The Banana Sieve, as an efficient screening equipment, features a multi-stage inclined angle design, which enables you to achieve high output and high precision screening. However, the full realization of this advantage depends entirely on the quality of installation and commissioning - if there are issues such as inclination deviation during installation or inaccurate positioning of the exciter, it will not only reduce the screening efficiency but also accelerate the wear of the equipment.
For the 1-2 layer Banana Sieve s with a processing capacity ranging from 100 to 2500 t/h that you are using, proper installation can directly reduce the failure risk by over 30% and maintain a sieve separation efficiency of over 90%. This article will guide you through the entire process from installation preparation to commissioning and optimization, helping you complete your tasks efficiently.
Preparations Before Installing The Banana Sieve
● Site And Environment Preparation
During the operation of the banana sieve, certain dynamic loads will be generated. The installation site must meet the load-bearing requirements - the ground's load-bearing capacity should be no less than 1.2 times the equipment's own weight, and the flatness error should be controlled within ±2mm per meter to avoid uneven force distribution due to ground inclination.
At the same time, considering the frequent humid and dusty working conditions of the banana sieve, the site environment needs to be optimized: ventilation conditions must ensure equipment cooling, dust prevention measures (such as installing dust-proof cover frame foundations) should be reserved in advance, and the drainage system should cover a 1.5-meter radius around the equipment to prevent water accumulation from eroding the foundation or components.
In addition, sufficient working space must be reserved at the site: at least 1.2 meters of operation distance should be maintained on both sides and at the top of the equipment, the connection space between the feeding end and the chute, and between the discharge end and the conveyor belt should match the drawing dimensions to ensure smooth material transportation without interfering with equipment maintenance.
● Equipment And Accessories Inspection
After unpacking, each component needs to be carefully verified for integrity, including the sieve box (side plates, cross beams, rear back plates), exciter, shock-absorbing springs, transmission device (V-belts, pulleys, expansion sleeves), sieve plates, etc. Ensure there is no damage during transportation or any missing parts.
Key components require special inspection: The sieve plate should be checked for no cracks on the surface and the opening rate should meet the design requirements (50% for the upper layer and 40% for the lower layer); the exciter bearings need to rotate freely without sticking, and the seals should be intact; weld seams should be visually inspected for no burn-through, cracks or incomplete fusion defects. For important parts, ultrasonic flaw detectors can be used for auxiliary detection.
Auxiliary materials and tools need to be prepared in advance, including: fastening bolts meeting strength requirements (such as 10.9S grade high-strength bolts), lubricating oil suitable for the exciter and motor, special torque wrenches, level meters, amplitude measurement instruments, etc.
● Study Of Technical Documents
Before installation, it is necessary to thoroughly study the installation drawings, focusing on confirming the centerline of the foundation, the position of the anchor bolts, the overall assembly dimensions of the equipment, and the dynamic load parameters. Ensure that the site foundation exactly matches the drawings.
The technical manual should summarize the key points: clearly define the assembly sequence of each component (such as installing the screen frame first and then the exciter), prohibitions (such as not allowing additional components to be welded on the side plate), and critical dimension tolerances (such as the gap between the crossbeam and the side plate). Avoid affecting the equipment performance due to improper operation.
Installation Process Of Banana Sieve Core
- Basic Positioning And Fixation
First, perform the calibration of the basic centerline. Use a laser level instrument to align the equipment centerline with the foundation baseline. The deviation should be controlled within ±1mm. Then, use a level gauge to check the levelness of the foundation. The error per meter should not exceed 0.5mm. If it does not meet the standard, adjustments through shims are required.
The installation of anchor bolts should be carried out according to the positioning on the drawings. The verticality error of the bolts should be ≤1°. After installation, use a torque wrench to tighten them according to the specified torque (refer to the equipment manual. Generally, the torque of high-strength bolts should reach 800-1200N·m). Also, install anti-loosening nuts or perform spot welding for anti-loosening to prevent loosening during operation.
After the equipment is in place, recheck the levelness and verticality: Use a level gauge to detect the upper plane of the screen frame. The longitudinal levelness error should be ≤0.1%, and the transverse levelness error should be ≤0.05%. Use a plumb line to detect the verticality of the side plates. The deviation per meter should not exceed 1mm to ensure uniform force distribution during operation.
- Core Component Assembly
- ① Screen Frame Installation
The installation of the screen frame requires first connecting the side plates and the crossbeam: The crossbeam adopts a rectangular hollow structure, and when connecting with the side plates, ensure that the flange end faces are tightly adhered. The bolts should be tightened in a diagonal sequence in several stages to avoid local stress concentration; the back plate uses bent steel plates, and when connecting with the track beam, it needs to be fixed with rivets and additional bent steel plates for reinforcement to prevent cracking.
All connection parts need to be checked for no gaps. The side plates should have no splicing and the flatness error should not exceed 1mm per square meter. The connection between the crossbeam and the side plate should have no welding stress (which can be confirmed by a stress detector). Ensure that the overall stiffness of the screen frame meets the standards.
