What are the common maintenance issues for feeder breakers
In mining production, especially in coal mining processes, the feeder breaker plays a crucial role in transporting and crushing materials, ensuring the continuous operation of the production. However, due to its harsh working environment and heavy load, various maintenance problems are prone to occur. Let’s now introduce the common maintenance issues of the feeder breaker in detail.
Common Mechanical Wear and Tear Issues
The feeder breaker is subjected to significant mechanical stress, which leads to common wear problems that can affect its performance.
Degradation of chains and sprockets
The degradation of chains and sprockets is very common. The continuous contact between the chain and sprocket, combined with the influence of coal dust and sand, can cause chain pin wear, chain elongation, and erosion of sprocket teeth. This can result in uneven feeding, slippage, or sudden jamming, disrupting the flow of materials.
Wear of gearbox components
Wear of gearbox components is another key issue. The gears in the drive system suffer from abrasive wear due to the contamination of coal particles, resulting in pitting, tooth fracture, or misalignment. Usually, the failure of lubricant due to dust entering can accelerate this process, increasing friction and heat accumulation, and further damaging the gear surface.
Bearings failure
Bearings failure is frequent in heavy-load areas such as the rotor of the crusher and the drive device of the feeder. The continuous vibration, combined with the infiltration of coal dust into the seals, can cause wear of the bearing seat ring, resulting in increased clearance, noise, and ultimately bearing jamming. Poor lubrication or excessive lubrication can exacerbate this situation, as insufficient lubricant will cause the metal surface to lose protection, while excessive lubricating grease will trap contaminants.
Blade wear
Blade wear in the crusher section is inevitable. Impact from hard coal or foreign objects (such as rocks, metals) can cause the blade to become blunt, cracked, or unevenly thinned. This reduces the crushing efficiency and forces the machine to work more strenuously, thereby increasing the pressure on other components.
Wear of the feeding belt
Although the wear of the feeding belt is not severe, it still causes problems. Sharp edges of coal causing wear or misalignment can lead to thinning, wear, or deviation of the belt, resulting in material leakage and increased maintenance downtime. Regular inspection and timely replacement of worn components are crucial to alleviating these problems.
Electrical System Malfunctions
The electrical system is an important guarantee for the normal operation of the feeder breaker, and its failure can cause the equipment to stop, affecting the production schedule.
Motor: Every shift, check the operation of the crusher motor, observe for abnormal sounds, whether the temperature rise is continuously increasing, whether the fan is intact, and whether the temperature of the bearing end is normal. Every six months, add lubricating oil to both bearing ends to ensure the good operation of the motor.
Electrical control box: Every day, inspect the appearance of the electrical control box, check for any loose wiring, whether the contactor actions are flexible and reliable, and whether the contacts have any burnout or welding conditions. Ensure the normal operation of the electrical control box to guarantee the stable electrical control of the equipment.
Other parts: Every shift, visually inspect the external connection cables for any damage, the fixing bolts of sensors and magnetic wheels for any looseness, and the normal operation of the automatic part. Timely detection and handling of problems in these parts can prevent major failures from arising from minor issues.
Hydraulic system: Every shift, check the operation, pressure, and temperature rise of the hydraulic oil pump, whether the sound is normal, and whether there is any noise. The normal operation of the hydraulic system is crucial for the power transmission and action execution of the equipment.
Material blockage and jamming
Material blockage and jamming are common problems in the operation of the feeder breaker, often disrupting the workflow and putting pressure on the equipment.
These problems usually occur at key locations: the inlet of the feeder, the conveying chute, or between the rotating parts of the crusher and the fixed grating. Common causes include oversized or irregularly shaped materials such as large chunks of coal, rocks, or metal fragments, which exceed the processing capacity of the crusher. Humidity can also exacerbate the clogging problem as damp coal adheres to the surface, forming a compact layer that hinders the flow of materials. Uneven distribution of materials at the feed inlet leads to overload in certain areas, further increasing the risk of blockage.
If not addressed promptly, the blockage will force the motor to work harder, resulting in overheating, belt slippage, and even motor burnout. Blockage can also damage the teeth or shear pins of the crusher, which are designed as vulnerable components for safety purposes, but replacement is costly.
