What are the causes of the failure of Shanghai diesel generator sets?

The generator set is mainly composed of three parts: engine, AC synchronous generator and control box (screen). The engine is part of the power generated by the unit and is most likely to fail. There are internal and external causes for faults in the unit.

One, internal reasons

1, the nature of materials and oil

In the process of designing and manufacturing, materials should be correctly selected according to the nature and characteristics of the parts of the generator set . Inappropriate choice of materials, non-conformity of materials, and inappropriate substitutes are major causes of wear, corrosion, deformation, cracking, and aging of parts. The properties of various materials and oils used in the unit can be summed up in three aspects: physical properties, chemical properties and mechanical properties. Many of the crew's failures are the result of external factors and the effect of these properties. If the metal material is subjected to general deformation, it will be oxidized under the effect of high temperature; non-metallic materials will be aged, and the acid substances contained in the oil will corrode the metal and will also deteriorate the oil.

2, the structural characteristics of the parts

Each unit of the unit has its own characteristics in terms of structure. In the work, external factors often work through these features, causing the related parts to fail. For example, due to the structural characteristics of the engine water jacket itself, under the effect of high temperature, cooling water forms scale on the outer wall of the cylinder sleeve, which affects the cooling effect of the cylinder sleeve.

3, the working characteristics of the parts

Parts that are in direct contact and have relative motion wear due to friction. For example, the piston ring of a diesel engine is in direct contact with the cylinder. During operation, the piston ring performs a high-speed reciprocating linear motion in the cylinder, resulting in wear of the cylinder. Components that undergo severe temperature changes during operation are deformed and cracked due to thermal stress. For example, in the diesel engine working process, due to the effects of high tide, the cylinder block and the cylinder head are redistributed to achieve a new balance, resulting in warping deformation of the cylinder head plane.

Second, external reasons

1, improper use

The user did not use the unit in accordance with the operating procedures. If the engine is running at a low speed frequently, the load will increase rapidly without warming up, and the oil pressure will be too low to accelerate the wear of the parts. Excessive working hours, excessive load changes, and long-term overload operation may also cause premature damage of parts.

2, poor maintenance

In the maintenance of the unit, the work was not completed in strict accordance with the prescribed technical requirements, or wrong methods of operation were used, resulting in human error. In normal maintenance, it is necessary to replace the oil in time and regularly clean the scales of the air filter and the tank. According to the requirements of the daily maintenance of the unit and the first, second and third level maintenance.

3, repair quality is not high

During the repair process, if it is improperly processed and does not meet the technical requirements for repairs, such as improper fit clearance of various parts, insufficient smoothness of the surface, unclean cleaning during assembly, etc., will cause the unit to malfunction during use. In the assembly process, the accuracy of the mutual position between the parts is also very important. If it fails to meet the requirements, it will cause additional stress, produce adverse effects such as eccentric wear, and accelerate the failure of the parts.

The establishment of a reasonable maintenance system and the strict implementation of technical regulations for the maintenance and use of diesel generator sets are important conditions for ensuring the reliable operation of the generator set and increasing its service life. In addition, maintenance personnel need to be trained regularly to improve their business level.