Common Brick Making Machine Troubleshooting and Troubleshooting: Understanding These Signals to Avoid Significant Downtime Costs

Common Brick Making Machine Troubleshooting and Troubleshooting: Understanding These Signals to Avoid Significant Downtime Costs

A brick making machine is like a tireless worker, but during long periods of high-load operation, it may also signal discomfort through "abnormal signals." Promptly understanding these signals and taking appropriate action is key to ensuring production continuity and avoiding significant economic losses. The following are the most common types of faults and their corresponding solutions.

1. Brick Forming Problems: A "Warning Bell" for Product Quality

The brick itself is the most direct indicator of the health of the brick making machine.

Fault Symptom: The brick is loose, lacks strength, and falls apart easily.

Diagnosis: This is a typical sign of "insufficient pressure" or "lack of vibration."

Troubleshooting Key Points:

Hydraulic System Pressure: Check for insufficient or contaminated hydraulic oil. Are the hydraulic pump and relief valve functioning properly? Are there any leaks in the system?

Vibration System: Check for the vibration motor's excitation force reaching the set value? Are bearings damaged, causing a drop in speed? Are there any phases missing in the electrical circuit?

Raw Material Proportion: Check for excessive or insufficient moisture in the raw materials? Is the aggregate-to-cement ratio imbalanced? Too much water will "stretch" the particles, while too little will prevent effective gelation.

Fault Symptom: Uneven brick thickness, with "chipped corners" or "fractures."

Diagnosis: This usually points to "uneven material distribution" or "uneven pallet."

Troubleshooting Key Points:

Material Distribution System: Is the material distribution vehicle moving smoothly? Are there any lumps in the hopper that could hinder material discharge?

Pallet (Pallet): Check for warping or deformation. A warped pallet can lead to uneven heights in the molding chamber.

Mold: Check for any residual hard material in the mold, which could hinder the filling of new material.

II. Hydraulic System Problems: The "Heart Disease" of Equipment Operation

The hydraulic system is the power core of the brick making machine, and its failure often leads to a complete shutdown.

Fault Symptom: Insufficient system pressure, slow and weak operation.

Diagnosis: Insufficient power output.

Troubleshooting Key Points:

Hydraulic Oil: Is the oil level too low? Has the oil deteriorated due to long-term use, has low viscosity, or is it foaming? Oil filter: Is the filter element clogged, causing oil flow obstruction?

Hydraulic pump: Is internal pump leakage increasing, causing reduced efficiency?

Relief valve: Is the valve core stuck or is the set pressure unexpectedly lowered?

Fault symptom: Abnormally high oil temperature

Diagnosis: Abnormal energy loss in the system, usually due to friction or pressure loss.

Troubleshooting points:

Cooling system: Is the cooling water flowing freely? Is the fan working?

Hydraulic oil: Improper oil selection or contamination.

Internal leakage: Internal leaks in the hydraulic cylinder or valve block cause high-pressure oil to flow directly back into the tank, converting energy into heat.

Fault symptom: Cylinder movement creeps or vibrates.

Diagnosis: Unstable actuator operation.

Troubleshooting points:

Oil intake: Check the oil suction line for leaks and remove air from the system.

Seals: Are the cylinder seals worn, causing uneven friction? 3. Vibration System Issues: The Densely Molded "Core Engine"

Fault Symptom: Abnormally increased vibration noise, accompanied by a banging sound

Diagnosis: Loose or damaged vibration components

Troubleshooting Points:

Tightening Bolts: Immediately stop the machine and check for loose bolts connecting the vibration motor, vibration table, and frame! This is the most common and dangerous situation.

Vibration Motor Bearings: Are the bearings damaged due to lack of oil or fatigue?

Buffer Device: Are the buffer springs or rubber pads under the vibration table broken or deteriorating?

4. Electrical and Control System Issues: The "Nerve Center" of the Equipment's Operation

Fault Symptom: No PLC output, the entire machine does not operate

Diagnosis: Power supply or core controller failure

Troubleshooting Points:

Power Supply: Check the main power supply and control power supply fuses for blown fuses.

Emergency Stop: Is it pressed but not reset?

Safety Limit Switches: Are the safety switches on each protective door in place?

Fault Symptom: A specific actuator (such as a motor or solenoid valve) is not operating.

Diagnosis: Local circuit or component failure. Troubleshooting Key Points:

Wire Connections: Check for loose connections on the component's control circuit.

Contactor/Relay: Is the corresponding intermediate relay or contactor engaged?

Sensor: Check for malfunctioning limit switches and proximity switches, preventing the PLC from receiving the action enable signal.

Establish a Maintenance Culture to Nip Faults in the Bud

More important than troubleshooting is preventing them:

Adhere to daily maintenance: Strictly perform pre-shift inspections, post-shift cleaning, and regular lubrication.

Establish an Inspection System: Create a checklist and systematically inspect and record key components (such as bolts, oil levels, and abnormal noises) daily, weekly, and monthly.

Listen to the Equipment's "Language": Experienced operators can detect early signs of equipment anomalies through changes in sound, vibration, and temperature.

Conclusion: Brick-making machines don't always suddenly fail; they often send out distress signals before a malfunction occurs. By cultivating keen insight, mastering scientific diagnostic methods, and establishing a preventative maintenance system, you can mitigate the costs of potentially costly downtime through meticulous daily management. Remember, every successful troubleshooting not only repairs a machine, but also provides a solid insurance for your production efficiency.