How To Determine If A Copper Granulator Machine Needs Repair
May 04, 2026
I. Pre-Start Inspection: Identifying Potential Hazards
1. Fasteners and Structural Condition
Check anchor bolts, barrel flanges, and transmission components for looseness. Significant shaking or abnormal noise may indicate unstable foundation or internal wear.
Check the protective cover, emergency stop button, and interlock devices for effectiveness, ensuring normal safety functions.
2. Lubrication and Cooling System
Check if the gearbox oil level is within the standard range and if the grease is emulsified or deteriorated. Low oil level or cloudy oil indicates the need for replacement or replenishment.
Confirm the cooling water valve is open, there are no leaks in the water pipes, and the water level in the tank is normal. A malfunctioning cooling system can easily lead to overheating of the motor or screw.
3. Electrical and Sensors
Check if the thermocouples are securely inserted and if the wiring is free of exposed or aged wires. Thermocouple failure alarms are often caused by loose or damaged sensors.
Test the control cabinet indicator lights and voltmeter for normal operation to avoid shutdowns due to electrical faults.
II. Monitoring During Operation: Identifying Operational Abnormalities
1. Temperature Abnormalities
If the heating zone temperature fluctuates greatly, heats up slowly, or fails to reach the set value, it may indicate a damaged heating coil or a malfunctioning thermocouple.
If the motor casing temperature exceeds 70℃, accompanied by an unusual odor, it suggests winding overload or bearing wear.
2. Sound and Vibration
If the equipment produces sharp abnormal noises or periodic impact sounds, stop the machine immediately and check for wear on the main shaft bearings and rotor dynamic imbalance.
Continuous severe vibration may originate from screw jamming or misalignment of transmission components, requiring disassembly and inspection.
3. Discharge Status
Irregular particle shape and fluctuating discharge speed are commonly caused by clogged template holes, worn cutter blades, or excessive clearance.
If the particles are too long or connected to the blade, it indicates poor fit between the bottom blade and the rotating blade, requiring blade adjustment or replacement.
4. Current and Pressure
A sudden increase of more than 20% in the main unit current indicates overload, possibly due to screw jamming or excessively moist material.
Hydraulic system pressure below 80% of the set value is often due to oil pump wear or hydraulic valve jamming.
III. Post-shutdown inspection: Confirm maintenance needs
1. Visual inspection of key components
Disassembly inspection revealing bearing ball bearing dents, charred motor windings, and aged, leaking seals; all require replacement.
Pear-shaped die holes or severely clogged screens indicate wear, affecting particle quality; replacement is recommended.
2. Comparison of preventative maintenance records
If the equipment has run continuously for over 300 hours without cleaning the wear rings and seals, and dust overflow is severe, maintenance should be arranged.
If the blades have exceeded their service life without sharpening, cutting efficiency will decrease; they should be re-sharpened or replaced promptly.
