核心设备组件的保养与维护详解

　　Detailed explanation of maintenance and upkeep of core equipment components

　　本章节将对气力输送系统的各个核心设备进行详细的维护保养阐述。

　　This chapter will provide a detailed explanation of the maintenance and upkeep of each core equipment in the pneumatic conveying system.

　　2.1 供料装置 (Feeding Devices)

　　2.1 Feeding Devices

　　供料装置是气力输送系统的“心脏”，负责将物料稳定、连续地喂入输送管道。其性能直接影响系统的稳定性和输送效率。

　　The feeding device is the "heart" of the pneumatic conveying system, responsible for stably and continuously feeding materials into the conveying pipeline. Its performance directly affects the stability and delivery efficiency of the system.

　　2.1.1 旋转供料器/关风机 (Rotary Airlock Valves)

　　2.1.1 Rotary Airlock Valves

　　旋转供料器是稀相和低压浓相系统中最常用的供料设备。

　　Rotary feeders are the most commonly used feeding equipment in dilute and low-pressure dense phase systems.

　　日常维护 (Daily Maintenance):

　　Daily Maintenance:

　　听觉检查： 倾听设备运行时是否有异常噪音，如金属摩擦声、轴承异响等。

　　Auditory examination: Listen to whether there is any abnormal noise during the operation of the device, such as metal friction sound, bearing abnormal noise, etc.

　　视觉检查： 检查设备外部是否有物料泄漏，特别是轴端密封处。

　　Visual inspection: Check for material leakage outside the equipment, especially at the shaft end seal.

　　驱动检查： 检查电机、减速机运行是否平稳，有无过热现象。对于链条传动，检查链条张紧度是否合适。

　　Drive inspection: Check whether the motor and reducer are running smoothly and whether there is any overheating phenomenon. For chain drive, check if the chain tension is appropriate.

　　每周维护 (Weekly Maintenance):

　　Weekly Maintenance:

　　清理： 清洁设备外部的积尘。

　　Cleaning: Clean the dust accumulation outside the equipment.

　　润滑： 对链条进行清洁和润滑。检查减速机油位，必要时补充。

　　Lubrication: Clean and lubricate the chain. Check the oil level of the gearbox and replenish it if necessary.

　　紧固： 检查所有外部连接螺栓，确保没有松动。

　　Tightening: Check all external connecting bolts to ensure they are not loose.

　　每月维护 (Monthly Maintenance):

　　Monthly Maintenance:

　　内部检查： 在系统停机并确保安全的情况下，打开检查口，检查叶轮与壳体的间隙。正常间隙应在0.1mm-0.3mm之间。间隙过大会导致漏风，降低效率；间隙过小或不均可能导致磨损或卡死。

　　Internal inspection: With the system shut down and safety ensured, open the inspection port and check the clearance between the impeller and the housing. The normal gap should be between 0.1mm-0.3mm. Excessive gaps can lead to air leakage and reduce efficiency; Small or uneven gaps may cause wear or jamming.

　　磨损检查： 检查叶片和壳体内壁的磨损情况，特别是对于磨蚀性物料。可使用耐磨涂层或更换耐磨材质的部件。

　　Wear inspection: Check the wear condition of the blades and the inner wall of the shell, especially for abrasive materials. Wear resistant coatings or replacement of wear-resistant materials can be used for components.

　　轴封检查： 检查轴端密封件（如填料密封、气密封）的状况，如有泄漏需及时调整或更换。对于气密封，需检查其供气压力是否正常。

　　Shaft seal inspection: Check the condition of the shaft end seals (such as packing seals and airtight seals), and adjust or replace them in a timely manner if there is any leakage. For gas seals, it is necessary to check whether the gas supply pressure is normal.

　　年度维护 (Annual Maintenance):

　　Annual Maintenance:

　　全面解体检查： 拆卸设备，对叶轮、壳体、端盖、轴承、密封件等所有部件进行彻底的清洁和详细检查。

　　Comprehensive disassembly inspection: Disassemble the equipment and thoroughly clean and inspect all components such as impellers, shells, end caps, bearings, seals, etc.

　　轴承更换： 无论轴承状况如何，建议根据厂家推荐或运行时间（如8000小时）进行预防性更换。

　　Bearing replacement: Regardless of the condition of the bearing, it is recommended to perform preventive replacement according to the manufacturer's recommendation or operating time (such as 8000 hours).

　　间隙调整： 重新组装时，精确调整叶轮与壳体、端盖的间隙。

　　Gap adjustment: When reassembling, accurately adjust the gap between the impeller, housing, and end cap.

　　减速机换油： 彻底更换减速机润滑油。

　　Gearbox oil change: Thoroughly replace the lubricating oil of the gearbox.

　　故障排除 (Troubleshooting):

　　Troubleshooting:

　　原因： 叶轮与壳体间隙过大、轴端密封失效。

　　Reason: The clearance between the impeller and the shell is too large, and the shaft end seal has failed.

