高壓去毛刺清洗機(jī)在設(shè)備運(yùn)行過程中，噴嘴系統(tǒng)、傳動(dòng)系統(tǒng)以及電氣控制系統(tǒng)常面臨各類問題，這些問題不僅影響設(shè)備的正常運(yùn)轉(zhuǎn)，還可能對(duì)生產(chǎn)效率和產(chǎn)品質(zhì)量產(chǎn)生不利影響，以下是對(duì)這些系統(tǒng)常見故障的詳細(xì)分析及針對(duì)性解決方案。

During the operation of the high-pressure deburring cleaning machine, the nozzle system, transmission system, and electrical control system often face various problems. These problems not only affect the normal operation of the equipment, but may also have adverse effects on production efficiency and product quality. The following is a detailed analysis and targeted solutions to common faults in these systems.

噴嘴系統(tǒng)問題主要體現(xiàn)在噴霧形態(tài)異常和噴嘴快速磨損兩個(gè)方面。當(dāng)出現(xiàn)噴霧形態(tài)異常時(shí)，可依據(jù)具體現(xiàn)象判斷故障原因并采取相應(yīng)解決措施。若噴霧發(fā)散，通常是由于噴嘴磨損所致，此時(shí)需更換硬質(zhì)合金噴嘴以提升耐磨性；若噴霧不對(duì)稱，很可能是流道堵塞造成的，可采用超聲波清洗的方式清理噴嘴；而流量突變則大概率是密封圈失效引起，應(yīng)及時(shí)更換氟橡膠密封件。針對(duì)噴嘴快速磨損的問題，改進(jìn)方案包括升級(jí)為陶瓷噴嘴，其壽命相較普通噴嘴可延長(zhǎng) 3 - 5 倍；增加精度≤50μm 的前置過濾器，過濾掉可能磨損噴嘴的雜質(zhì)；優(yōu)化噴射角度，避免噴霧反彈對(duì)噴嘴造成沖擊，從而有效減緩噴嘴磨損速度。

The problems of the nozzle system are mainly reflected in the abnormal shape of the spray and the rapid wear of the nozzle. In case of abnormal spray shape, the fault cause can be judged according to the specific phenomenon and corresponding solutions can be taken. If the spray is divergent, it is usually caused by nozzle wear. At this time, the cemented carbide nozzle needs to be replaced to improve wear resistance; If the spray is asymmetric, it is likely that the flow channel is blocked, the nozzle can be cleaned by ultrasonic cleaning; The sudden change in flow rate is most likely caused by the failure of the sealing ring, and the fluororubber seal should be replaced in a timely manner. To address the issue of rapid nozzle wear, the improvement plan includes upgrading to ceramic nozzles, which can extend their lifespan by 3-5 times compared to ordinary nozzles; Add a pre filter with an accuracy of ≤ 50 μ m to filter out impurities that may wear out the nozzle; Optimize the spray angle to avoid the impact of spray rebound on the nozzle, thus effectively slowing down the wear rate of the nozzle.

傳動(dòng)系統(tǒng)故障主要表現(xiàn)為輸送帶跑偏和旋轉(zhuǎn)機(jī)構(gòu)卡滯。對(duì)于輸送帶跑偏問題，校正流程需從多個(gè)方面入手。首先，調(diào)整張緊氣缸的壓力至 0.4 - 0.6MPa，確保輸送帶具有合適的張緊度；其次，使用激光校準(zhǔn)導(dǎo)軌，將平行度控制在≤0.2mm/m，保證輸送帶運(yùn)行的直線性；最后，更換防滑花紋帶，使摩擦系數(shù)達(dá)到≥0.8，防止輸送帶打滑跑偏。在處理旋轉(zhuǎn)機(jī)構(gòu)卡滯問題時(shí)，維護(hù)要點(diǎn)包括每月對(duì)旋轉(zhuǎn)接頭進(jìn)行清洗，去除可能導(dǎo)致卡滯的水垢；選用 NLGI 2# 食品級(jí)潤(rùn)滑脂進(jìn)行潤(rùn)滑，確保旋轉(zhuǎn)部件的順暢運(yùn)轉(zhuǎn)；加裝 IP68 等級(jí)的防水軸承，防止水分侵入影響旋轉(zhuǎn)機(jī)構(gòu)性能。

The main manifestations of transmission system faults are conveyor belt deviation and rotating mechanism jamming. For the problem of conveyor belt deviation, the correction process needs to start from multiple aspects. Firstly, adjust the pressure of the tensioning cylinder to 0.4-0.6MPa to ensure that the conveyor belt has the appropriate tension; Secondly, use laser to calibrate the guide rail and control the parallelism within ≤ 0.2mm/m to ensure the straightness of the conveyor belt operation; Finally, replace the anti slip patterned belt to achieve a friction coefficient of ≥ 0.8 to prevent the conveyor belt from slipping and deviating. When dealing with the problem of stuck rotating mechanisms, maintenance points include cleaning the rotating joints monthly to remove scale that may cause sticking; Use NLGI 2 # food grade grease for lubrication to ensure smooth operation of rotating components; Install waterproof bearings with IP68 rating to prevent moisture from entering and affecting the performance of the rotating mechanism.

電氣控制系統(tǒng)方面，PLC 故障和安全聯(lián)鎖失效是較為突出的問題。在 PLC 故障處理中，針對(duì)模擬量干擾，可加裝 4 - 20mA 信號(hào)隔離器，有效阻隔外界干擾信號(hào)；對(duì)于數(shù)字量抖動(dòng)問題，通過增加軟件濾波功能，設(shè)置 50ms 延時(shí)，消除信號(hào)抖動(dòng)；當(dāng)出現(xiàn)通訊中斷情況時(shí)，改用波特率≥1Mbps 的光纖傳輸，提升通訊的穩(wěn)定性和傳輸速度。針對(duì)安全聯(lián)鎖失效問題，改造措施包括構(gòu)建雙回路急停系統(tǒng)，達(dá)到 CAT4 安全等級(jí)，確保緊急情況下能可靠停機(jī)；安裝分辨率≤14mm 的光柵保護(hù)裝置，實(shí)時(shí)監(jiān)測(cè)工作區(qū)域安全；采用機(jī)械表與傳感器相結(jié)合的壓力雙重監(jiān)測(cè)方式，提高壓力監(jiān)測(cè)的可靠性，全方位保障設(shè)備運(yùn)行安全。

In terms of electrical control systems, PLC failures and safety interlock failures are prominent issues. In PLC fault handling, for analog interference, a 4-20mA signal isolator can be installed to effectively block external interference signals; For the problem of digital jitter, adding software filtering function and setting a 50ms delay can eliminate signal jitter; When communication interruption occurs, switch to fiber optic transmission with baud rate ≥ 1Mbps to improve communication stability and transmission speed. Regarding the issue of safety interlock failure, the renovation measures include building a dual circuit emergency stop system to achieve CAT4 safety level, ensuring reliable shutdown in emergency situations; Install grating protection devices with a resolution of ≤ 14mm to monitor the safety of the work area in real-time; Adopting a dual pressure monitoring method combining mechanical gauges and sensors to improve the reliability of pressure monitoring and ensure the safe operation of equipment in all aspects.

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