The disc feeder is a key equipment in the batching process of large-scale
quartz sand production lines (daily processing capacity ≥ 3000t), responsible
for accurately conveying quartz sand to subsequent processes such as fine
crushing and ball milling (requiring feeding accuracy deviation ≤ 3%, feeding
range 50-200t/h), directly determining the stability of finished sand grading
and subsequent processing efficiency. If there is poor feeding accuracy
(deviation exceeding 8%) and frequent jamming (more than 3 times a week), it
will lead to an imbalance in the proportion of ingredients, material breakage in
the production line, and significantly increase the rate of defective products.
Based on the strong fluidity and impurity characteristics of quartz sand, a
three-step optimization plan is summarized to improve the stability and accuracy
of the disc feeder operation.
Step 1: Optimize the disk structure and wear-resistant configuration,
strengthen the load-bearing and conveying stability
Insufficient wear resistance of the disc surface, improper scraper angle, or
uneven feeding of the silo are the core reasons for material jamming and poor
accuracy, and targeted optimization and adaptation requirements are needed.
Optimization of disk surface and lining plate: ordinary steel plate disk
surface is selected, which wears out quickly when facing quartz sand, and the
feeding trajectory deviates when the disk surface is depressed by more than 5mm;
The missing lining plate causes direct wear of the quartz sand on the disc
surface. Replace the high manganese steel wear-resistant disc surface (thickness
≥ 15mm) and install a polyurethane wear-resistant lining plate (thickness
8-10mm) on the surface, which improves the wear resistance by more than 4 times;
The lining plate is fastened with bolts, and the fastening status is checked
regularly. If the wear exceeds 3mm, it should be replaced in a timely manner;
Install a material blocking ring (height 150-200mm) at the edge of the disc to
prevent quartz sand from falling and ensure stable feeding trajectory.
Optimization of scraper and feeding structure: The angle deviation of the
scraper exceeds 5 °, and the feeding amount fluctuates greatly; Scraper wear
exceeds 2mm, unable to fully scrape quartz sand; There is no diversion device at
the discharge port of the silo, and there is a partial accumulation of quartz
sand on the surface, which is prone to material jamming. Calibrate the scraper
angle to 30-35 ° to ensure a tight fit with the disc surface; Select high
chromium alloy scraper, check the wear condition every half month, and adjust or
replace it in a timely manner; Install conical deflectors and electric gates at
the discharge port of the silo to control the discharge speed and avoid
excessive accumulation of quartz sand on the disc surface.
Step 2: Calibrate the driving system parameters to improve the
controllability of feeding accuracy
Insufficient driving power, speed fluctuations, or transmission failure can
lead to insufficient feeding power and imbalanced accuracy, requiring precise
control of system parameters.
Optimization of drive system adaptation: ordinary asynchronous motors are
selected, with a narrow speed adjustment range, which cannot adapt to the
feeding requirements of multiple working conditions; The speed fluctuation
exceeds 2r/min, and the feeding amount fluctuates rapidly. Replace the variable
frequency speed regulating motor (power 15-30kW) with a planetary reducer, with
a speed adjustment range of 5-25r/min, and accurately match the feeding amount
according to the subsequent process requirements; Install a speed encoder to
monitor the speed in real time, automatically calibrate when the deviation
exceeds 0.5r/min, and ensure stable speed; Replacing belt transmission with
coupling transmission reduces transmission losses and improves power
transmission stability.
Optimization of braking and protection: The aging of the braking device leads
to inertial rotation of the disc surface during shutdown, resulting in excessive
feeding; The transmission parts are not protected, and quartz sand dust invades,
causing jamming. Replace the electromagnetic braking device (braking torque ≥
150N · m) to ensure that the disc brakes within 3 seconds when stopping the
machine; Install a sealed protective cover on the transmission part, with a
protection level of IP65, to prevent dust from entering; Regularly lubricate the
transmission parts with oil and choose anti-wear grease to reduce the frictional
resistance during operation.
Step 3: Optimize feed control and anti jam protection to ensure feed
uniformity
Overloading of feed volume, excessive impurities, or imbalanced feeding speed
can exacerbate material jamming and accuracy fluctuations, requiring effective
front-end control.
Feed quantity and feeding control: The feed quantity exceeds the bearing
limit of the disc surface (over 200t/h), and the accumulation of quartz sand on
the disc surface causes material jamming; The feeding speed fluctuates greatly,
and the feeding amount follows the fluctuation. Real time monitoring of the
material level in the silo using a level gauge, coupled with precise control of
the material through an electric gate, to maintain the feed rate at 80% -90% of
the rated load capacity of the panel; Install a variable frequency vibrator at
the bottom of the silo to prevent quartz sand from arching and blocking,
ensuring even feeding; Based on the feedback of feeding accuracy, dynamically
adjust the motor speed to ensure stable feeding quantity.
Anti jamming protection and impurity cleaning: Large impurities (particle
size exceeding 100mm) mixed in the raw materials can easily get stuck between
the disc surface and the material blocking ring; The residual material on the
surface was not cleaned up in a timely manner, which affected the accuracy of
subsequent feeding. Install a mesh screen (with a diameter of 80mm) at the
discharge port of the silo to remove large impurities; Install an automatic
scraping device on one side of the panel to clean up residual material in real
time; Set up a card alarm device that automatically stops and alarms when the
motor load exceeds the set value by 120%, to avoid equipment overload
damage.
Daily maintenance should pay attention to: checking the feeding accuracy,
disc wear, and operating status every day; Clean the dust on the disk and
transmission parts every week, and check the fastening of the scraper and lining
plate; Monthly calibration of rotational speed and feeding accuracy, replacement
of aging seals; Conduct comprehensive maintenance on the drive motor and reducer
every quarter. By implementing the above measures, the feeding accuracy
deviation can be stabilized within 2%, and the jamming rate can be reduced to
less than once per month, ensuring the precise and efficient operation of the
batching process in large-scale quartz sand production lines.