核心設(shè)備組件的保養(yǎng)與維護詳解

　　Detailed explanation of maintenance and upkeep of core equipment components

　　本章節(jié)將對氣力輸送系統(tǒng)的各個核心設(shè)備進行詳細的維護保養(yǎng)闡述。

　　This chapter will provide a detailed explanation of the maintenance and upkeep of each core equipment in the pneumatic conveying system.

　　2.1 供料裝置 (Feeding Devices)

　　2.1 Feeding Devices

　　供料裝置是氣力輸送系統(tǒng)的“心臟”，負責將物料穩(wěn)定、連續(xù)地喂入輸送管道。其性能直接影響系統(tǒng)的穩(wěn)定性和輸送效率。

　　The feeding device is the "heart" of the pneumatic conveying system, responsible for stably and continuously feeding materials into the conveying pipeline. Its performance directly affects the stability and delivery efficiency of the system.

　　2.1.1 旋轉(zhuǎn)供料器/關(guān)風機 (Rotary Airlock Valves)

　　2.1.1 Rotary Airlock Valves

　　旋轉(zhuǎn)供料器是稀相和低壓濃相系統(tǒng)中最常用的供料設(shè)備。

　　Rotary feeders are the most commonly used feeding equipment in dilute and low-pressure dense phase systems.

　　日常維護 (Daily Maintenance):

　　Daily Maintenance:

　　聽覺檢查： 傾聽設(shè)備運行時是否有異常噪音，如金屬摩擦聲、軸承異響等。

　　Auditory examination: Listen to whether there is any abnormal noise during the operation of the device, such as metal friction sound, bearing abnormal noise, etc.

　　視覺檢查： 檢查設(shè)備外部是否有物料泄漏，特別是軸端密封處。

　　Visual inspection: Check for material leakage outside the equipment, especially at the shaft end seal.

　　驅(qū)動檢查： 檢查電機、減速機運行是否平穩(wěn)，有無過熱現(xiàn)象。對于鏈條傳動，檢查鏈條張緊度是否合適。

　　Drive inspection: Check whether the motor and reducer are running smoothly and whether there is any overheating phenomenon. For chain drive, check if the chain tension is appropriate.

　　每周維護 (Weekly Maintenance):

　　Weekly Maintenance:

　　清理： 清潔設(shè)備外部的積塵。

　　Cleaning: Clean the dust accumulation outside the equipment.

　　潤滑： 對鏈條進行清潔和潤滑。檢查減速機油位，必要時補充。

　　Lubrication: Clean and lubricate the chain. Check the oil level of the gearbox and replenish it if necessary.

　　緊固： 檢查所有外部連接螺栓，確保沒有松動。

　　Tightening: Check all external connecting bolts to ensure they are not loose.

　　每月維護 (Monthly Maintenance):

　　Monthly Maintenance:

　　內(nèi)部檢查： 在系統(tǒng)停機并確保安全的情況下，打開檢查口，檢查葉輪與殼體的間隙。正常間隙應(yīng)在0.1mm-0.3mm之間。間隙過大會導(dǎo)致漏風，降低效率；間隙過小或不均可能導(dǎo)致磨損或卡死。

　　Internal inspection: With the system shut down and safety ensured, open the inspection port and check the clearance between the impeller and the housing. The normal gap should be between 0.1mm-0.3mm. Excessive gaps can lead to air leakage and reduce efficiency; Small or uneven gaps may cause wear or jamming.

　　磨損檢查： 檢查葉片和殼體內(nèi)壁的磨損情況，特別是對于磨蝕性物料。可使用耐磨涂層或更換耐磨材質(zhì)的部件。

　　Wear inspection: Check the wear condition of the blades and the inner wall of the shell, especially for abrasive materials. Wear resistant coatings or replacement of wear-resistant materials can be used for components.

　　軸封檢查： 檢查軸端密封件（如填料密封、氣密封）的狀況，如有泄漏需及時調(diào)整或更換。對于氣密封，需檢查其供氣壓力是否正常。

　　Shaft seal inspection: Check the condition of the shaft end seals (such as packing seals and airtight seals), and adjust or replace them in a timely manner if there is any leakage. For gas seals, it is necessary to check whether the gas supply pressure is normal.

