The sudden decrease in the production of fruit net machines may be caused by factors such as raw materials, equipment, and operation. The following is a specific analysis and solution:
In terms of raw materials
Raw material blockage
Reason: Large particles of impurities may be mixed in the raw materials, or the raw materials may become damp and agglomerate, causing blockage of the feeding pipeline or hopper during the feeding process, resulting in poor supply of raw materials and affecting the output of the mesh machine. For example, polyethylene particles become block like due to moisture and get stuck at the feeding port.
Solution: Install a raw material filter to screen and remove impurities from the raw materials before feeding. At the same time, dry or replace damp raw materials, regularly clean the feeding pipeline and hopper to ensure smooth transportation of raw materials.
Poor fluidity of raw materials
Reason: Irregular particle shape, unreasonable particle size distribution, or improper proportion of additives in raw materials can all affect their fluidity. Raw materials with poor fluidity are difficult to evenly disperse and plasticize in the barrel, which reduces production efficiency. For example, larger polyethylene particles can cause slow flow of raw materials in the barrel.
Solution: Optimize the raw material formula, adjust the proportion of additives, and ensure that the raw materials have good fluidity. Select raw material particles with uniform particle size and regular shape, and if necessary, perform pre-treatment on the raw materials, such as grinding, granulation, etc., to improve their flowability.
Equipment aspect
Screw wear
Reason: During long-term operation, the friction between the screw and the raw material, as well as the high temperature and high pressure environment, will gradually wear down the surface of the screw, reduce the height of the screw edge, lead to a decrease in the conveying capacity of the screw, uneven plasticization of the material, and thus affect the output.
Solution: Regularly check the wear of the screw, and replace it with a new one when the wear is severe. When selecting screws, it is necessary to consider the characteristics of raw materials and production process requirements, choose screws with suitable materials and specifications, and optimize screw speed and temperature control to reduce screw wear.
Heating system malfunction
Reason: Heating system problems such as damaged heating coils and malfunctioning temperature controllers can cause unstable or unable to reach the set temperature of the material barrel, resulting in incomplete plasticization of raw materials, poor material fluidity, difficult extrusion, and reduced output. For example, if the heating coil is partially damaged, causing the temperature in some areas of the material barrel to be too low, the raw materials cannot be fully melted.
Solution: Check if the heating coil is working properly, measure the resistance of the heating coil with a multimeter, and replace it if the resistance is abnormal. Calibrate the thermostat to ensure accurate temperature control. At the same time, install a temperature alarm device to promptly sound an alarm when the temperature exceeds the set range, so that operators can handle it in a timely manner.
Mold blockage or wear
Reason: During the production process, impurities, decomposition products, or carbonized substances in the raw materials may accumulate in the mold, block the discharge port, and prevent smooth extrusion of the mesh sleeve. After long-term use of the mold, the internal flow channels wear out, leading to poor mesh forming and affecting production output. For example, the discharge port of the mold is blocked by carbonized polyethylene, which affects the discharge speed.
Solution: Regularly clean the mold, use specialized mold cleaning agents and tools to remove internal impurities and scale. Repair or replace severely worn molds. During the production process, strictly control the quality of raw materials to avoid impurities entering the mold. At the same time, adjust the processing temperature and pressure reasonably to reduce raw material decomposition and carbonization.
Operational
Improper parameter settings
Reason: The operator did not adjust the production parameters reasonably based on the characteristics of the raw materials and equipment status, such as screw speed, temperature, traction speed, etc. For example, the screw speed is too fast, resulting in insufficient plasticization time of the raw materials; The mismatch between traction speed and extrusion speed causes excessive stretching or stacking of the mesh sleeve, affecting production continuity.
Solution: Strengthen operator training to familiarize them with equipment performance and raw material characteristics, and master the correct parameter setting methods. Before production, the optimal production parameters are determined through experiments based on the requirements of raw materials and products, and fine tuned according to the actual situation during the production process.
Equipment maintenance is not timely
Reason: Due to long-term operation of the equipment, the precision of the coordination between various components will decrease, such as loose transmission chains, belt slippage, etc., which affects the normal operation of the equipment and leads to a decrease in production. Meanwhile, excessive accumulation of dust, oil stains, and other contaminants inside the equipment can also affect its performance.
Solution: Develop a detailed equipment maintenance plan and regularly perform comprehensive maintenance on the equipment, including inspecting and adjusting transmission components such as tensioning chains and replacing worn belts; Clean the dust and oil stains inside the equipment, lubricate and rust proof key components. Establish equipment maintenance files to record equipment maintenance status and fault handling records, in order to promptly identify potential issues.