　　解决： 调整或更换叶轮/壳体，更换轴端密封件。

　　Solution: Adjust or replace the impeller/housing, and replace the shaft end seal.

　　原因： 物料流动性差、有异物进入、叶轮与壳体间隙过小、下游管道堵塞。

　　Reason: Poor material fluidity, foreign objects entering, small gap between impeller and shell, and downstream pipeline blockage.

　　解决： 检查物料状况，清除异物，调整间隙，检查并清理下游管道。

　　Solution: Check the condition of materials, remove foreign objects, adjust gaps, and inspect and clean downstream pipelines.

　　问题： 堵料或电机过载。

　　Problem: Material blockage or motor overload.

　　问题： 漏风/漏料严重。

　　Problem: Severe air/material leakage.

　　2.1.2 螺旋给料机 (Screw Feeders)

　　2.1.2 Screw Feeders

　　常用于将物料从料仓稳定地输送至供料器或直接进入输送管道。

　　Commonly used to stably transport materials from the silo to the feeder or directly into the conveying pipeline.

　　维护要点：

　　Maintenance points:

　　轴承润滑： 定期（每周或每月）对头尾部及中间悬挂轴承进行润滑。

　　Bearing lubrication: Regularly (weekly or monthly) lubricate the head, tail, and middle suspension bearings.

　　螺旋叶片检查： 定期（每月或每季度）检查螺旋叶片的磨损情况，特别是输送磨蚀性物料时。磨损严重会影响输送效率。

　　Spiral blade inspection: Regularly (monthly or quarterly) inspect the wear of spiral blades, especially when conveying abrasive materials. Severe wear and tear can affect conveying efficiency.

　　驱动系统： 维护同旋转供料器，检查电机、减速机和传动链。

　　Drive system: Maintain the same rotating feeder, check the motor, reducer, and transmission chain.

　　清洁： 防止物料在U型槽内结块，特别是在停机时。

　　Cleaning: prevent materials from clumping in the U-shaped groove, especially during shutdown.

　　故障排除：

　　Troubleshooting:

　　原因： 螺旋叶片磨损，电机转速下降。

　　Reason: Wear of spiral blades and decrease in motor speed.

　　解决： 修复或更换叶片，检查电机和电路。

　　Solution: Repair or replace the blades, check the motor and circuit.

　　原因： 物料含水量大、结拱，进料不均，螺旋轴弯曲。

　　Reason: The material has a high moisture content, arches, uneven feeding, and a bent spiral shaft.

　　解决： 安装仓壁振动器或破拱装置，调整上游给料，校直或更换螺旋轴。

　　Solution: Install a silo wall vibrator or arch breaking device, adjust the upstream feeding, straighten or replace the spiral shaft.

　　问题： 堵料。

　　Problem: Material blockage.

　　问题： 产量下降。

　　Problem: Decreased production.

　　2.1.3 发送罐 (Pressure Vessel/Blow Tank)

　　2.1.3 Pressure Vessel/Low Tank

　　是浓相气力输送系统的核心供料设备。

　　It is the core feeding equipment of the dense phase pneumatic conveying system.

　　日常维护：

　　Daily maintenance:

　　阀门检查： 检查所有气动阀门（进料阀、出料阀、排气阀、补气阀等）的开关是否到位、有无泄漏。

　　Valve inspection: Check whether the switches of all pneumatic valves (feed valve, discharge valve, exhaust valve, air supply valve, etc.) are in place and whether there is any leakage.

　　压力表检查： 确认压力表读数是否正常、稳定。

　　Pressure gauge inspection: Confirm whether the pressure gauge reading is normal and stable.

　　密封检查： 检查进料阀阀座的密封性，确保在输送期间无气体反窜至料仓。

　　Sealing inspection: Check the sealing of the feed valve seat to ensure that there is no gas backflow into the silo during transportation.

　　每周维护：

　　Weekly maintenance:

　　气源三联件： 检查气动执行机构的气源处理器（三联件），排出过滤器中的积水，检查油雾器油位。

　　Air source triple piece: Check the air source processor (triple piece) of the pneumatic actuator, drain the accumulated water in the filter, and check the oil level of the oil mist device.

　　每月维护：

　　Monthly maintenance:

　　内部检查： 在清空物料并断电断气后，进入罐内（需遵守密闭空间作业安全规程），检查罐内壁及流化装置（流化板或喷嘴）有无磨损、堵塞或损坏。

　　Internal inspection: After emptying the material and cutting off the power and gas, enter the tank (following the safety regulations for working in a confined space) and check the inner wall of the tank and the fluidization device (fluidization plate or nozzle) for wear, blockage, or damage.

　　阀门密封圈检查： 检查所有阀门的密封圈，特别是进、出料阀，磨损后需及时更换。

　　Valve sealing ring inspection: Check the sealing rings of all valves, especially the inlet and outlet valves, and replace them in a timely manner if they are worn.

　　年度维护：

　　Annual maintenance:

　　安全阀校验： 将罐体上的安全阀送至有资质的机构进行校验。

　　Safety valve calibration: Send the safety valve on the tank to a qualified institution for calibration.

