Common Problems Encountered During Cable Granulator Machine Operation
May 11, 2026
I. Incomplete sorting (copper containing plastic or plastic containing copper)
This is the most common problem, directly affecting the quality of the output and its recycling value.
Causes:
Mismatch between airflow and vibration frequency; malfunctioning airflow separator parameters.
Unstable electrostatic separation voltage or high humidity, leading to decreased adsorption force.
Damaged or clogged screens, resulting in insufficient material separation.
Solutions:
Adjust the airflow speed and vibration frequency of the airflow separator to maintain coordinated operation.
Check the electrostatic system's operating status; maintain workshop humidity below 60%.
Regularly stop the machine to check screen integrity and clean any clogged dust.
II. Equipment jamming (crusher blockage)
Sudden stoppage or motor overload during operation severely impacts production efficiency.
Main causes: Excessive or uneven feeding speed, resulting in excessive load; Severely worn or broken blades, unable to cut effectively; Inclusion of hard foreign objects (such as nails or stones).
Remedies: Immediately stop the machine and disconnect the power; clean the accumulated material from the crushing chamber. Control the feeding rhythm; it is recommended to feed once every 20 seconds to maintain stability. Regularly check the blade condition; the gap between the moving and stationary blades should be maintained at 0.5–0.78 mm.
III. Abnormal noise or severe vibration: A harsh noise or machine vibration during operation poses a safety hazard.
Possible Causes:
Excessive clearance between moving and fixed blades, leading to increased impact.
Insufficient or damaged bearings, loose eccentric sleeve.
Equipment not placed horizontally, affecting overall balance.
Remedies:
Check and recalibrate the blade clearance.
Add lubricating oil every 150 working hours, and replace bearings regularly.
Use a level during installation to prevent resonance caused by unstable foundation.
IV. Dust Collection System Failure or Leakage
Dust spillage not only pollutes the environment but may also pose occupational health risks.
Typical Manifestations:
Visible dust emission from the air outlet.
Damaged filter bags, clogged filter cartridges, or poor dust removal efficiency.
Troubleshooting Steps:
Visually inspect filter bags for damage and seals for aging.
Test the pulse valve for proper operation and ensure compressed air pressure meets standards (recommended ≥0.5MPa).
Clean accumulated dust in the ash hopper to prevent secondary dust generation.
V. Excessive Blade Wear or Frequent Blade Replacement
Affects crushing efficiency and increases operating costs.
Influencing Factors: Processing waste wires with high oil content accelerates blade corrosion. Hard objects mixed in the feed cause blade chipping.
Optimization Suggestions: Avoid processing heavily oiled cables; pre-clean if necessary. Use SKD-11 high-hardness alloy blades to extend service life. Perform professional sharpening after processing approximately 10 tons of wire.
✅ Tip: Good daily maintenance can reduce equipment failure rate by more than 50%. It is recommended to establish a daily inspection system, focusing on lubrication, tightening, and cleaning.
