The long service life of the granulator die depends first on the manufacturer's manufacturing quality, but the correct operating technique is also essential. Domestic feed mills have increased rapidly, and pellet feed is being promoted from south to north. It is understood that many small and medium-sized manufacturers have caused the premature wear and burst of the stamper due to improper operation of the granulator. The production capacity of the stamper has not been exerted, which has affected the output of the entire production line. The stamper is a relatively expensive wearing part. If used properly, the cost per ton is 2.50~3.50 yuan. If the operation is improper, the cost of the ton mold is more than 5.00 yuan, which increases the production cost.
1 New mold installation
After the inspection of each part of the granulator is normal, carry out the dry running test, check whether the main shaft and the pressure roller are swaying, and adjust it. The feeding scraper should also be adjusted, otherwise it will make it difficult for the material to enter between the stamper and the press roller, and a part of the material will be thrown out from the stamper cover, and the powdering rate is high. Adjust the gap between the upper edge curve of the scraper and the die and the die cover so that it is controlled between 2~3mm. The position of the front end of the scraper into the die should not exceed the undercut of the inner hole of the die.
The gap between the new stamper and the new press roller is 0.05mm~0.5mm, so as to rotate the stamper, the press roller does not rotate very well. Adjust the axial nut of the pressure roller until it is adjusted and locked, and add enough butter (usually use high temperature lithium grease, 8h once) to avoid burning the die bearing due to excessive temperature. The gap between the stamper and the press roller is too small, the stamper and the press roller are easily worn, and in severe cases, the stamper (when the mold quality is poor) is accelerated. Moreover, the noise is large and affects the output. Generally, the gap should be selected according to the size of the die hole. The small gap of the die hole is smaller, and the gap of the die hole is larger; the gap of the new die is smaller, and the gap of the old die is larger. The gap between the stamper and the press roller is too large, which may cause difficulty in discharging. A new press roll should be used for the new press.
2 How to use the new stamper
The various parts of the granulator are well adjusted, and the mechanism can be opened. The new mold has poor oxide finish, oxide layer, rust point, etc., and the feeding or feeding is slightly larger, which is easy to block the die hole. Burned to death. Therefore, the new stamper should be washed for 15-30 minutes before starting to use, first added to the machine with wheat husk added with about 5~8% oil, and then added after the discharge, repeated for 15min. In this way, the die hole can be squeezed and cleaned, and the original sundries oil in the mold is washed. Note that the added oil should be a harmless oil for the livestock. In this way, repeated manual feeding and extrusion, if the main motor is not overloaded, the discharge is smooth, and the discharge of the die hole can be stopped, and more than 90% of the die holes should be discharged.
After washing with wheat husks, you can add some new granulation formula raw materials to the granules and test the pressure gradually, and gradually increase the proportion. If the discharge is smooth, it can be officially granulated. First open the granulator and material state. In order to prevent the sundries from entering the die, the machine's external discharge door should be opened first, and the waste machine should be mixed with debris. After being cleaned, the material can be switched into the mold. For the sake of caution, the hand should hold the switch handle, first let some of the material enter the die, and then part of the material is discharged. Observe whether the die is discharged smoothly and observe whether the current of the main motor is stable. If it is normal, the material can be completely switched in. At this time, the feed can be gradually increased, and the main motor current is continuously observed. If the current increases sharply, stop the feeder immediately and switch the material out of the door. When it is not serious, the granulator will return to normal after running for more than ten seconds. For example, if the die is not pressed within ten seconds, a bamboo pole can be used from the door to the bottom, or from the door, it can be normal, and then recovered. When feeding more than one place, when the material is increased to a certain amount (about 1/4 of the full load), steam can be slowly added to gradually increase the supply and increase the steam simultaneously. When the temperature of the mold material reaches 85 °C, the feed is increased, and the steam is added until the main motor current approaches the rated current, and the feed is stopped, and the steam is added to keep the temperature of the mold material between 85-90 °C. At this point, the granulator is in optimal working condition.
It is worth reminding that when you are at the beginning, do not rush to add steam. Because at this time, the material is small, the steam is much less, and it is easy to block the machine. It is better to add steam to improve when it is added to a certain amount.