　　罐体测厚： 对于输送强磨蚀性物料的发送罐，应定期（每年或每两年）进行壁厚测量，以评估磨损情况。

　　Tank thickness measurement: For sending tanks that transport highly abrasive materials, wall thickness measurements should be conducted regularly (annually or every two years) to assess wear and tear.

　　故障排除：

　　Troubleshooting:

　　原因： 进气阀故障，排气阀未关紧，进料阀密封泄漏，安全阀起跳。

　　Reason: Inlet valve malfunction, exhaust valve not tightly closed, feed valve seal leakage, safety valve popping.

　　解决： 检查并维修相关阀门，检查安全阀设定。

　　Solution: Check and repair the relevant valves, and verify the safety valve settings.

　　原因： 进料阀或出料阀密封不严，流化装置效果不佳，补气阀门或管路设定不当，物料特性变化。

　　Reason: Poor sealing of the feed valve or discharge valve, ineffective fluidization device, improper setting of the air supply valve or pipeline, and changes in material characteristics.

　　解决： 检查并更换阀门密封，清理或更换流化板，重新调整补气参数，分析物料变化原因。

　　Solution: Check and replace valve seals, clean or replace fluidized bed plates, readjust air supply parameters, and analyze the reasons for material changes.

　　问题： 输送不稳定或堵管。

　　Problem: Unstable delivery or pipe blockage.

　　问题： 罐内压力无法建立或上升缓慢。

　　Problem: The pressure inside the tank cannot be established or rises slowly.

　　2.2 动力气源 (Air Power Source)

　　2.2 Air Power Source

　　气源是输送的动力来源，其稳定性和气体质量至关重要。

　　Gas source is the power source for transportation, and its stability and gas quality are crucial.

　　2.2.1 罗茨鼓风机 (Roots Blower)

　　2.2.1 Roots Blower

　　主要用于稀相正压输送系统。

　　Mainly used in dilute phase positive pressure conveying systems.

　　日常维护：

　　Daily maintenance:

　　压力与温度： 检查进出口压力和机体温度是否在正常范围内。

　　Pressure and temperature: Check whether the inlet and outlet pressure and body temperature are within the normal range.

　　油位： 检查齿轮箱和轴承处的润滑油油位。

　　Oil level: Check the lubricating oil level at the gearbox and bearings.

　　声音与振动： 监听有无异常噪音和振动。

　　Sound and vibration: Monitor for abnormal noise and vibration.

　　皮带： 检查V型皮带的张紧度和磨损情况。

　　Belt: Check the tension and wear of the V-belt.

　　每周维护：

　　Weekly maintenance:

　　空气过滤器： 检查并清洁入口空气过滤器。在粉尘大的环境中应缩短周期。

　　Air filter: Check and clean the inlet air filter. In environments with high levels of dust, the cycle should be shortened.

　　每月维护：

　　Monthly maintenance:

　　润滑： 给轴承加注润滑脂。

　　Lubrication: Add lubricating grease to the bearings.

　　季度/半年度维护：

　　Quarterly/Semi Annual Maintenance:

　　更换润滑油： 更换齿轮箱内的润滑油。

　　Replace lubricating oil: Replace the lubricating oil inside the gearbox.

　　皮带张力： 重新检查并调整皮带张力。

　　Belt tension: Recheck and adjust the belt tension.

　　地脚螺栓： 检查并紧固地脚螺栓。

　　Anchor bolts: Check and tighten the anchor bolts.

　　年度维护：

　　Annual maintenance:

　　间隙检查： 检查叶轮之间、叶轮与机壳、叶轮与墙板之间的间隙。

　　Gap inspection: Check the gaps between impellers, impellers and casings, and impellers and wall panels.

　　轴承检查： 检查轴承的磨损情况，必要时更换。

　　Bearing inspection: Check the wear of the bearings and replace them if necessary.

　　故障排除：

　　Troubleshooting:

　　原因： 油位过低或油质差，出口压力过高（可能由管道堵塞引起），环境温度高，通风不良。

　　Reason: Low oil level or poor oil quality, high outlet pressure (possibly caused by pipeline blockage), high ambient temperature, poor ventilation.

　　解决： 补充或更换润滑油，检查并疏通管道，改善通风。

　　Solution: Supplement or replace lubricating oil, check and clear pipelines, and improve ventilation.

　　原因： 入口滤清器堵塞，皮带打滑，管道泄漏，风机内部间隙过大。

　　Reason: The inlet filter is clogged, the belt slips, the pipeline leaks, and the internal clearance of the fan is too large.

　　解决： 清洁滤清器，调整皮带张力，检查管道密封，检修风机。

　　Solution: Clean the filter, adjust the belt tension, check the pipeline seal, and inspect the fan.

　　问题： 流量不足。

　　Problem: Insufficient traffic.

　　问题： 温度过高。

　　Problem: The temperature is too high.

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