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Common Troubleshooting Methods of Concrete Batching Plant

Thomas Huang posted this article in August 03, 2020

The good application of the mixing plant can not only improve the production efficiency of concrete, but also save time and improve production. Nowadays, various enterprises have realized the important role of mixing plant, and constantly improve the measures and technologies, and strengthen the application. This article takes the most commonly used dual-shaft forced mixer as a reference, briefly explains the main faults in the operation of the mixing plant, and further analyzes and proposes improved treatment countermeasures to lay a solid foundation for the further development of the mixing plant. The following is a simple analysis of these problems to further strengthen the processing.
Dust appears on the top of the powder irrigation
This phenomenon is one of the common failures of mixing plants. It is manifested in that when the mixing pump is transporting dispersed powder, due to the small particles, the powder will be exposed, which will pollute the environment and cause waste. The reason for this phenomenon is mostly because the filter core in the dust collector is blocked, which makes the pressure of the powder filling rise, or the safety valve is seriously blocked due to the humidity of the external environment, which causes the dusty gas to break through the sealing ring. , Causing dust leakage.
For this phenomenon, we must solve it from two aspects. First, before the mixing pump carries out the powder transportation, start the topping dust collector for a period of time and ensure that there is no dust on the equipment. After the pump is delivered, the dust collector is activated again to vibrate to ensure its cleanliness and hygiene. Second, during the operation of the mixing plant, it is necessary to select high-quality filter core equipment. Only in this way can the filtering effect be good, and a higher filtering effect can be achieved, reducing the frequency of failures and increasing the use time limit of the mixing plant.
Feeding speed of powder is slow
The reason for this failure is mostly due to the slow feeding speed of the powder after the screw machine is started, or the screw machine is stuck on the way in. According to the analysis, it can be known that the cause of this phenomenon is probably due to the arching of the powder or the agglomeration blocking the outlet. In addition, the gap of the screw blades not meeting the regulations will seriously hinder the transportation of the materials. Faced with such a situation, we must proceed from the following aspects to improve. First of all, start the air blowing arch breaking equipment. If the unloading is still not guaranteed after starting, then the screw feed manual butterfly valve is closed. Secondly, check whether the screw blades are deformed or damaged. Once the problem is found, correct it immediately. Thirdly, the conveying and protection of the screw conveyor should be strengthened in the normal working process. After the operation is over, vent the machinery and equipment, and check them regularly to check the operation and lubrication of the reducer, and only use it if there is no abnormality. Finally, check the connection of the whole machine at regular intervals and relubricate it after every 1,000 hours.
The number of the weighing instrument drifts
Under normal circumstances, when the number displayed by the meter is constantly changing, fluctuating, and the final value cannot be determined, it means that the weighing meter is malfunctioning. When the weighing instrument of the mixing building has the above failure, it should be analyzed in time. The weight data displayed by the weighing instrument in the mixing building is the current signal from the sensor, which indicates that the greater the weight fluctuation of the weighing instrument, the stronger the current intensity transmitted by the sensor. When the sensor is damaged or the wire end of the junction box becomes loose, it may cause current fluctuations. To solve this kind of failure, you can use the elimination method and the signal transmission method to determine it.
 (1) Elimination method
 Remove all wiring on the sensor and observe whether the meter data continues to fluctuate. Assuming that after removing the wiring on the sensor, it is found that the meter data stops swinging, it means that the wiring of the sensor is loose or the entire sensor is damaged. Reconnect the removed sensor to the junction box. If you find that the meter data is not drifting, it indicates that there is a high probability that the meter is drifting due to loose wiring. You only need to reconnect it if you find this kind of situation. If the weighing instrument keeps drifting, it indicates that there is a problem with the sensor itself, which needs to be replaced and solved in time.
(2) Signal transmission judgment method
After the weighing instrument is energized, check the sensors one by one, remove all the output wires of the sensor to keep it empty, and use a multimeter to measure the U output value of DC mV. Under the same conditions, the MV values of the same type of sensors are basically the same without load. If the measured output value of the sensor exceeds the calculated value or the rated output value of the sensor, it means that the sensor has malfunctioned.
(3) Choose the sensor that is sealed

During the installation process, butter should be used to evenly spread the wiring and the outside of the entire sensor to ensure that the sensor can be completely sealed. The main purpose of this is to make it waterproof and moisture-proof. In daily work, it is necessary to weigh according to the load weight, and at the same time, better quality shock absorption equipment can be installed on the weighing platform. In order to ensure that the sensor has a stable zero potential, when grounding the sensor, it must be grounded separately.
The mixing host has tripped
During the mixing process, the mixer often trips and produces waste, which not only increases the production cost, but also delays the construction period and brings serious adverse effects to daily work. There are several reasons for this situation:
(1) The blade gap between the liner and the mixing system is too large, and the aggregate is accidentally mixed in while mixing, which increases the resistance of mixing.
(2) The triangular traditional belt in the mixing main engine has experienced aging, which ultimately leads to a great reduction in the efficiency of the traditional system.
(3) Do not pay attention to the feeding, too much feeding, which causes the mixer to overload.
When these situations occur, remedial measures should be taken in time. The console ammeter can be monitored; the distance between the liner and the blade of the mixer can be checked to see if it exceeds 5 cm. When the V-belt is aging, it should be replaced as soon as possible. At the same time, it should be checked whether the main shaft and the linkage shaft are fixed. Fully inspect the batching system of the mixer to ensure that there is no over-standard and secondary feeding, and check the sensor to make it work normally. Before running the mixer, check the upper cover of the main unit to see if there is any looseness or damage. If there is, it should be replaced in time.
Deviation in the weighing of powder and aggregate
When weighing aggregates and powders, it is found that there are always deviations in the weighing measurement. The main reason is that the uniformity of aggregate weighing and discharge is inseparable. The drop must be smaller than the fine setting data, otherwise, if the fine setting signal has not been output, the drop signal has already been sent, and the unloading will stop. This situation can be solved by the following methods:
When there are too many raw materials, the drop can be adjusted. If the drop is greater than the fine setting, the coefficient of the fine drop should be continuously adjusted to make it larger. If the raw material is small, the drop can be made smaller. When the drop is adjusted, the fine setting usually does not need to be adjusted. If it is found that the raw materials are weighed more often than not, first check the uniformity of the discharge, carefully check whether the discharge port is normal, whether there are debris or agglomerates and other objects stuck, if any debris is found, then It should be processed immediately, and finally the drop and fine settings are adjusted.
Conclusion
All in all, the mixing plant is an equipment installation involving more technology, including electrical, equipment, and materials. In the actual operation process, it is inevitable that various problems will occur. In order to avoid these problems, it is necessary to implement systematic and refined management of the mixing plant, carry out production operations in strict accordance with the rules and regulations, and strengthen the regular maintenance and maintenance of the mixing plant, thereby reducing the frequency of failures and further improving Production efficiency makes the mixing plant a controllable and efficient operation mode, thereby promoting the improvement and progress of production.

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