The high temperature environment in summer can exacerbate lubricant dilution, motor overheating, seal aging, powder agglomeration, and hydraulic oil temperature surge. The vertical axis planetary engine has a precise structure (planetary carrier, mixing arm, wear-resistant lining plate, planetary reducer, hydraulic station, sealing assembly), and five major modules for high-temperature maintenance: pre shift inspection, temperature control during operation, post shift cleaning, periodic special maintenance, and high-temperature emergency response.
1、 Pre shift special inspection for high temperature startup (10 minutes before daily startup)
Inspection of gearbox and lubricating oil
Check the oil level of the planetary reducer and rotary support. The oil is prone to thin leakage at high temperatures, and the oil level should be maintained within the range of 1/2 to 2/3 of the oil gauge. Oil shortage and overflow are prohibited.
Observe the color of the lubricating oil: if it turns white, water enters, turns black, carbonizes, or bubbles appear, the oil should be changed immediately; Special high-temperature extreme pressure gear oil for summer to avoid high-temperature failure of ordinary oil.
Check for oil leakage in the gearbox oil seal and end cover. High temperatures can accelerate the softening and leakage of rubber oil seals. If there is slight oil leakage, tighten the end cover in a timely manner. If there is severe leakage, replace the skeleton oil seal.
Motor cooling system
Cleaning the main motor, hydraulic motor cooling fan cover, dust accumulation on the cooling fins, and powder clumping can directly cause the motor to trip due to high temperature.
Check the fan blades manually for any damage or looseness; When the ambient temperature exceeds 35 ℃, an industrial axial fan is installed outside the motor to assist in heat dissipation.
Check the motor wiring terminals. Insulation is prone to aging at high temperatures. If the terminals heat up or the rubber melts, tighten and replace the insulation sheath in a timely manner.
High temperature pre inspection of hydraulic station
The hydraulic oil level is sufficient. Replace 46 # anti-wear and high-temperature hydraulic oil in summer, and do not mix low-temperature hydraulic oil.
Check the cooler (air-cooled/water-cooled): Use air-cooled to clean the dust on the radiator; Water cooling inspection shows that the cooling water circulation is unobstructed, without scale blockage or water pipe leakage.
Check the hydraulic oil pipe. High temperature rubber pipes are prone to bulging and cracking. Replace aging oil pipes in advance and prevent loose joints and oil leakage.
Sealing and wear-resistant components of mixing chamber
The floating seal at the bottom of the main shaft and the seal at the end of the mixing shaft are high-temperature vulnerable parts, which are prone to burning due to high temperature and powder friction. Check for any mud leakage.
Check the fastening bolts of the lining plate, mixing arm, and mixing blade. They are prone to loosening due to high temperature thermal expansion and contraction, and all should be tightened again; Wear resistant parts that exceed the standard should be replaced in a timely manner to prevent scraping the cylinder.
Water supply and sprinkler system
Clean the waterway filter and nozzle. In summer, powder materials are prone to dry up and block the nozzle when exposed to high temperatures, ensuring smooth cooling and water supply channels; Waterproof wrapping for waterway water pipes to prevent aging and cracking due to exposure to sunlight.
2、 Temperature control and operating standards during operation (core anti high temperature damage)
Control continuous working hours
Environmental temperature>35 ℃: Continuous stirring for no more than 2 hours, shutdown for 20-30 minutes to dissipate heat; Try to stagger production during high temperature noon from 11:30 to 15:00 to avoid continuous operation at full load.
It is prohibited to start with full load and idle for a long time while carrying materials. Overloading can cause rapid heating of the reducer, motor, and hydraulic system.
Real time monitoring of temperature indicators
The temperature of the main motor casing should be ≤ 75 ℃. If it exceeds 80 ℃, the machine should be stopped immediately to cool down;
If the temperature of the planetary gearbox housing is ≤ 85 ℃ and the oil temperature exceeds 90 ℃, the machine will shut down;
The oil temperature of the hydraulic oil tank is normal at 40-60 ℃. If it exceeds 70 ℃, forced cooling will be activated. If it exceeds 80 ℃, the cooling system will be shut down for maintenance.
Cooling and anti sticking material for the cavity
Spray the cylinder wall promptly after mixing each batch. High temperature refractory materials, castables, and dry powders are prone to sticking to the cylinder and hardening, and clumping will increase the load and exacerbate equipment heating.
The outer wall of the cylinder can be equipped with a spray cooling pipeline to continuously dissipate heat and reduce the working temperature of the internal sealing components.
Lubrication dynamic oil replenishment
The automatic butter lubrication system has increased the frequency of oil spraying in summer: the planetary carrier bearings, rotary supports, and shaft end seals should be lubricated with high-temperature grease every 30 minutes;
Using high-temperature resistant lithium based grease (temperature resistance ≥ 180 ℃), ordinary butter fails due to high-temperature loss, resulting in dry grinding and burning of bearings.
