在工業(yè)生產(chǎn)設(shè)備運(yùn)行過程中，拋丸機(jī)的各系統(tǒng)常面臨諸多故障挑戰(zhàn)，以下將從拋丸器系統(tǒng)、丸料循環(huán)系統(tǒng)、電氣控制系統(tǒng)三大方面，對其常見故障進(jìn)行深度剖析并給出針對性解決方案。

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.

拋丸器系統(tǒng)故障中，拋丸器振動異常問題較為突出。其產(chǎn)生原因主要包括葉輪不平衡，當(dāng)動平衡偏差超過 0.5g 時(shí)，葉輪在高速旋轉(zhuǎn)下會因質(zhì)量分布不均產(chǎn)生劇烈振動；軸承磨損，一旦軸承徑向游隙超過 0.15mm，將無法有效支撐主軸運(yùn)轉(zhuǎn)，導(dǎo)致振動加??；主軸彎曲，若跳動量大于 0.1mm，會使拋丸器運(yùn)行穩(wěn)定性受到嚴(yán)重影響。針對這些問題，有效的解決措施為使用現(xiàn)場動平衡儀對葉輪進(jìn)行精準(zhǔn)校正，將殘余不平衡量嚴(yán)格控制在≤0.2g 的范圍內(nèi)，以保障葉輪運(yùn)轉(zhuǎn)平穩(wěn)；更換 SKF/NSK 等高品質(zhì)軸承，并將潤滑脂填充量控制在 70 - 80%，確保軸承良好的潤滑與運(yùn)行性能；采用激光校準(zhǔn)技術(shù)對主軸進(jìn)行調(diào)整，保證其直線度達(dá)到≤0.05mm/m 的標(biāo)準(zhǔn)。而拋丸量不足也是拋丸器系統(tǒng)常見故障，其典型表現(xiàn)為丸料流量下降幅度超過 20%，工件表面覆蓋率低于 90%，這會直接影響拋丸處理效果，需要進(jìn)一步排查原因并解決 。

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.

丸料循環(huán)系統(tǒng)故障主要體現(xiàn)在提升機(jī)卡死與分離器效率下降兩個(gè)方面。提升機(jī)卡死的主要原因涉及皮帶打滑，當(dāng)皮帶摩擦系數(shù)低于 0.3 時(shí)，無法有效傳遞動力；畚斗變形，容積損失超過 15%，影響丸料提升量；底部積料，厚度超過 100mm，阻礙畚斗正常運(yùn)行。對應(yīng)的解決方案為張緊皮帶，將撓度精準(zhǔn)調(diào)整至 1.5% 跨距，以恢復(fù)皮帶摩擦力；更換尼龍?jiān)鰪?qiáng)抗沖擊型畚斗，提高其耐用性和可靠性；安裝料位開關(guān)，并與清理裝置聯(lián)動，及時(shí)清除底部積料。分離器效率下降可通過丸料含粉率大于 3%、廢料中含可用鋼丸超過 5% 來判斷，優(yōu)化方案包括調(diào)整風(fēng)量，將風(fēng)速嚴(yán)格控制在 4 - 6m/s，確保分離效果；更換篩網(wǎng)，保證其孔徑公差在 ±0.1mm 范圍內(nèi)，提高篩分精度；加裝二次分離裝置，進(jìn)一步提升分離效率。

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.

電氣控制系統(tǒng)故障涵蓋 PLC 程序異常與電機(jī)過載等問題。PLC 程序異常的典型問題包括傳感器誤信號，當(dāng)干擾超過 10% 量程時(shí)，會導(dǎo)致錯(cuò)誤指令；通訊中斷，丟包率大于 1%，影響數(shù)據(jù)傳輸；程序死循環(huán)，掃描周期超過 200ms，使系統(tǒng)無法正常運(yùn)行。解決這些問題需要實(shí)施信號隔離，采用 4 - 20mA 隔離器，減少信號干擾；改用 PROFINET 通訊協(xié)議，將響應(yīng)時(shí)間縮短至＜10ms，提高通訊穩(wěn)定性；增加看門狗程序，防止程序陷入死循環(huán)。針對電機(jī)過載問題，有效的保護(hù)措施包括對熱繼電器進(jìn)行整定，設(shè)定為 110% 額定電流，實(shí)現(xiàn)過載保護(hù)；加裝振動開關(guān)，當(dāng)振動速度超過 7.1mm/s 時(shí)觸發(fā)報(bào)警；實(shí)施軟啟動，將啟動時(shí)間延長至＞15s，減小啟動電流沖擊，保護(hù)電機(jī)安全運(yùn)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.

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