulley.
- The pulley is worn, resulting in an increase in the matching clearance between the belt and the pulley.
Troubleshooting method:
- Use a tensioning device to adjust the tension of the belt so that the belt reaches the appropriate tightness. Generally, this can be achieved by adjusting the position of the tensioning pulley or using a tensioning bolt.
- Dip a clean cloth in an appropriate amount of detergent, wipe the oil and impurities on the surface of the belt, then rinse it with clean water and dry it. At the same time, clean the pulley surface to ensure good contact between the two.
- Check the wear of the pulley. If the wear is severe, replace the pulley. Choose the right pulley to match the model and specification of the belt.
Gear wear and abnormal noise
Fault description: When the equipment is running, the gear transmission part makes an abnormal noise and the gear is obviously worn.
Possible reasons:
- Insufficient gear lubrication leads to increased friction between gears.
- The gear installation accuracy is not enough, and the meshing clearance is too large or too small.
- The load is too large, exceeding the load capacity of the gear.
Troubleshooting method:
- Check the lubrication of the gear regularly and add appropriate lubricating oil according to the requirements of the equipment manual. At the same time, check whether the lubrication system is working properly. If there is blockage or leakage, repair it in time.
- Use professional measuring tools, such as feeler gauges, dial indicators, etc., to check the meshing clearance and installation accuracy of the gear. According to the measurement results, adjust the installation position of the gear to ensure that the meshing clearance is within a reasonable range.
- Evaluate the load condition of the equipment to avoid overload operation. If the load must be increased due to production needs, consider replacing gears with higher load capacity or upgrading the entire transmission system.
The above troubleshooting manual can be used as a reference for daily maintenance and troubleshooting of the
thermoformed plastic sheet automatic traction online crusher. In actual operation, it can be adjusted and improved according to the specific model and actual situation of the equipment. If you encounter complex faults or problems that cannot be solved by yourself, you should contact the equipment manufacturer or professional maintenance personnel for repair in time.
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