In many industrial fields, such as oil drilling, building construction, sewage treatment, etc., mud agitator plays an indispensable role. It makes the mud components mix uniformly through mixing, ensures stable mud performance, and meets the requirements of the production process. However, long-term high load operation of the mud agitator is prone to various problems, affecting its normal work. Therefore, it is important to do a good job of maintenance and timely and accurate fault diagnosis to ensure the efficient and stable operation of the mud agitator.
一.Mud agitator Maintenance
1.Daily Maintenance
Cleaning: Keeping the appearance of the agitator and the surrounding environment clean is the basis of daily maintenance. Regularly remove mud, dust and debris from the surface of the mixer to prevent these pollutants from entering the interior of the equipment and affecting the normal operation of the equipment. At the same time, clean the residual mud in the mixing tank to avoid the mud drying up and affecting the mixing effect next time, and also prevent the dry mud from causing wear and tear on the wall of the mixing tank.
Check the connecting parts: check the fastening of each connecting part of the mixer. Including the connecting bolts of the motor and the mixing shaft, the connecting parts of the mixing blades and the mixing shaft, and the fixing bolts of the mixer and the mixing tank. During the operation of the equipment, due to vibration and other reasons, the bolts of these connection parts may be loose. Once the bolts are loose, it will not only affect the normal operation of the agitator, but also may lead to parts falling off and cause safety accidents. Therefore, the connection parts should be carefully checked before and after work every day, and tighten them in time if they are found to be loose.
Lubrication management: good lubrication is the key to ensure the normal operation of the agitator and prolong the service life of the equipment. Regularly lubricate the bearings, gears and other key parts of the agitator according to the requirements of the equipment manual. Choose the right lubricant and make sure the lubricant amount is sufficient. Generally speaking, for high-speed running bearings, high viscosity lubricant should be used; for gear transmission parts, gear oil or grease can be used. When adding lubricant, pay attention to clean the oil injection port to prevent impurities from entering the lubrication system.
2.Regular Maintenance
Motor Maintenance: As the power source of the mixer, the performance of the motor directly affects the working effect of the mixer. Regularly check the insulation performance of the motor and use an insulation resistance tester to measure the insulation resistance between the motor windings and the shell to ensure that it meets the specified value. If the insulation resistance is too low, it may lead to a short circuit and damage the motor. At the same time, check the wear and tear of the carbon brushes of the motor, and replace the carbon brushes in time when they are badly worn to ensure the normal commutation and operation of the motor. In addition, carry out regular maintenance on the motor, such as cleaning the internal dust of the motor and adding lubricant to the motor bearings.
Inspection and Replacement of Mixing Blade: The mixing blade is the part that directly contacts with the slurry and carries out the mixing work, and its wear and tear situation is more serious. Regularly check the wear degree of mixing blade, when the blade wear exceeds the specified range, it should be replaced in time. Uneven or excessive wear of the blades will affect the mixing effect, resulting in uneven mixing of slurry. When replacing the blades, pay attention to choosing products with the same specifications as the original blades, and make sure that they are firmly installed and that the angles and positions of the blades are correct.
Transmission system maintenance: the transmission system of mud agitator includes belt transmission, chain transmission or gear transmission. For the belt transmission system, check the tension of the belt, the belt is too loose will lead to slippage, affecting the transmission efficiency; the belt is too tight will increase the load of the motor and bearings, shorten the service life of the equipment. Regularly adjust the belt tension, and check whether the belt has wear, cracks and other conditions, if any problem timely replacement. For the chain drive system, clean the chain regularly and add lubricant to prevent the chain from rust and wear. At the same time, check the chain tightness and sprocket wear, adjust or replace if necessary. For the gear transmission system, check the meshing of the gears for tooth wear, broken teeth and other problems. Replace the gear oil regularly to ensure that the gears work under good lubrication conditions.
Electrical system maintenance: in addition to motor maintenance, the entire electrical system should be inspected regularly. Check whether the electrical wiring is broken, aged, short-circuited, etc., to ensure that the electrical connection is reliable. Clean up the dust in the electrical control cabinet to prevent the accumulation of dust from affecting the normal operation of the electrical components. Carry out function tests on various switches, contactors, relays and other components of the electrical control system to ensure that they operate accurately and sensitively. Regularly calibrate various protection devices, such as overload protection, short-circuit protection, etc., to ensure that the power supply can be cut off in a timely manner when the equipment is in an abnormal situation, to protect the equipment and personnel safety.