　　年度維護 (Annual Maintenance):

　　Annual Maintenance:

　　全面解體檢查： 拆卸設(shè)備，對葉輪、殼體、端蓋、軸承、密封件等所有部件進行徹底的清潔和詳細檢查。

　　Comprehensive disassembly inspection: Disassemble the equipment and thoroughly clean and inspect all components such as impellers, shells, end caps, bearings, seals, etc.

　　軸承更換： 無論軸承狀況如何，建議根據(jù)廠家推薦或運行時間（如8000小時）進行預(yù)防性更換。

　　Bearing replacement: Regardless of the condition of the bearing, it is recommended to perform preventive replacement according to the manufacturer's recommendation or operating time (such as 8000 hours).

　　間隙調(diào)整： 重新組裝時，精確調(diào)整葉輪與殼體、端蓋的間隙。

　　Gap adjustment: When reassembling, accurately adjust the gap between the impeller, housing, and end cap.

　　減速機換油： 徹底更換減速機潤滑油。

　　Gearbox oil change: Thoroughly replace the lubricating oil of the gearbox.

　　故障排除 (Troubleshooting):

　　Troubleshooting:

　　原因： 葉輪與殼體間隙過大、軸端密封失效。

　　Reason: The clearance between the impeller and the shell is too large, and the shaft end seal has failed.

　　解決： 調(diào)整或更換葉輪/殼體，更換軸端密封件。

　　Solution: Adjust or replace the impeller/housing, and replace the shaft end seal.

　　原因： 物料流動性差、有異物進入、葉輪與殼體間隙過小、下游管道堵塞。

　　Reason: Poor material fluidity, foreign objects entering, small gap between impeller and shell, and downstream pipeline blockage.

　　解決： 檢查物料狀況，清除異物，調(diào)整間隙，檢查并清理下游管道。

　　Solution: Check the condition of materials, remove foreign objects, adjust gaps, and inspect and clean downstream pipelines.

　　問題： 堵料或電機過載。

　　Problem: Material blockage or motor overload.

　　問題： 漏風/漏料嚴重。

　　Problem: Severe air/material leakage.

　　2.1.2 螺旋給料機 (Screw Feeders)

　　2.1.2 Screw Feeders

　　常用于將物料從料倉穩(wěn)定地輸送至供料器或直接進入輸送管道。

　　Commonly used to stably transport materials from the silo to the feeder or directly into the conveying pipeline.

　　維護要點：

　　Maintenance points:

　　軸承潤滑： 定期（每周或每月）對頭尾部及中間懸掛軸承進行潤滑。

　　Bearing lubrication: Regularly (weekly or monthly) lubricate the head, tail, and middle suspension bearings.

　　螺旋葉片檢查： 定期（每月或每季度）檢查螺旋葉片的磨損情況，特別是輸送磨蝕性物料時。磨損嚴重會影響輸送效率。

　　Spiral blade inspection: Regularly (monthly or quarterly) inspect the wear of spiral blades, especially when conveying abrasive materials. Severe wear and tear can affect conveying efficiency.

　　驅(qū)動系統(tǒng)： 維護同旋轉(zhuǎn)供料器，檢查電機、減速機和傳動鏈。

　　Drive system: Maintain the same rotating feeder, check the motor, reducer, and transmission chain.

　　清潔： 防止物料在U型槽內(nèi)結(jié)塊，特別是在停機時。

　　Cleaning: prevent materials from clumping in the U-shaped groove, especially during shutdown.

　　故障排除：

　　Troubleshooting:

　　原因： 螺旋葉片磨損，電機轉(zhuǎn)速下降。

　　Reason: Wear of spiral blades and decrease in motor speed.

　　解決： 修復(fù)或更換葉片，檢查電機和電路。

　　Solution: Repair or replace the blades, check the motor and circuit.

　　原因： 物料含水量大、結(jié)拱，進料不均，螺旋軸彎曲。

　　Reason: The material has a high moisture content, arches, uneven feeding, and a bent spiral shaft.

