Common Faults Of Copper Granulator Machines

I. No Material Output or Poor Material Output

Possible Causes:
Clogged die orifices (common in wet granulation); worn or improperly positioned cutter; unsuitable material moisture content (too dry or too wet); feeding system malfunction (e.g., screw jamming, uneven feeding).

Solutions:
Stop the machine and clean the die orifices (using a copper needle or a special cleaning tool); check and adjust the cutter gap or replace the cutter; adjust the material moisture content to the required range (usually 8%–15%, depending on the material); clean the feed inlet and check if the screw is jammed or if the motor is functioning properly.

II. Granules Not Formed or Severely Powdered

Possible Causes: Insufficient binder or uneven mixing; insufficient extrusion pressure (excessive gap between pressure rollers, low hydraulic/pneumatic pressure); material formulation problems (lack of viscous components); excessively high drying temperature leading to embrittlement.

Solutions: Optimize the type and amount of binder to ensure uniform mixing; adjust the gap between pressure rollers or increase the system pressure; add an appropriate amount of binder (such as starch paste, PVP, etc.) to the formulation; control drying process parameters to avoid over-drying.

III. Motor Overload or Tripping

Possible Causes: Material is too hard or contains impurities (such as metal, lumps); material jamming inside the equipment; poor lubrication of transmission components or damaged bearings; motor or frequency converter malfunction.

Solutions: Stop the machine and check if the material contains foreign objects; sieve out large or hard objects; open the equipment and clean the jamming parts (such as the extrusion chamber, die); check the gearbox and bearing lubrication; add lubricating oil or replace bearings if necessary; check the motor current, insulation, and frequency converter parameter settings.

IV. Uneven Particle Size

Possible Causes: Unstable or worn cutter speed; partial blockage of die holes; poor material flowability or uneven feeding; fluctuations in pressure rollers.

Solutions: Calibrate or replace the cutter to ensure stable speed; clean the die holes to ensure all holes are clear; improve material flowability (e.g., add flow aids) or optimize the feeding system; check the pressure stability of the hydraulic/pneumatic system.

V. Abnormal Equipment Vibration or Excessive Noise

Possible Causes: Imbalance of the main shaft or pressure rollers; loose anchor bolts; worn or damaged bearings; improper die plate installation.

Solutions: Stop the machine and tighten the anchor bolts; check the concentricity of the main shaft, correct or replace worn parts; replace damaged bearings; reinstall the die plate, ensuring alignment.