The grease addition system is a critical component in compound feed mills, designed for the precise introduction of liquid nutrients such as oils and fats into the mixing process. This system plays a vital role in enhancing the palatability of feed products, increasing their energy content, and improving overall quality. Therefore, ensuring the proper functioning of the grease addition system is essential for maintaining smooth production and consistent product quality.
During operation, several common faults may occur, which can disrupt the feeding process and affect the final output. One frequent issue is the failure of the system to spray liquid. Symptoms include an increase in motor current, excessive drag, loud noises from the fuel injection pump, rising pressure on the pressure gauge, automatic opening of the relief valve, backward flow of liquid to the tank, and error messages on the intelligent flow meter.
This issue is often caused by blockages in the pipeline, which can be due to a closed plug or solenoid valve, clogged nozzles, or low ambient temperatures that cause the oil to thicken or solidify. In winter, it's especially important to ensure that any remaining liquid is drained after production, or that the grease lines are preheated to prevent solidification. Additionally, if the supply line from the tank to the spray pump becomes blocked, the system will fail to spray. In this case, the spray motor may idle, the pressure gauge shows no pressure, and no liquid returns to the tank.
To resolve these issues, it's necessary to inspect and clean the solenoid valves, remove and clean the nozzles with a fine needle, and ensure all relevant valves are fully open. Regular maintenance of filters and removal of impurities from the bottom of the tank are also crucial to maintain system efficiency.
Another common problem is the loss of control over the spray solenoid valve. If the valve cannot open, it may block the pipeline, while if it opens but does not close properly, it can lead to excessive oil delivery. This results in errors in both the solenoid valves and the intelligent flow meter. Faults in the solenoid valve could be due to a broken coil, power line issues, or a damaged return spring. In such cases, replacing the spring or moving core is usually required.
For the intelligent flow meter, there are three start modes: manual, high-level control, and short-delay terminal. If the flow meter fails to start, it may indicate internal faults, communication issues, or problems with the control signals. It’s important to check the wiring and ensure all connections are secure.
Uneven spraying from the nozzles can lead to poor mixing of oil and feed materials. Dust accumulation in the mixer, combined with low injection pressure, can cause agglomeration and even linear oil flow. To prevent this, nozzles should be regularly cleaned, the overflow valve adjusted, and the injection pressure increased. Optimizing the pipeline layout and minimizing its length can also help achieve more uniform distribution.
Finally, discrepancies between the actual and specified oil quantities are another concern. The smart flow meter uses two methods: closed-loop control and time-based control. Proper calibration of parameters like oil density, pulse equivalents, and hourly values is essential for accurate measurements. Any deviations in these parameters can lead to miscalculations and improper oil delivery.
In summary, maintaining the grease addition system requires regular inspection, cleaning, and calibration. By addressing these common issues promptly, feed mill operators can ensure efficient and reliable performance, ultimately contributing to better feed quality and production stability.
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