Dust removal and cleaning machine is a key equipment used in agriculture, grain processing, feed production and other fields to remove impurities (such as dust, straw, stones, metals, etc.) from materials and screen them in a graded manner. The common faults can be divided into four categories: mechanical faults, electrical faults, pneumatic faults, and improper operation and maintenance. The following is a specific analysis:

1、 Mechanical malfunction

Screen blockage or damage

Reason:

Excessive humidity of materials: Wet materials (such as freshly harvested grains) are prone to adhere to the sieve and form blockages.

Improper sieve size: The sieve aperture is too small, causing large particles of impurities to be unable to pass through; Or if the aperture is too large, small impurities may leak through.

Improper installation of screen mesh: The screen mesh is not tensioned or firmly fixed, loose and deformed during operation, and damaged by friction with the frame.

Excessive impurities in the material: Excessive impurities exceed the processing capacity of the sieve and accelerate wear.

Performance: Decreased screening efficiency, increased impurities at the discharge outlet, and local damage and leakage of the screen mesh.

solve:

Pre treat materials (such as drying, air drying) to reduce humidity.

Select a suitable mesh size based on the characteristics of the material (such as using a 1.5-3mm round hole sieve for grain cleaning).

Re tighten the screen mesh and secure it firmly, regularly inspect and replace worn screens.

Add pre cleaning steps (such as air separation and magnetic separation) to reduce impurities entering the sieve.

Fan failure

Reason:

Impeller wear: Long term inhalation of dust or hard impurities can cause imbalance or perforation of the impeller.

Bearing damage: Insufficient lubrication or dust intrusion can cause the bearing to jam or overheat.

Belt slack: The fan drive belt is aging or the tension is insufficient, resulting in a decrease in speed.

Air duct blockage: Dust or foreign objects block the air duct, reducing the air volume.

Performance: Weakened wind force, poor dust removal effect, increased abnormal noise or vibration of the fan.

solve:

Regularly clean the dust accumulation on the impeller and replace the worn impeller.

Regularly lubricate the bearings (such as adding lithium based grease every 3 months) and install dust covers.

Adjust the belt tension and replace the aging belt.

Clean up debris in the air duct and keep it unobstructed.

Transmission component malfunction

Reason:

Chain/belt breakage: breakage caused by excessive tension, sudden load changes, or aging.

Gear wear: Poor lubrication or invasion of impurities can cause pitting or tooth breakage on the tooth surface.

Coupling damage: Poor alignment or overload can cause the elastic body of the coupling to rupture.

Performance: Equipment shutdown, abnormal transmission noise, and excessive vibration.

solve:

Adjust the tension of the chain/belt to the specified range (such as a chain sag of 1% -2%).

Regularly replace lubricating oil and clean impurities in the gearbox.

Re calibrate the coupling alignment and replace the damaged elastic body.

2、 Electrical malfunction

Motor overheating or burning out

Reason:

Overload operation: The motor load increases due to screen blockage or insufficient fan airflow.

Voltage instability: The voltage fluctuation of the power grid exceeds ± 10%, resulting in excessive motor current.

Poor heat dissipation: The motor's cooling fan is damaged or the ambient temperature is too high.

Insulation aging: Long term operation of the motor leads to a decrease in the insulation performance of the winding.

Performance: The motor casing is hot to the touch, smoking, emitting a strange odor, and even tripping and shutting down.

solve:

Clean the screen and air duct to ensure the normal operation and load of the equipment.

Install a voltage regulator or voltage compensation device.

Repair the cooling fan and improve ventilation conditions.

Regularly check the insulation resistance of the motor (should be ≥ 0.5M Ω), and if necessary, rewire the winding.

Control circuit malfunction

Reason:

Sensor failure: Control failure caused by faults in wind pressure sensors, material level sensors, etc.

Contactor/relay adhesion: Contact erosion or arcing causes inability to disconnect normally.

Line aging: Vibration causes loose wiring terminals or insulation damage and short circuits.

Performance: Equipment failure to start, automatic control failure, frequent tripping.

solve:

Regularly calibrate sensors and replace faulty components.

Clean the contactor contacts and replace the adhesive relay.

Tighten the wiring terminals and wrap the damaged insulation layer of the circuit.

Inverter fault

Reason:

Parameter setting error: Short acceleration/deceleration time, improper overload protection threshold.

Poor heat dissipation: Dust accumulation inside the frequency converter or fan failure causing overheating.

Harmonic interference: Harmonics in the power grid can cause false alarms or damage to the frequency converter.

Performance: The frequency converter reports fault codes (such as OC overcurrent, OH overheating) and unstable output voltage.

solve:

Reset the frequency converter parameters based on the motor parameters (such as acceleration time of 5-10 seconds).

Clean the cooling fins of the frequency converter and replace the faulty fan.

Install reactors or filters to suppress harmonics.

3、 Air circuit failure (for pneumatic cleaning machine models)

Insufficient air volume

Reason:

Fan speed decrease: belt looseness, motor failure, or insufficient voltage.

Air leakage in the air duct: The sealing at the pipeline connection is not tight or damaged.

Dust collector blockage: Excessive dust accumulation in bag filters leads to increased resistance.

Performance: Insufficient suspension of materials and poor separation of light impurities.

solve:

Check the fan transmission system and restore the rated speed.

Seal the air duct interface and repair damaged pipelines.

Regularly clean or replace the filter bag of the dust collector (such as vibrating the dust collector every shift).

Unstable air pressure

Reason:

Air compressor malfunction: The air valve is damaged and the piston ring is worn, resulting in insufficient air supply.

Leakage of gas storage tank: safety valve and drain valve are not tightly closed or the tank body is corroded and leaked.

Pneumatic component failure: stuck solenoid valve, aging cylinder sealing ring.

Performance: Slow action of pneumatic valve and abnormal vibration of screen mesh.

solve:

Repair or replace the air valve and piston ring of the air compressor.

Check the sealing of the gas storage tank and repair any leaks.

Clean the solenoid valve and replace the cylinder seal ring.

4、 Malfunctions caused by improper operation and maintenance

Operation parameter setting error

Reason:

Improper air volume/pressure: Excessive air volume leads to material dispersion, while insufficient air volume prevents impurities from being separated.

Screen vibration frequency error: Excessive frequency accelerates screen wear, while low frequency reduces screening efficiency.

Performance: Poor discharge quality and increased equipment energy consumption.

solve:

Adjust the air volume according to the material characteristics (such as wheat cleaning air speed of 3-5 m/s).

Adjust the vibration frequency of the screen mesh (usually 50-100Hz) through a frequency converter or eccentric block.

Insufficient maintenance and upkeep

Reason:

Failure to clean regularly: Dust accumulation leads to poor heat dissipation of equipment and increased component wear.

Lack of lubrication: bearings, chains, and other parts were not lubricated on time.

Vulnerable parts not replaced: screen mesh, belt, filter bag, etc. are used beyond their expiration date.

Performance: Increased failure rate and shortened service life.

solve:

Develop maintenance plans (such as daily cleaning, weekly lubrication, and monthly replacement of vulnerable parts).

Establish equipment archives to record maintenance history and replacement cycles.

Uneven feeding of materials

Reason:

Feeding machine malfunction: unstable speed of screw conveyor or blockage of hopper.

Poor material flowability: Excessive moisture content or clumping can cause poor feeding.

Performance: Uneven screen load and accelerated local wear.

solve:

Inspect the transmission system of the feeder to ensure uniform feeding.

Preprocess materials (such as crushing lumps, reducing humidity).