Preventive measures: Regularly inspect the inlet screen to filter out oversized materials, adjust the feeding speed to match the material flow, and ensure appropriate humidity control. Install sensors to detect blockages early, which can trigger alarms or automatic shutdowns to minimize damage. Regularly clean the chute and grates to remove residues, which can also reduce the risk of accumulation and maintain the smooth operation of the through-type crusher.
Lubrication Problems
Good lubrication is crucial for the normal operation and extended lifespan of the through-type crusher. Lubrication problems can lead to increased wear on equipment components, affecting equipment performance.
The regular maintenance of the lubrication system has specific time and content requirements:
- Check the oil level, oil temperature, flow meter readings, return oil condition, oil tank filter, and air filter of the blower every 8 hours.
- Check for leaks, inspect the sedimentation tank, and clean the ventilation holes of the oil tank every 40 hours.
- Conduct lubricant quality analysis and check the safety interlock device every 200 hours.
- Replace the lubricant filter every 1000 hours, and replace the reducer oil every 2000 hours as needed. Only by strictly following these requirements for lubrication system maintenance can each component of the equipment be well lubricated, reducing wear.
Preventive maintenance strategies
To ensure the long-term stable operation of the through-type crusher and reduce failure occurrences, implementing effective preventive maintenance strategies is very important.
Lubrication maintenance
Good lubrication is an important part of crusher maintenance. Ensuring adequate lubrication of machine components can reduce wear, lower energy consumption, and extend equipment lifespan. Here are some key maintenance steps:
- Regularly replace lubricating oil: Regular replacement of lubricating oil is necessary based on the usage of the crusher. According to the manufacturer’s recommendations, ensure the selection of suitable lubricating oil for the machine model and replace it on time.
- Clean the oil circuit system: Regularly inspect and clean the oil circuit system of the crusher to remove impurities and contaminants, ensuring the smooth operation of the lubrication system.
- Control oil temperature: Ensure the oil temperature is within the normal range to avoid adverse effects on the machine from overheating or undercooling. Temperature controllers can be installed to monitor and control the oil temperature.
Replacement of spare parts
Regular replacement of key spare parts of the crusher is one of the important measures for maintenance. Bearings are key components that bear heavy loads and vibrations in the crusher and need to be regularly checked for lubrication and wear conditions. Replace aging or damaged bearings in time to ensure the stability and reliability of the machine.
Maintenance points
Regularly inspect the components of the equipment, replace damaged parts in time, especially vulnerable components such as crushing blades and bearings.
Pay attention to the working conditions of components such as the motor, drive belt, and lubrication system, and eliminate faults promptly when abnormalities occur.
Regularly clean the inside and outside of the equipment to prevent dust, debris from blocking and corroding the equipment.
Perform maintenance and upkeep while the equipment is shut down to ensure the safety of operators.
Daily inspection and cleaning
Crushers should be inspected and cleaned regularly during daily use to ensure the normal operation of their mechanical components. First, check the tightness of all parts of the crusher, including the transmission device and connecting bearings. If any part is loose, it needs to be tightened promptly. Secondly, clean the dust and dirt inside and outside the crusher to keep the components clean. Especially, thoroughly clean the accumulated materials around the crushing chamber and the feed opening to avoid affecting the crushing effect.
Adjusting the settings of the crusher
During the use of the crusher, it needs to be adjusted according to the hardness and particle size requirements of different ores to achieve the best crushing effect. During maintenance, regularly check and adjust the size of the discharge port and feed port of the crusher to ensure the appropriate gap between them and the crushing tooth plate. In addition, the rotor speed and crushing angle of the crusher should also be adjusted according to the actual situation to improve the crushing efficiency and output.
Precautions for maintenance and repair
Operators must be familiar with the operation manual and maintenance manual of the equipment and operate and maintain it according to the requirements.
During maintenance, the power supply must be cut off and the switch locked to ensure operational safety.
When repairing the equipment, appropriate tools and equipment must be used to avoid secondary damage.
Conduct a comprehensive inspection and maintenance of the equipment regularly, establish a sound maintenance record, and promptly identify and solve problems.
In conclusion, the maintenance and repair work of the feeder breaker is of great significance for the normal operation and service life of the equipment. Operators should strictly follow the maintenance and repair points for operation and maintenance to ensure the long-term stable operation of the equipment and improve production efficiency.