二.Troubleshooting of mud agitator
1.Abnormal speed of agitator
Motor failure: short circuit, broken motor winding or damaged motor bearing may cause the motor output power to drop, thus reducing the speed of the agitator. In addition, unstable or too low motor power supply voltage will also affect the motor speed.
Transmission system failure: transmission system problems such as belt slippage, chain looseness or serious gear wear will lead to poor power transmission and make the mixer speed abnormal. For example, the belt will elongate after long-term use, and the tension is insufficient, which is easy to slip during operation, resulting in unstable mixer speed.
Excessive load: too much mud in the mixing tank, too much viscosity of the mud or the mixing blades are stuck by foreign objects, etc. will increase the load of the agitator, which will lead to a decrease in speed. When the load exceeds the rated output of the motor, the motor may even stop running.
2.Stirrer vibration is too large
Unbalanced mixing blades: The mixing blades may lose balance due to uneven wear or external impact during long-term use. An unbalanced blade generates centrifugal force when rotating, causing the mixer to vibrate. In addition, improper installation of the blades, such as loose connection bolts between the blades and the mixing shaft, will also lead to shaking of the blades during rotation, triggering vibration.
Damaged bearings: The bearings of the agitator may be damaged after a long time of operation due to wear and tear, poor lubrication or impact. Damaged bearings cannot properly support the rotation of the mixing shaft, which will cause the mixing shaft to shake, thus causing the mixer to vibrate. Damaged bearings may also be accompanied by abnormal noise, which can be initially judged by listening to the sound.
The foundation is not solid: If the installation foundation of the agitator is not solid, it will be displaced due to vibration during the operation of the equipment, which will aggravate the vibration of the agitator. Failure of the foundation may be due to irrational foundation design, poor quality of foundation construction or long-term vibration caused by loosening of the foundation and other reasons.
3.Motor overheating
Overload operation: As mentioned earlier, when the agitator is overloaded, the motor needs to output more power to drive the agitator, which will lead to an increase in the motor current, thus heating up the motor. Long-term overload operation will seriously affect the service life of the motor and may even burn the motor.
Poor heat dissipation: the motor generates heat during operation, which needs to be dissipated through the heat sink. If the cooling fan of the motor is damaged, the vents are blocked or the ambient temperature is too high, it will lead to poor heat dissipation and increase the temperature of the motor. In addition, too much dust inside the motor will also affect the heat dissipation effect.
Motor failure: motor winding short circuit, broken circuit and other faults will lead to increased motor current, generating excessive heat. At the same time, motor bearing damage, rotor and stator friction and other problems will also make the motor heat.
三.Troubleshooting Methods
Discover the clues to the fault by observing the running state of the mixer. Observe whether the speed of the stirrer is uniform, with or without abnormal fluctuations; observe whether the stirring blades are worn, deformed or detached; observe whether there are traces of vibration on the surface of the equipment, and whether the connecting parts are loosened; and observe whether the motor has any abnormalities, such as smoke, odour and so on. In addition, you can also observe the indicator lights and meters on the electrical control cabinet to judge whether the electrical system is working normally.
Use the sense of hearing to judge whether the mixer is faulty. Normal operation of the stirrer sound smooth and uniform. If you hear abnormal noise, such as friction, impact, vibration or motor humming sound is too large, etc., may indicate that there are problems with the equipment. For example, when the bearing is damaged, it will make a sharp friction sound; when the gear is badly worn, it will produce a periodic impact sound. By listening to the sound can initially determine the location and type of failure.
Use various measuring instruments to measure the relevant parameters of the agitator to determine the cause of the fault. For example, use the tachometer to measure the speed of the agitator, and compare it with the rated speed of the equipment to determine whether the speed is normal; use the vibration tester to measure the vibration amplitude and frequency of the agitator, and analyse whether the vibration is over the standard; use the multimeter to measure the resistance of the motor’s windings, current, voltage and other parameters, and determine whether there is an electrical fault in the motor; use the thermometer to measure the temperature of the motor, bearings and other parts to check whether there is an overheating phenomenon. overheating phenomenon.
Maintenance and troubleshooting of the mud agitator is an important part to ensure its long-term stable operation. Through scientific and reasonable routine maintenance and regular maintenance, it can effectively prevent the occurrence of failures and prolong the service life of the equipment. And when a fault occurs, the use of correct fault diagnosis methods can quickly and accurately find out the cause of the fault, take timely and effective maintenance measures to reduce equipment downtime and reduce production losses.
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