Disc granulators, as core equipment in the production of organic fertilizers and compound fertilizers, are widely used in various granulation production lines due to their high pelletizing rate and uniform particle size. However, under long-term high-intensity operation, various faults are prone to occur due to factors such as operation, maintenance, and materials. This not only affects production progress but may also accelerate equipment wear and increase production costs. Mastering common faults and basic solutions can effectively reduce downtime losses and extend equipment lifespan.
Low pelletizing rate and uneven particle size are the most common faults of disc granulator machines, directly affecting the quality of the finished product. The main causes include incompatible material parameters, improper equipment parameter adjustment, and scraper wear. Material moisture content should be controlled at 25%-35%, and particle size at 80-120 mesh. Excessive moisture content easily leads to clumping, while insufficient moisture prevents adhesion. The disc inclination angle should be 45°-55°, and the rotation speed 15-20 r/min is ideal; parameter deviations can cause particles to roll off or accumulate. Scraper wear and excessive gaps can cause material to stick to the wall, affecting pellet uniformity. When dealing with these issues, adjust the material moisture and particle size, fine-tune equipment parameters, and replace or adjust the scraper promptly.
Disc misalignment and abnormal operating noise are easily overlooked faults, often related to the transmission system and support structure. Uneven wear of support wheels and loose fixing bolts can cause disc misalignment, while insufficient bearing lubrication and worn gears can cause abnormal noise. If not addressed promptly, these issues may lead to bearing damage and frame deformation. Solutions include tightening bolts, replacing worn support wheels, replenishing lubricating oil, and replacing bearings or gears if necessary.
Motor overheating and overload shutdown are serious faults that endanger equipment safety, often caused by excessive load, poor heat dissipation, or circuit problems. Excessive feeding and excessively viscous materials can easily cause motor overload. Dust accumulation on the heat sink and fan malfunction can affect heat dissipation, and poor circuit contact can also cause overheating. Solutions include cleaning excess material, controlling the feeding speed, cleaning the heat sink, inspecting the fan, checking the circuit, and ensuring stable voltage.
Most malfunctions stem from improper operation or untimely maintenance. Regular lubrication, pre-start checks, and material pretreatment can prevent 80% of failures. When a disc granulator malfunctions, first identify the cause before addressing the problem. For major malfunctions, contact the manufacturer for professional repairs. Do not attempt to disassemble the equipment yourself to ensure stable operation and efficient production line operation.