In long-term use, various common problems are prone to occur in the rough crusher of corner type due to factors such as material characteristics, operation methods, and equipment wear. The following are specific problem classifications, possible causes, and corresponding solutions to help ensure stable operation of the equipment:
1、 Poor material crushing effect (oversized/uneven particles)
Common reasons
1. The broken cutting tool is severely worn, the blade becomes dull, and cannot effectively cut or impact materials;
2. The installation position of the cutting tool is offset, and the gap between the fixed tool (or the inner wall of the crushing chamber) is too large, resulting in insufficient compression and shearing of the material;
3. The feeding speed is too fast, the equipment is running at overload, and the material has insufficient residence time in the crushing chamber;
4. The material itself has high humidity (such as moisture in angular materials), which makes it easy to adhere and clump, affecting the crushing process.
solution
1. Stop the machine to check the wear of the cutting tool. If the blade is dull or has a notch, the tool needs to be disassembled for grinding and repair. If the wear is severe, replace it with a new tool of the same model directly;
2. Adjust the gap between the cutting tool and the fixed tool (or crushing chamber), refer to the equipment manual to control the gap within a reasonable range (usually set according to the target crushing particle size, generally 1-5mm), to ensure that the material can be effectively sheared;
3. Reduce the feeding speed by adjusting the gate or conveyor belt speed of the feeding hopper to ensure that the material enters the crushing chamber evenly and stably, avoiding overload;
4. Pre treat damp corner materials, such as reducing moisture content (generally controlled below 10% -15%) through drying equipment, and then carry out crushing operations.
2、 Abnormal noise during equipment operation (sudden increase/accompanied by abnormal noise)
Common reasons
1. Hard impurities such as metal and stones are mixed into the crushing chamber, causing abnormal noise when colliding with cutting tools or crushing chambers;
2. Bearing wear or insufficient lubrication, resulting in frictional noise during operation;
3. Loose cutting tools, fixed cutting tools, or crushing chamber components cause vibration and abnormal noise during equipment operation;
4. Misalignment or wear of motor and equipment transmission components (such as belts and couplings) can cause transmission noise.
solution
1. Immediately stop the machine, open the crushing chamber to inspect and remove internal hard impurities, and check whether the cutting tools and crushing chamber have deformed due to impact. If necessary, repair or replace damaged parts;
2. Disassemble the bearing components, clean the oil stains inside the bearing. If the bearing ball is worn or the raceway is deformed, replace it with a bearing of the same model; Regularly (e.g. every 1-2 months) add specialized lubricating grease (such as lithium based grease) to the bearings;
3. Check each connecting bolt of the equipment one by one (such as tool fixing bolts, crushing chamber cover plate bolts), tighten them in a timely manner if any looseness is found, and ensure the stability of the components;
4. Adjust the concentricity between the motor and transmission components. If the belt is severely worn, replace it with a new one. If there is any gap or deformation in the coupling, repair or replace it in a timely manner.
3、 Equipment blockage (blockage of feed inlet/crushing chamber/discharge outlet)
Common reasons
1. The amount of feed far exceeds the processing capacity of the equipment, and materials accumulate at the feed inlet;
2. The material inside the crushing chamber is not fully crushed, and block shaped materials are stuck between the cutting tool and the crushing chamber, hindering the passage of subsequent materials;
3. The discharge port conveying device (such as conveyor belt, screw conveyor) malfunctions, and the crushed materials cannot be discharged in a timely manner, resulting in a backlog in the crushing chamber;
4. The material contains a lot of fibers or has high viscosity (such as undried horns), which can cause blockages by sticking and clumping at the discharge outlet.
solution
1. Immediately stop feeding and reduce the feeding amount to the rated processing range of the equipment. If there is material accumulation at the feeding port, manual cleaning is required before restarting the equipment;
2. After stopping the machine, open the crushing chamber, clean the block materials stuck in the chamber, check whether the cutting tools are worn (if worn, it needs to be treated), and adjust the tool clearance if necessary to improve the crushing efficiency;
3. Repair the discharge port conveyor device, fix faults (such as adjusting the tension if the conveyor belt slips, and cleaning if the screw conveyor gets stuck), to ensure smooth discharge of materials;
4. Pre treat materials with high viscosity or fiber content (such as drying and shredding), and install vibration devices (such as small vibration motors) at the discharge outlet to reduce material adhesion and blockage.
4、 Motor overload (motor overheating/tripping)
Common reasons
1. Long term overload operation of equipment (such as excessive feed volume, crushing of hard materials), and motor load exceeding rated power;
2. Blockage of the crushing chamber and accumulation of materials result in increased resistance to motor rotation;
3. The voltage of the motor power supply is unstable (too high or too low), or the motor wiring is loose or poorly connected;
4. The aging or short circuit of the internal winding of the motor, or the damage of the bearings, leads to an increase in the resistance of the motor operation.
solution
1. Reduce the feeding amount to avoid equipment overload. If it is necessary to crush hard materials, the single feeding amount should be controlled to avoid centralized input;
2. Clean the crushing chamber according to the solution of "equipment blockage", eliminate material backlog, and restore normal operation of the equipment;
3. Check the power supply voltage to ensure that it is stable within the rated voltage range of the motor (such as 380V industrial electricity), tighten the motor wiring terminals to avoid poor contact;
4. If the motor continues to heat up or trip, it is necessary to stop and inspect the inside of the motor. If the winding is short circuited, it needs to be repaired by professional personnel. If the bearing is damaged, it should be replaced; Regularly (such as every 3-6 months) maintain and upkeep the motor, clean the dust on the motor cooling fins, and ensure good heat dissipation.
5、 Material contamination after crushing (including metal shavings/impurities)
Common reasons
1. Wear or corrosion of cutting tools and crushing chamber components, and mixing of metal debris into materials;
2. The equipment has not been cleaned for a long time, and impurities such as previous materials and dust remaining in the crushing chamber have mixed into new crushed materials;
3. The raw materials were not screened during feeding, and impurities (such as sediment and metal fragments) contained in the raw materials themselves entered the crushing system.
solution
1. Regularly inspect the cutting tools and the inner walls of the crushing chamber. If rust appears, it needs to be polished and cleaned. If severe wear causes metal debris to fall off, replace the components in a timely manner; After crushing, a metal detector or magnetic separation device (such as a permanent magnet cylinder) can be installed at the discharge port to separate metal shavings from the material;
2. After each change in the type of crushed material or shutdown, open the crushing chamber, inlet, and outlet for comprehensive cleaning to remove residual materials and dust;
3. Install screening devices (such as grilles and vibrating screens) at the feed inlet to filter impurities such as sediment and metal fragments in the raw materials in advance, reducing subsequent pollution.