　　解決： 安裝倉壁振動器或破拱裝置，調(diào)整上游給料，校直或更換螺旋軸。

　　Solution: Install a silo wall vibrator or arch breaking device, adjust the upstream feeding, straighten or replace the spiral shaft.

　　問題： 堵料。

　　Problem: Material blockage.

　　問題： 產(chǎn)量下降。

　　Problem: Decreased production.

　　2.1.3 發(fā)送罐 (Pressure Vessel/Blow Tank)

　　2.1.3 Pressure Vessel/Low Tank

　　是濃相氣力輸送系統(tǒng)的核心供料設(shè)備。

　　It is the core feeding equipment of the dense phase pneumatic conveying system.

　　日常維護：

　　Daily maintenance:

　　閥門檢查： 檢查所有氣動閥門（進料閥、出料閥、排氣閥、補氣閥等）的開關(guān)是否到位、有無泄漏。

　　Valve inspection: Check whether the switches of all pneumatic valves (feed valve, discharge valve, exhaust valve, air supply valve, etc.) are in place and whether there is any leakage.

　　壓力表檢查： 確認壓力表讀數(shù)是否正常、穩(wěn)定。

　　Pressure gauge inspection: Confirm whether the pressure gauge reading is normal and stable.

　　密封檢查： 檢查進料閥閥座的密封性，確保在輸送期間無氣體反竄至料倉。

　　Sealing inspection: Check the sealing of the feed valve seat to ensure that there is no gas backflow into the silo during transportation.

　　每周維護：

　　Weekly maintenance:

　　氣源三聯(lián)件： 檢查氣動執(zhí)行機構(gòu)的氣源處理器（三聯(lián)件），排出過濾器中的積水，檢查油霧器油位。

　　Air source triple piece: Check the air source processor (triple piece) of the pneumatic actuator, drain the accumulated water in the filter, and check the oil level of the oil mist device.

　　每月維護：

　　Monthly maintenance:

　　內(nèi)部檢查： 在清空物料并斷電斷氣后，進入罐內(nèi)（需遵守密閉空間作業(yè)安全規(guī)程），檢查罐內(nèi)壁及流化裝置（流化板或噴嘴）有無磨損、堵塞或損壞。

　　Internal inspection: After emptying the material and cutting off the power and gas, enter the tank (following the safety regulations for working in a confined space) and check the inner wall of the tank and the fluidization device (fluidization plate or nozzle) for wear, blockage, or damage.

　　閥門密封圈檢查： 檢查所有閥門的密封圈，特別是進、出料閥，磨損后需及時更換。

　　Valve sealing ring inspection: Check the sealing rings of all valves, especially the inlet and outlet valves, and replace them in a timely manner if they are worn.

　　年度維護：

　　Annual maintenance:

　　安全閥校驗： 將罐體上的安全閥送至有資質(zhì)的機構(gòu)進行校驗。

　　Safety valve calibration: Send the safety valve on the tank to a qualified institution for calibration.

　　罐體測厚： 對于輸送強磨蝕性物料的發(fā)送罐，應(yīng)定期（每年或每兩年）進行壁厚測量，以評估磨損情況。

　　Tank thickness measurement: For sending tanks that transport highly abrasive materials, wall thickness measurements should be conducted regularly (annually or every two years) to assess wear and tear.

　　故障排除：

　　Troubleshooting:

　　原因： 進氣閥故障，排氣閥未關(guān)緊，進料閥密封泄漏，安全閥起跳。

　　Reason: Inlet valve malfunction, exhaust valve not tightly closed, feed valve seal leakage, safety valve popping.

　　解決： 檢查并維修相關(guān)閥門，檢查安全閥設(shè)定。

　　Solution: Check and repair the relevant valves, and verify the safety valve settings.

　　原因： 進料閥或出料閥密封不嚴，流化裝置效果不佳，補氣閥門或管路設(shè)定不當，物料特性變化。

　　Reason: Poor sealing of the feed valve or discharge valve, ineffective fluidization device, improper setting of the air supply valve or pipeline, and changes in material characteristics.

