Common Faults and Cause Analysis of Air Compressor

As a kind of driving power energy, the application scenario of air compressor is more common and plays a very important role in all production and processing. However, during the operation of the air compressor, due to the poor actual effect of refrigeration and heat transfer, abnormal working pressure, insufficient exhaust volume, etc., the specific operation time of the air compressor is relatively short, the parking lot and operation of the equipment are frequent, and the regulations on high-efficiency and safe operation cannot be achieved, which immediately affects the production and manufacturing and causes immeasurable damage to the company. Therefore, it is necessary to properly identify the common faults of air compressors, analyze the reasons, reduce the frequency of common faults, and clearly put forward preventive measures to ensure the safe operation of air compressors.

Common fault categories and root causes of air compressor:

1. Insufficient displacement

the main manifestation of insufficient displacement is that the working pressure cannot reach the working pressure of the terminal station. Judging from the common fault conditions, it is likely to be caused by the following factors:

one is the common failure of the channel air filter. When the scaling in the filter device is blocked, the exhaust volume will be reduced; and the suction pipe is too long and the pipe diameter is small, which will immediately affect the suction friction resistance. Exhaust volume.

Second, too low a rotation speed ratio of the air compressor will reduce the displacement: the displacement of the air compressor is designed according to the specified altitude, suction temperature and ambient humidity. If it is applied at high altitude beyond the above specifications, the suction working pressure will decrease and the displacement will also decrease. The deviation of the transmission belt will reduce the rotation speed ratio of the air compressor, thus affecting the reduction of the displacement.

Third, it is caused by the change of the air compressor's mutual cooperation gap caused by the damage of the parts: the cylinder, piston rod and engine piston are seriously damaged and deviated, resulting in the expansion of the relevant gap and the expansion of the leakage volume. If it is more serious, it will affect the displacement.

Fourth, the software of the air compressor system is seriously leaking steam, mainly because the ferrule joint is not tight, thus causing the leakage of steam and reducing the air supply. In the final analysis, first of all, the ferrule joint itself does not conform to the regulations during production and manufacture. Secondly, it is very likely that the core of the hydraulic cylinder and the ferrule joint was not properly aligned during installation, causing steam leakage caused by damage, contusion, etc.

Fifth, the common faults of the air compressor pressure valve affect the exhaust volume. The key is to drop metal fragments or other dirt between the high-pressure gate valve of the finger suction and automatic exhaust valve and the pump casing, resulting in tight shutdown and steam leakage.

In addition, the failure to match the torsion spring force of the valve with the steam force will also affect the displacement. If the elasticity is too strong, the pump casing will open slowly. If the elasticity is weak, the pump casing will not be closed immediately, which will not only affect the displacement. In more serious cases, it will affect the increase of output power, and even affect the service life of the valve pump casing and torsion spring.

2. Abnormal exhaust pipe temperature

the abnormal temperature of the exhaust pipe means that it is higher than the value of the design scheme, which is mainly caused by the abnormal refrigeration system. From the basic theory of diligence, the key factors affecting the exhaust pipe temperature are: inlet temperature, working pressure ratio, and its reduction index value (for compressed air index value K = 1.4). The actual situation affects the high suction temperature, such as: the high efficiency of the middle refrigeration is low, or the dirt in the intercooler affects the heat transfer, the suction temperature of the rear stage must be high, and the temperature of the exhaust pipe will also be high. Valve leakage and engine piston leakage will not only affect the temperature rise of the exhaust pipe, but also change the working pressure of the stage. As long as the working pressure ratio is higher than the standard value, the temperature of the exhaust pipe will rise. In addition, the water cooler equipment, less water or water flow is not enough to make the exhaust pipe temperature rise.

3. Faster oscillation and noise

if some components of the air compressor are abnormal, abnormal sound will be emitted. Generally speaking, the actual operation staff can identify the abnormal oscillation and noise according to the listening sample. Unstable operation of the push motor and changes in the centering of the shaft will cause abnormal oscillation and noise. If the gap between the piston rod and the cylinder head is too small, it will collide immediately; the connecting screw cap of the hydraulic cylinder and the piston rod is loosening or spalling, the inner hole of the piston rod is blocked by the silk, the piston rod shakes up and hits the cylinder head, and the metal material fragments and the cylinder fall into the cylinder. The accumulation of water in the cylinder can transmit the impact sound in the cylinder. The automatic exhaust valve plate is broken, the valve torsion spring is soft or damaged, and the load controller is adjusted unreasonably. All of these can send out knocking sound in the valve cavity.

4. Common faults of overtemperature

in the parts where the crosshead and double rocker, engine crankshaft and rolling bearings, fillers and hydraulic cylinders cause friction, the temperature is too high and exceeds the required data is called overtemperature. The adverse effects provided by overheating: one is to accelerate the damage of the friction parts. Second, overtemperature makes a lot of heat.

Continuous accumulation directly causes damage to the friction surface and its burning, resulting in major safety accidents of the equipment. The primary factors leading to overtemperature of rolling bearings are: rolling bearings and motor shafts cater to unevenness or touch the total area is too small; The rolling bearing tilts the crankshaft of the engine and bends, the grease viscosity is too small, the oil passage is blocked, and the gasoline pump has common faults leading to flameout, etc. During installation, there was no ground leveling, no gap, no alignment between the main shaft of the machine tool and the motor bearing, skew, etc.

There are many factors that cause common failures of air compressors, not only for the sake of design and manufacturing, but also for the sake of actual operation, maintenance and management methods. Some reasonable and effective solutions should be clearly proposed based on comprehensive analysis of such common failures. Increase the service life of air compressors.