Sunscreen protection for electrical control box
The electrical control cabinet should avoid direct sunlight and be equipped with a sunshade. The cooling fan inside the cabinet should be turned on 24 hours a day; Regularly clean the dust inside the cabinet to prevent the contactor and frequency converter from tripping due to high temperature protection.
The temperature control of the frequency converter is within 45 ℃, and high temperatures are prone to overload alarms and unstable outputs.
3、 Post shift shutdown, high-temperature cleaning and maintenance (must be done daily after work)
Thoroughly clean the cavity
The high-temperature residual mixture hardens overnight, and the load suddenly increases the next day when starting up: the high-pressure water gun flushes the cylinder wall, mixing arm, and planetary carrier bottom for clumping, and hard objects are prohibited from hitting the wear-resistant lining plate.
Deep cleaning of the cooling system
Blow out all dust and powder from the motor, hydraulic cooler, and electrical control cabinet, and wait for the equipment to cool down to below 50 ℃ after high-temperature shutdown before cleaning to prevent burns.
Cleaning and maintenance of sealed parts
Rinse the floating sealing groove at the bottom of the spindle, wash away the high-temperature dry powder, and avoid wear of the sealing ring by hard particles; After rinsing, add a small amount of high-temperature butter and seal to prevent dust.
Hydraulic and reducer static inspection
After 30 minutes of shutdown and oil reflux, check the oil level for leaks; Wipe all oil leakage points, mark the leakage location, and handle it before the next shift.
Equipment sunshade protection
Cover the motor, hydraulic station, and electrical control box of outdoor equipment after shutdown to avoid exposure to sunlight and accelerate the aging of rubber and plastic parts; Wrap oil and water pipes with sunscreen cotton.
4、 Special maintenance for summer high temperature cycle (weekly/monthly)
Weekly maintenance
Disassemble and clean the hydraulic oil cooler and waterway filter, remove scale and dust blockages;
Tighten all the bolts of the mixing assembly, planetary carrier, and lining plate. Loose bolts caused by thermal expansion are common faults in summer;
Detect the floating seal gap and replenish high-temperature resistant lubricating grease;
Check the operating conditions of the cooling fan and circulating water pump, and promptly repair any abnormal noise or insufficient flow.
Monthly maintenance
Sampling and testing of gear oil and hydraulic oil, replacement of all oil that oxidizes and becomes thinner, and impurities that exceed the standard; Synchronize the replacement of oil and air filters;
Disassemble and inspect the floating seal assembly of the spindle. High temperature can easily cause deformation of the sealing ring and spring failure. If damaged, replace the entire set of seals directly;
Add high-temperature lubricating grease to the motor bearings and clean the dust inside the motor;
Check the rotary support tooth surface, clean up high-temperature dry dust, apply high-temperature lubricating grease, and eliminate dry grinding noise;
Conduct a comprehensive inspection of all rubber components (oil seals, oil pipes, gaskets) and replace them uniformly if any hardening, cracking, or bulging occur.
5、 Emergency Response for High Temperature Weather Malfunctions
Motor high temperature trip
Immediately stop the machine, turn off the feed, and turn on the fan for forced air cooling; Clean the accumulated dust on the heat dissipation fins, check for prolonged full load, unstable voltage, and no-load test run after the temperature drops.
Hydraulic oil temperature too high
Check for blockages in the cooler and insufficient cooling water; If there is no malfunction in the cooling system, reduce the single feeding amount and shorten the continuous working time; Replace the hydraulic oil if the oil temperature continues to exceed the standard.
Leakage of slurry at the shaft end and burning of the seal
High temperature and lack of butter are the main reasons. Immediately stop the machine and replace the floating seal assembly, increase the automatic oil injection cycle, and ensure continuous oil supply to the sealing area on a daily basis.
Gearbox oil leakage and abnormal noise
The oil seal softens and leaks at high temperatures. Replace the high-temperature resistant oil seal; Abnormal noise is often caused by the failure of lubricating oil at high temperatures. It is necessary to replace the high-temperature gear oil in a timely manner.
Powder clumping and sticking to the cylinder increase the load
Increase inter batch spray cooling, reduce the production of high viscosity materials during the high temperature period at noon, and thoroughly clean the pipes after work every day.
6、 Key points for selecting key consumables for summer maintenance
Gear oil: High temperature special extreme pressure synthetic gear oil, temperature resistance ≥ 120 ℃;
Hydraulic oil: 46 # high-temperature anti-wear hydraulic oil, anti-oxidation formula;
Lubricating grease: composite lithium based high-temperature grease, capable of withstanding temperatures above 180 ℃;
Sealing components: Fluororubber oil seal, floating sealing ring, high temperature and wear-resistant, replacing ordinary nitrile rubber.