　　解決： 檢查并更換閥門密封，清理或更換流化板，重新調(diào)整補氣參數(shù)，分析物料變化原因。

　　Solution: Check and replace valve seals, clean or replace fluidized bed plates, readjust air supply parameters, and analyze the reasons for material changes.

　　問題： 輸送不穩(wěn)定或堵管。

　　Problem: Unstable delivery or pipe blockage.

　　問題： 罐內(nèi)壓力無法建立或上升緩慢。

　　Problem: The pressure inside the tank cannot be established or rises slowly.

　　2.2 動力氣源 (Air Power Source)

　　2.2 Air Power Source

　　氣源是輸送的動力來源，其穩(wěn)定性和氣體質(zhì)量至關(guān)重要。

　　Gas source is the power source for transportation, and its stability and gas quality are crucial.

　　2.2.1 羅茨鼓風機 (Roots Blower)

　　2.2.1 Roots Blower

　　主要用于稀相正壓輸送系統(tǒng)。

　　Mainly used in dilute phase positive pressure conveying systems.

　　日常維護：

　　Daily maintenance:

　　壓力與溫度： 檢查進出口壓力和機體溫度是否在正常范圍內(nèi)。

　　Pressure and temperature: Check whether the inlet and outlet pressure and body temperature are within the normal range.

　　油位： 檢查齒輪箱和軸承處的潤滑油油位。

　　Oil level: Check the lubricating oil level at the gearbox and bearings.

　　聲音與振動： 監(jiān)聽有無異常噪音和振動。

　　Sound and vibration: Monitor for abnormal noise and vibration.

　　皮帶： 檢查V型皮帶的張緊度和磨損情況。

　　Belt: Check the tension and wear of the V-belt.

　　每周維護：

　　Weekly maintenance:

　　空氣過濾器： 檢查并清潔入口空氣過濾器。在粉塵大的環(huán)境中應(yīng)縮短周期。

　　Air filter: Check and clean the inlet air filter. In environments with high levels of dust, the cycle should be shortened.

　　每月維護：

　　Monthly maintenance:

　　潤滑： 給軸承加注潤滑脂。

　　Lubrication: Add lubricating grease to the bearings.

　　季度/半年度維護：

　　Quarterly/Semi Annual Maintenance:

　　更換潤滑油： 更換齒輪箱內(nèi)的潤滑油。

　　Replace lubricating oil: Replace the lubricating oil inside the gearbox.

　　皮帶張力： 重新檢查并調(diào)整皮帶張力。

　　Belt tension: Recheck and adjust the belt tension.

　　地腳螺栓： 檢查并緊固地腳螺栓。

　　Anchor bolts: Check and tighten the anchor bolts.

　　年度維護：

　　Annual maintenance:

　　間隙檢查： 檢查葉輪之間、葉輪與機殼、葉輪與墻板之間的間隙。

　　Gap inspection: Check the gaps between impellers, impellers and casings, and impellers and wall panels.

　　軸承檢查： 檢查軸承的磨損情況，必要時更換。

　　Bearing inspection: Check the wear of the bearings and replace them if necessary.

　　故障排除：

　　Troubleshooting:

　　原因： 油位過低或油質(zhì)差，出口壓力過高（可能由管道堵塞引起），環(huán)境溫度高，通風不良。

　　Reason: Low oil level or poor oil quality, high outlet pressure (possibly caused by pipeline blockage), high ambient temperature, poor ventilation.

　　解決： 補充或更換潤滑油，檢查并疏通管道，改善通風。

　　Solution: Supplement or replace lubricating oil, check and clear pipelines, and improve ventilation.

　　原因： 入口濾清器堵塞，皮帶打滑，管道泄漏，風機內(nèi)部間隙過大。

　　Reason: The inlet filter is clogged, the belt slips, the pipeline leaks, and the internal clearance of the fan is too large.

　　解決： 清潔濾清器，調(diào)整皮帶張力，檢查管道密封，檢修風機。

　　Solution: Clean the filter, adjust the belt tension, check the pipeline seal, and inspect the fan.

　　問題： 流量不足。

　　Problem: Insufficient traffic.

　　問題： 溫度過高。

　　Problem: The temperature is too high.

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