The impact sand making machine is the core equipment for shaping and finely
crushing quartz sand particles. If the finished particle size is poor (needle
like content exceeds 15%) and the return rate is high (return proportion exceeds
30%), it will increase screening load, reduce production capacity, and also
affect downstream product quality. Based on years of operation and maintenance
experience, summarize a three-step troubleshooting method to quickly restore
device performance.
Step 1: Check the crushing chamber and vulnerable parts - the core components
determine the particle size and return material
The main cause is the wear and tear of vulnerable parts such as impellers and
impact plates, or improper structure of broken chambers.
Impeller wear or imbalance: Impeller blades wear more than 1/3 of their
original thickness, uneven material ejection force, and deterioration of
particle size; The impeller balance is unbalanced, causing significant vibration
during operation, disrupting the trajectory of material ejection, and increasing
material return. The high chromium alloy impeller needs to be replaced and
calibrated with a dynamic balance meter after installation to ensure a deviation
of ≤ 0.5g · m.
Unreasonable angle of the counterattack board: excessive angle (over 30 °),
weak rebound force of the material, insufficient crushing, and excessive
material return; The angle is too small (less than 15 °), and the material is
prone to excessive crushing, resulting in a high proportion of fine powder.
According to the particle size adjustment of the finished product, when the
particle size is 1-3mm, the angle should be set at 20 ° -25 °, and fixed with
adjusting bolts to ensure precise fit with the impeller.
Step 2: Calibrate operating parameters - parameter deviation amplification
issue
Improper settings of impeller speed, feed rate, and feed particle size
directly affect the sand making effect.
High or low rotation speed: When the rotation speed exceeds 3000r/min, the
material is excessively crushed and there is a lot of fine powder; Below
2000r/min, insufficient crushing force, poor particle size, and high material
return. Use a tachometer to test and adjust according to the hardness of the raw
material - set 2500-2800r/min for hard quartz sand (Mohs 7 grade) and
2200-2500r/min for soft material.
Overloading of feed volume or excessive particle size: exceeding the rated
processing capacity (such as rated 50t/h, actual 70t/h), accumulation in the
crushing chamber, and a surge in return material; The feed particle size exceeds
50mm (equipment rated upper limit), the impeller has a large ejection load, and
the particle size is poor. Use an electronic belt scale to control the quantity
and maintain it at 80% -90% of the rated value. Add a pre sieve before feeding
to ensure that the particle size is ≤ 40mm.
Step 3: Adaptation of materials and daily maintenance - raw material
issues+maintenance deficiencies hinder progress
Inadequate material characteristics and maintenance can exacerbate equipment
issues.
Excessive moisture content of the material (over 8%): Particles are prone to
sticking, blocking the impeller channel, increasing material return, and uneven
particle size. It is necessary to add a drying process before feeding to reduce
the moisture content to below 5%, or install a dispersing device in the sand
making machine to break down clumps.
Maintenance deficiency: The lack of oil in the bearings leads to unstable
impeller speed, aging of seals, sand ingress, and wear of components. Check the
bearing temperature daily (≤ 65 ℃), add high-temperature resistant grease every
week, replace seals every month, conduct comprehensive maintenance of vulnerable
parts every quarter, and replace worn parts in a timely manner.
By following the above three steps, the needle like content of the finished
product can be reduced to below 8%, and the return rate can be controlled within
15%. If there are still problems, it is recommended to contact the manufacturer
to test the compatibility of the equipment and ensure that it matches the
production requirements.