What are the common faults of automatic emulsifiers, and how to troubleshoot them?
During the operation of automatic emulsifiers, common faults mainly include emulsification effect degradation, equipment abnormal noise, temperature deviation, and system alarm. The corresponding troubleshooting methods are as follows:
1) Poor Emulsification Effect (e.g., uneven texture, phase separation): a) Check whether the rotor-stator working head is worn or damaged—worn parts will reduce shear force, so they need to be replaced in time. b) Verify if the process parameters are reasonable (e.g., insufficient rotational speed, too short emulsification time). Adjust the parameters according to the material properties and re-test. c) Check if the raw material ratio is correct—an incorrect oil-water ratio or insufficient emulsifier addition can lead to poor emulsification. Recheck the formula and adjust the raw material ratio. d) Check if the material temperature is within the optimal range—too high or too low temperature will affect the emulsification effect. Adjust the temperature control parameters.
2) Abnormal Noise During Operation: a) Check if the rotor-stator working head is loose—tighten the fixing bolts. b) Check if there are foreign objects (e.g., metal particles, hard impurities) in the mixing tank—foreign objects will collide with the working head to produce noise. Stop the equipment immediately, clean the mixing tank, and remove the foreign objects. c) Check the drive system (e.g., motor, transmission shaft) for abnormal wear or lack of lubrication. Add lubricating oil as required, or replace worn parts.
3) Temperature Deviation Exceeds the Set Range: a) For temperature that is too high: Check if the cooling system is working normally (e.g., cooling water flow, refrigeration unit). Clean the cooling pipeline if it is blocked, or repair the refrigeration unit if it fails. Also, check if the emulsification speed is too high—high speed will generate excessive heat; reduce the speed appropriately. b) For temperature that is too low: Check if the heating system (e.g., heating jacket, heating tube) is working. Repair or replace the heating element if it is damaged, and check if the temperature sensor is accurate—calibrate the sensor if there is a deviation.
4) System Alarm (e.g., overload alarm, leak alarm): a) Overload Alarm: Stop the equipment immediately, check if the material viscosity is too high (reduce viscosity by heating or diluting) or if the working head is blocked (clean the working head). Also, check if the motor is overheated—wait for it to cool down before restarting. b) Leak Alarm: Check the pipelines, valves, and mixing tank seals for leaks. Replace the seal ring if it is damaged, and tighten the pipeline connections.
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