在工业生产设备运行过程中，抛丸机的各系统常面临诸多故障挑战，以下将从抛丸器系统、丸料循环系统、电气控制系统三大方面，对其常见故障进行深度剖析并给出针对性解决方案。

In the operation of industrial production equipment, the various systems of shot blasting machines often face many fault challenges. The following will deeply analyze the common faults from three aspects: shot blasting system, shot material circulation system, and electrical control system, and provide targeted solutions.

抛丸器系统故障中，抛丸器振动异常问题较为突出。其产生原因主要包括叶轮不平衡，当动平衡偏差超过 0.5g 时，叶轮在高速旋转下会因质量分布不均产生剧烈振动；轴承磨损，一旦轴承径向游隙超过 0.15mm，将无法有效支撑主轴运转，导致振动加剧；主轴弯曲，若跳动量大于 0.1mm，会使抛丸器运行稳定性受到严重影响。针对这些问题，有效的解决措施为使用现场动平衡仪对叶轮进行精准校正，将残余不平衡量严格控制在≤0.2g 的范围内，以保障叶轮运转平稳；更换 SKF/NSK 等高品质轴承，并将润滑脂填充量控制在 70 - 80%，确保轴承良好的润滑与运行性能；采用激光校准技术对主轴进行调整，保证其直线度达到≤0.05mm/m 的标准。而抛丸量不足也是抛丸器系统常见故障，其典型表现为丸料流量下降幅度超过 20%，工件表面覆盖率低于 90%，这会直接影响抛丸处理效果，需要进一步排查原因并解决 。

Among the faults in the shot blasting system, the problem of abnormal vibration of the shot blasting device is particularly prominent. The main reasons for its occurrence include impeller imbalance. When the dynamic balance deviation exceeds 0.5g, the impeller will experience severe vibration due to uneven mass distribution during high-speed rotation; Bearing wear, once the radial clearance of the bearing exceeds 0.15mm, it will be unable to effectively support the operation of the main shaft, resulting in increased vibration; If the spindle is bent and the jumping amount is greater than 0.1mm, it will seriously affect the stability of the shot blasting machine operation. An effective solution to these issues is to use an on-site dynamic balancing instrument to accurately calibrate the impeller, strictly controlling the residual unbalance within the range of ≤ 0.2g to ensure smooth operation of the impeller; Replace high-quality bearings such as SKF/NSK and control the amount of lubricating grease filling at 70-80% to ensure good lubrication and operational performance of the bearings; Adjust the spindle using laser calibration technology to ensure its straightness meets the standard of ≤ 0.05mm/m. Insufficient shot blasting volume is also a common fault in shot blasting systems, characterized by a decrease of more than 20% in shot flow rate and a surface coverage rate of less than 90% on the workpiece. This directly affects the shot blasting treatment effect and requires further investigation and resolution of the cause.

丸料循环系统故障主要体现在提升机卡死与分离器效率下降两个方面。提升机卡死的主要原因涉及皮带打滑，当皮带摩擦系数低于 0.3 时，无法有效传递动力；畚斗变形，容积损失超过 15%，影响丸料提升量；底部积料，厚度超过 100mm，阻碍畚斗正常运行。对应的解决方案为张紧皮带，将挠度精准调整至 1.5% 跨距，以恢复皮带摩擦力；更换尼龙增强抗冲击型畚斗，提高其耐用性和可靠性；安装料位开关，并与清理装置联动，及时清除底部积料。分离器效率下降可通过丸料含粉率大于 3%、废料中含可用钢丸超过 5% 来判断，优化方案包括调整风量，将风速严格控制在 4 - 6m/s，确保分离效果；更换筛网，保证其孔径公差在 ±0.1mm 范围内，提高筛分精度；加装二次分离装置，进一步提升分离效率。

The main faults of the pellet circulation system are manifested in two aspects: the elevator getting stuck and the separator efficiency decreasing. The main reason for elevator jamming is belt slippage. When the friction coefficient of the belt is below 0.3, it cannot effectively transmit power; The deformation of the dustpan results in a volume loss of over 15%, which affects the lifting capacity of the pellets; Bottom accumulation, with a thickness exceeding 100mm, hinders the normal operation of the dustbin. The corresponding solution is to tighten the belt and accurately adjust the deflection to 1.5% span to restore the friction of the belt; Replace the nylon reinforced impact resistant bucket to improve its durability and reliability; Install the material level switch and link it with the cleaning device to promptly remove the accumulated material at the bottom. The decrease in separator efficiency can be judged by the powder content of the pellets being greater than 3% and the available steel pellets in the waste exceeding 5%. The optimization plan includes adjusting the air flow rate to strictly control it at 4-6m/s to ensure the separation effect; Replace the screen mesh to ensure its aperture tolerance is within ± 0.1mm and improve screening accuracy; Install a secondary separation device to further improve separation efficiency.

电气控制系统故障涵盖 PLC 程序异常与电机过载等问题。PLC 程序异常的典型问题包括传感器误信号，当干扰超过 10% 量程时，会导致错误指令；通讯中断，丢包率大于 1%，影响数据传输；程序死循环，扫描周期超过 200ms，使系统无法正常运行。解决这些问题需要实施信号隔离，采用 4 - 20mA 隔离器，减少信号干扰；改用 PROFINET 通讯协议，将响应时间缩短至＜10ms，提高通讯稳定性；增加看门狗程序，防止程序陷入死循环。针对电机过载问题，有效的保护措施包括对热继电器进行整定，设定为 110% 额定电流，实现过载保护；加装振动开关，当振动速度超过 7.1mm/s 时触发报警；实施软启动，将启动时间延长至＞15s，减小启动电流冲击，保护电机安全运行 。

Electrical control system failures include issues such as abnormal PLC programs and motor overload. Typical problems with abnormal PLC programs include sensor false signals, which can cause erroneous commands when interference exceeds 10% of the range; Communication interruption, packet loss rate greater than 1%, affecting data transmission; The program has a dead loop with a scanning period exceeding 200ms, causing the system to malfunction. To solve these problems, signal isolation needs to be implemented, using 4-20mA isolators to reduce signal interference; Switching to PROFINET communication protocol, reducing response time to<10ms and improving communication stability; Add a watchdog program to prevent the program from getting stuck in a dead loop. Effective protection measures for motor overload include setting the thermal relay to 110% of the rated current to achieve overload protection; Install a vibration switch that triggers an alarm when the vibration speed exceeds 7.1mm/s; Implement soft start, extend the start time to>15s, reduce the impact of starting current, and protect the safe operation of the motor.

本文由自动式抛丸机,友情奉献.更多有关的知识请点击:http://www.sdcjtz.com我们将会对您提出的疑问进行详细的解答，欢迎您登录网站留言.

This article is dedicated to the automatic shot blasting machine and friendship For more information, please click: http://www.sdcjtz.com We will provide detailed answers to your questions. You are welcome to log in to our website and leave a message

上一篇：沸石转轮废气处理过程中哪些物质不能进入设备中
下一篇：