搜索历史清除全部记录
- All
- Product Management
- News
- Introduction
- Enterprise outlets
- FAQ
- Enterprise Video
- Enterprise Atlas
Guideline for Fault Diagnosis and Adjustment of Unstable Flow Rate in Wet Spray Machine Accelerator Pumps
Release time:
2025-12-24
Source:
Author:
Summary:
I. Common Failure Causes
1. Mechanical factors (40%): Piston/diaphragm wear (leakage exceeding 5%); one-way valve sticking (pressure difference for opening and closing exceeding 0.3 MPa); loosening of the transmission mechanism (coupling clearance exceeding 0.5 mm).
2. Hydraulic System Issues (30%): Pressure fluctuations (standard ±0.5 MPa; abnormal fluctuations > ±1 MPa); oil contamination (particles > 10 μm causing servo valve sticking).
3. Control system failure (20%): Flow sensor drift (error > ±3%); unstable PLC output signal (pulse width fluctuation > 10%).
4. Characteristics of the rapid-setting agent (10%): Excessive viscosity (>200 cP, making pumping difficult); contains crystalline particles (>0.5 mm in diameter).
II. Diagnostic Process
1. Preliminary inspection: Observe the pressure gauge fluctuations (normally ≤ ±0.2 MPa); listen for unusual noises from the pump body (a clicking sound indicates a check valve malfunction).
2. Flow Rate Testing: Use a measuring cup to directly measure the output volume over 10 minutes (and compare it with the set value).
Segmented testing: low speed (5 L/min); high speed (20 L/min).
3. Component Inspection: Disassemble and inspect the plunger seal (replace if wear groove depth exceeds 0.1 mm); test the solenoid valve response (actuation time < 100 ms).
III. Adjustment and Maintenance Plan
| Failure Type | Handling Measures | Tool Requirements |
| Mechanical Wear | Replace Plunger Kit (Clearance ≤ 0.03 mm) | Micrometer |
| Hydraulic Instability | Clean the proportional valve filter element (β₅≥200) | Ultrasonic Cleaner |
| Control abnormality | Calibrate flowmeter (±1% accuracy) | Standard flow calibration bench |
| Medium Issue | Heat to 40℃ or add a diluent | Viscometer |
IV. Key Adjustment Steps
1. Mechanical components: Adjust the plunger stroke (affecting the single-displacement volume); grind the check valve seat (sealing band width ≥ 1 mm).
2. Hydraulic System: Adjust the relief valve (to stabilize system pressure); replace with anti-wear hydraulic oil (ISO VG46).
3. Control parameters: Adjust the PLC pulse frequency (to match pump characteristics); reset the PID parameters (proportional band: 5%-10%).
V. Preventive Maintenance
1. Daily Maintenance: Clean the filter (100 mesh) every shift; check coupling alignment weekly (deviation < 0.1 mm).
2. Regular maintenance: Replace the sealing components every 500 hours; calibrate the flow sensor every 2,000 hours.
VI. Safety Precautions
1. Chemical Protection: When handling quick-setting agents, wear alkali-resistant gloves (pH > 11); equip the work area with eyewash stations.
2. Electrical Safety: Disconnect the 24V control power supply before performing maintenance; use intrinsically safe tools in explosion-proof areas.
VII. Economic Analysis
Rapid repair cost: ¥500–2000 (for replacing wear-and-tear parts)
System upgrade benefits: Installing a buffer tank (to reduce pulsation) → 40% improvement in flow stability; switching to servo motor drive → 30% energy savings.
RELATED INFORMATION
Contact Us
Changsha Base:Hunan Zenxon Heavy Industry Technology Co., Ltd.
Address: Jinrong Tongxin International Industrial Park, Changsha High-tech Zone
Loudi Base:Hunan Haoda Heavy Industry Technology Co., Ltd.
Address: Loudi Avenue, Loudi High-tech Industrial Development Zone, Lianyuan City, Loudi City, Hunan Province
Telephone:400-186-0868
E-mail:3804246750@qq.com
E-mail:19967177733@163.com
0
Consult now
WeChat Public Number
TikTok