3 reasons and countermeasures for blocking machine
The new die is not enough for the mold hole, the die is left too long, the die hole is rusted, etc., the raw material crushing particle size is too thick and too coarse, the raw material moisture is too high or too little (13-15%) can cause the plugging machine . Of course, the operator is not skilled, and without mastering the essentials and material characteristics, it is difficult to make the stamper discharge normally, and it is inevitable to block the mold.
When the new stamper is activated, three kinds of washing materials should be selected according to the mold hole finish: (1) better finish, wheat peel plus a little soybean oil; (2) poor finish or rust, jade peel plus oil, plus 50% fine Yellow sand. The method of washing the mold is as described above, and the three materials can be separately selected according to the mold hole condition, and the method of gradual upgrading can also be adopted, that is, (1) is selected, and (2) and (3) are not ideally selected. Note that the manual feeding should be slow and even, the eye always observes the motor ammeter, and it is found that the current rises suddenly, that is, the feeding is stopped. When the current is stable, the feeding can be increased, the inside of the machine can be pressurized, and the die hole can be more easily extruded. When the machine is severely blocked, it can be started after cleaning. Repeatedly washing for 15-30min, the heavy even takes 1h, until 90% of the die hole can be discharged. When washing the machine, when the machine is blocked several times, the mold temperature exceeds 100 °C. At this time, it is easier to block the machine. It is necessary to take measures to reduce the temperature: (1) When the mold discharge is slightly better, the oil can be added more in the feed, a little water; 2) Add 0.5-1.0kg oil to the mold and then add. (3) Stop, quickly open the door, level the die hole discharge port, and when the die temperature is high, use a small mop to brush the die hole with oil and close the door immediately. Let some of the oil become gas, and bulge the material inside the hole. If you look closely, you can see that most of the mold hole materials are taking small bubbles. This is an effective feature. After 15 minutes, the material will be discharged smoothly after pressing the machine. net.
When the die hole is blocked, the hand drill or the nail is used to open, so that the slow and easy damage to the die hole finish is insufficient. If the blockage is not very serious, and it is not in a hurry, it can be put into the oil for a week and then installed and squeezed to wash the mold, which can also be effective. If the blockage is serious, it is best to mold into the oil vat (using waste engine oil), and heat it for cooking. After the oil is turned on for about 20 minutes, the die hole material has a popping sound, and the mold is taken out after cooling. This will quickly remove the die hole material without damaging the die hole finish.
4 Repair of the stamper
During the use of the stamper, the wear of the inner surface of the mold becomes uneven, and it is a pity to discard it due to the serious local wear. There are many reasons for wear, which are divided into normal wear and abnormal wear. The main reason for abnormal wear: the pressure roller is adjusted too tightly, and the gap between the pressure die and the die is small; the blade angle is not good, resulting in uneven distribution of the material and partial wear; the metal falls into the mold and wears. When the stamper is used up to 60%, it can be repaired once and reused. The life of the stamper can be extended by nearly one week. It can produce 1000~2000t of material, which can save the mold cost by 2000~4000 yuan. With more than a dozen repairs a year, the economic benefits are considerable.
The specific repair method: the mold is clamped on the old lathe, and the cutter holder is modified with a small grinder. On the inner surface of the mold, find the wear point similar to the intermediate state as the reference, start the lathe to make the mold rotate slowly, and the cutter wheel will slowly feed. It will be worn higher than the reference part (which is a small part). It can be divided into several times. Care should be taken to add cooling medium during grinding to avoid reducing the surface hardness of the mold. Note that the benchmark should be reasonable, the reference is too low, the grinding cost is large, the mold is thin and not durable, and the material size is not hard enough; the reference is too high, and the effect after grinding is not good. Generally only repair once, wear too much will lose the value of repair. The pressure roller can also be repaired and must be grooved after grinding.
The life of the stamp directly affects the quality and yield of the product. The granulator and equipment management personnel must carefully summarize the experience, continuously improve the operational skills, control the tonnage cost of the stamper to a lower level, and create the best economic benefits.
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