What Are The Consequences Of The Cable Granulator Machine Running Overtime?
Sep 26, 2025
1. Electrical System Damage
1. Accelerated Insulation Aging
Long-term overvoltage operation (voltage > 10% of rated value) increases the electric field strength of the winding insulation material, exponentially accelerating insulation aging and increasing the risk of breakdown by 3-5 times.
2. Dramatic Increase in Copper and Iron Losses
Excessive operation causing the current to continuously exceed the rated value by more than 15% increases copper losses (I²R losses) by 2.3 times, core magnetic saturation causing iron losses to increase by 40%, and efficiency to decrease by 12-18%.
2. Mechanical Component Failure
1. Shortened Bearing Life
Abnormally high speeds (5-8% overrated) accelerate bearing wear by 3 times. When vibration values exceed 4.5 mm/s, the average bearing life is reduced to 30% of the normal value.
2. Abnormal Wear of Cutters and Screens
Continuous overload operation increases wear of SKD-11 alloy cutters by 50%, increases screen clogging by 60%, and reduces sorting efficiency to below 85%. III. Safety and Efficiency Risks
1. Overheating Chain Reaction
When bearing temperatures exceed 80°C or winding temperature rise exceeds 75°C, the risk of grease carbonization increases, potentially causing machine seizure or fire.
2. Increased Production Losses
For every hour of overtime operation, the probability of downtime increases by 25%, repair costs by 40%, and production capacity losses reach 15-20%.
