Sep 10, 2024
I. Sensory inspection method
1. Visual inspection
Carefully observe the various components of the equipment, including the biaxial shaft, agitator blades, dispersion disc, container, transmission components (such as belts, chains, couplings, etc.), brackets and bases. Check for obvious deformation, cracks, wear, corrosion or foreign matter adhesion. For example, observe whether the toothed parts of the agitator blades and dispersion discs are severely worn, whether there are scratches or bending on the shaft surface; check whether there are material accumulations, corrosion pits, etc. on the inner wall of the container.
Observe the state of the equipment during operation, such as whether there are abnormal vibration modes (such as large and irregular vibration amplitudes), whether there is relative displacement between components (such as whether there is shaking between the shaft and the bearing seat), and whether the flow state of the material is normal (whether there is local non-flow or excessive splashing, etc.).
2. Auditory inspection
During the operation of the equipment, listen carefully for abnormal sounds. For example, sharp friction sounds may indicate bearing wear or lack of lubrication; dull knocking sounds may be due to loose components, such as loose installation of agitator blades or dispersion discs; continuous humming sounds may be a signal of motor failure or unbalanced transmission components. By locating the source of the sound, the approximate location of the fault can be preliminarily determined.
3. Tactile inspection
When the equipment stops running and ensures safety, touch some parts with your hands to determine their status. For example, touch the motor housing to feel its temperature. If the temperature is too high, it may be due to motor overload, poor heat dissipation or internal fault; touch the area near the bearing seat. If you feel abnormal vibration or heat, it may indicate that there is a problem with the bearing; turn the pulley or coupling by hand to feel whether the rotation is smooth. If there is a sense of stagnation, it may be a problem with the shaft, bearing or transmission component.
2. Instrument detection method
1. Vibration detection
Use vibration sensors and vibration analyzers to perform vibration detection on the equipment. Parameters such as vibration amplitude, frequency and phase of the equipment under different operating conditions can be measured. By comparing with the vibration data during normal operation of the equipment, it can be accurately determined whether the equipment has problems such as imbalance, misalignment, looseness or bearing failure. For example, if the vibration amplitude exceeds the normal range and the vibration frequency is close to the natural frequency of a component, the component may be resonant.
2. Temperature detection
Use infrared thermal imager or contact thermometer to detect the temperature of key components of the equipment (such as motors, bearings, gears, etc.). Problems such as motor overload, bearing wear or poor lubrication usually cause the temperature of components to rise. By monitoring temperature changes, potential fault hazards can be discovered in time. For example, the temperature of a normally operating motor should be within a certain range. If the temperature of a certain part is too high, it is necessary to further check the heat dissipation, electrical connection or mechanical load of that part.
3. Speed detection
Use a tachometer to accurately measure the speed of the dual shafts. The output speed of the motor can be measured directly, or the speed of the agitator shaft in actual operation can be measured. Compare the measurement results with the rated speed of the equipment. If the speed is unstable or lower than the rated speed, it may be a motor failure, transmission component slippage or control system problem.
III. Disassembly inspection method
1. Step-by-step disassembly
After determining the approximate range of possible faults, the equipment can be disassembled and inspected step by step. For example, if you suspect that there is a problem with the stirring blade or dispersion disk, you can first remove the protective device at the end of the stirring shaft, and then remove the stirring blade or dispersion disk for detailed inspection. Check whether it is deformed, worn, broken, etc., and check whether the connection with the shaft is firm.
2. Internal component inspection
For some internal components that are difficult to observe directly, such as bearings, gears, etc., it is necessary to further disassemble the housing or box of the equipment for inspection. During the disassembly process, pay attention to marking the installation position and order of each component so that it can be installed correctly during reassembly. Check whether the ball of the bearing is worn, whether the raceway has pitting, and whether the tooth surface of the gear is worn, broken teeth, etc.
IV. Component replacement method
1. Suspected component replacement
When a component is suspected to be faulty but cannot be completely confirmed, the component replacement method can be used. For example, if it is suspected that there is a problem with the motor on a certain shaft, the motor can be replaced with a known normal motor, and then the equipment can be started to observe the operation. If the fault disappears, it means that the original motor is indeed faulty; if the fault still exists, it is necessary to continue to investigate other possible causes.
2. Replace vulnerable parts first
For some vulnerable parts, such as seals, belts, bearings, etc., replacement can be given priority to troubleshoot the fault. Because these parts are prone to wear or damage during equipment operation, if the equipment resumes normal operation after replacement, the cause of the failure can be quickly determined.
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