The vibrating feeder is the "flow control valve" of the quartz sand
production line, responsible for evenly feeding the crushing, screening, and
grinding equipment. If there is uneven feeding (flow fluctuation exceeding 20%)
and frequent blockage (more than 2 blockages per hour), it will cause downstream
equipment to overload or idle, disrupting the production rhythm. Based on
practical experience, summarize the three-step troubleshooting method to quickly
restore stable feeding.
Step 1: Check the vibration system and material tank - the core components
determine the feeding stability
Abnormal vibration motors, springs, and chute structures are the main causes
of material blockage and unevenness.
Unbalanced or insufficient power of vibration motor: The angle deviation of
the eccentric block of the motor (exceeding 5 °) can cause uneven vibration of
the material trough and local accumulation of materials; The motor power is
lower than the rated value of the equipment (for example, a 7.5kW motor is
required for a feeding rate of 50t/h, but 5.5kW is actually used), the vibration
intensity is weak, and the material is difficult to transport. The eccentric
block angle needs to be recalibrated (both sides should be consistent, it is
recommended to adjust it to 30 ° -45 °), and a motor with matching power should
be replaced to ensure uniform vibration of the material tank.
Aging or misalignment of supporting springs: A decrease of more than 30% in
spring elasticity can weaken vibration transmission and cause the material
trough to run in a stuck manner; The installation of the spring is misaligned
(not in the same vertical plane), and the material trough is prone to deviation,
causing the feeding to be biased to one side. Manganese steel springs need to be
replaced. During installation, calibrate with a level to ensure that the heights
of the four sets of springs are consistent with a deviation of ≤ 2mm.
Inappropriate angle of the material trough or wear on the inner wall: If the
inclination angle of the material trough is less than 10 °, the material flow is
slow and prone to blockage; Greater than 20 °, the material slides too quickly
and the feeding is uneven; The inner wall wear exceeds 5mm, reducing friction
and making the material prone to slipping. Adjust the inclination angle of the
material trough to 12 ° -15 °, and install a polyurethane wear-resistant lining
plate (thickness 8-10mm) on the inner wall to improve wear resistance and
friction.
Step 2: Calibrate operating parameters - parameter deviation amplification
issue
Improper settings of amplitude, frequency, and feed rate directly affect the
feeding effect.
Too small amplitude or too low frequency: amplitude less than 3mm, frequency
less than 15Hz, insufficient material vibration looseness, easy to agglomerate
and block materials; The amplitude exceeds 8mm and the frequency exceeds 25Hz,
causing the material to bounce and the feeding amount to fluctuate. Use a
vibration tester to detect and adjust the amplitude to 4-6mm and frequency to
18-22Hz. Use a frequency converter for precise control to ensure that the
material is evenly conveyed forward.
Overloading of feed volume or unreasonable design of silo: feed volume
exceeds the rated value (such as rated 50t/h, actual 60t/h), material
accumulation in the hopper exceeds 1/2, which is prone to material blockage; If
the diameter of the silo outlet is smaller than the width of the hopper (such as
a hopper width of 800mm and a silo outlet of only 500mm), the material will be
"bridged" and blocked. Use an electronic belt scale to control the measurement
and maintain it at 80% -90% of the rated value; Install an "activation cone" at
the bottom of the silo or expand the size of the bottom to over 80% of the width
of the hopper to avoid material bridging.
Step 3: Adaptation of materials and daily maintenance - raw material
issues+maintenance deficiencies hinder progress
Inadequate material characteristics and maintenance can exacerbate equipment
issues.
High moisture content or impurities in materials: if the moisture content
exceeds 10%, quartz sand is prone to clumping and sticking to the material
trough; If large impurities (over 50mm) are mixed in, they will get stuck at the
interface between the hopper and the material bin, causing material blockage.
Drying process should be added before feeding (moisture content should be
reduced to below 6%), and a grille (aperture ≤ 30mm) should be installed at the
upper opening of the silo to intercept large impurities; Install dispersing
teeth in the material trough to break down material clumps.
Maintenance deficiency: The lack of oil in the motor bearings leads to
unstable speed, and the loosening of the material slot bolts exacerbates
vibration displacement. Check the temperature of the motor bearings daily (≤ 65
℃) and add lithium based grease every week; Tighten the connecting bolts between
the material tank and the motor every month, using a torque wrench to ensure
that the torque meets the standard (80-100N · m); clean the residual materials
in the material tank every quarter, and check the wear of the lining plate.
By following the above three steps, the uniformity of feeding can be improved
to over 90%, and the number of blockages can be reduced to less than once a day.
If there are still problems, it is recommended to contact the manufacturer to
test the compatibility of the equipment and ensure accurate matching with the
production needs of quartz sand.