- ② Exciter Installation
Before installing the exciter, check the internal lubrication condition to ensure that the oil in the thin oil lubrication box is adequate and free of impurities; during installation, use positioning pins for precise positioning. The parallelism error of the exciter axis to the center line of the screen frame should be ≤ 0.1mm. The fixing bolts should use high-strength bolts, and the tightening torque should follow the instructions (usually 300-500N・m), to prevent displacement during operation.
Attention should be paid to the assembly of the bearings: Use hot or cold assembly methods to avoid damaging the bearings with hard knocking; after assembly, rotate the exciter to ensure no stuck or abnormal noise. The sealing parts should be tightly adhered to prevent lubricant leakage or dust from entering.
- ③ Damping System Installation
The damping spring uses a steel cylindrical helical compression spring. During installation, ensure that the spring axis is perpendicular to the installation surface, and the upper and lower ends of the spring should be tightly adhered to the support without offset. After installing multiple springs, detect the static compression amount. The static compression height error of the symmetrical points of the springs should not exceed 3mm to ensure uniform damping effect during equipment operation and avoid excessive local vibration.
- ④ Screen Plate Assembly
The screen plate uses a slot fixation method. Before installation, lay a rubber buffer plate between the screen plate and the support beam to prevent damage to the screen plate from material impact; during installation, ensure that the screen holes are aligned, and the gap between adjacent screen plates should not exceed 1mm to avoid material leakage; an isolation plate should be added at the inlet end to prevent crushing, and the screen plate sides should be pressed with polyurethane side strips and wedge blocks for fixation, which not only fixes the screen plate but also protects the side plate, extending the service life of the screen frame.
After the screen plate assembly of the entire equipment is completed, manually push the screen plate to check for no loosening. Before starting the equipment, reconfirm that all screen plates are firmly fixed to prevent detachment during operation.
- ⑤Transmission Device Installation
First, fix the motor bracket to ensure the motor shaft is parallel to the vibrator pulley shaft. The parallelism error between the two shafts should be ≤0.1mm, and the end face runout error should be ≤0.05mm. Then install the V-belt (such as an SPC type V-belt). The V-belt tension should be moderate; pressing the middle of the V-belt should allow it to sink 15-20mm. Too tight a belt will cause the bearing to overheat, while too loose a belt will cause slippage.
The pulley is connected to the shaft using an expansion sleeve. When installing the expansion sleeve, clean the contact surface, apply anti-rust grease, and tighten the expansion sleeve bolts in stages to the specified torque, ensuring a zero-clearance fit and preventing slippage or abnormal noise during transmission.
- Electrical System Connections
The wiring of the motor should be matched with the voltage level according to the equipment power: motors with power less than 280kW should use 660V voltage, and motors with power of 280kW or more should use 10kV voltage. During wiring, ensure the correct connection of phase wires and that the grounding resistance is ≤ 4Ω to avoid the risk of electric leakage.
Electrical components need to be checked for their protection level: for example, the protection level of the motor should reach IP55 to adapt to humid and dusty environments; the insulation performance should be tested using an insulation resistance meter, and the insulation resistance should be ≥ 1MΩ to prevent short-circuit faults.
Control lines and sensor installation: temperature sensors (usually 5 points) should be pre-installed in the motor windings and bearings, and vibration sensors should be installed in the middle of the side plate of the sieve frame. The sensor lines should be protected by conduit to avoid wear during operation and ensure that the monitoring data is accurately transmitted to the central control system.
Debugging Process For Banana Sieve ing Stage
- No-Load Debugging (24-Hour Standard)
① Pre-Power-On Inspection
Before powering on, recheck the tightness of all components: use a wrench to inspect the tightness of bolts, with a particular focus on the connecting bolts of the exciter, the motor, and the crossbeam, ensuring there is no loosening; rotate all rotating parts (such as the exciter, pulley) to ensure smooth operation without any jamming; inspect the lubrication system, with the lubricating oil level of the exciter at 1/2 - 2/3 of the oil gauge, and the motor bearings have been lubricated with grease, with no oil leakage.
② Monitoring Of Operating Parameters
After powering on, start the equipment and use an amplitude measuring instrument to detect the amplitude at the inlet and outlet ends. The double amplitude should be controlled within 8 - 10mm (in accordance with the equipment design requirements), and the difference in amplitude at the symmetrical points on both sides should not exceed 0.5mm; use a frequency meter to detect the operating frequency of the equipment, with the deviation not exceeding 2.5% of the specified value, to ensure that the vibration parameters are met.
③ Detection Of Key Indicators
Use an infrared thermometer to monitor the temperature of the bearings in real time. The temperature rise should not exceed 40℃, and the maximum temperature should not exceed 75℃; use a noise analyzer to detect the noise at a distance of 1 meter around the equipment, with the noise at no-load being no more than 80dB (A); observe the entire operation trajectory of the equipment, with the lateral oscillation not exceeding 1mm, and there should be no abnormal vibration or abnormal noise.
④ Timely Handling Of Problems
If there is uneven amplitude, check for errors in the height of the springs or the exciter counterweight, adjust the position of the springs or add or reduce the eccentric weight of the exciter; if the temperature of the bearings rises too high, check the type of lubricating grease or the tension of the V-belt, replace the appropriate grease or adjust the tension of the V-belt; if there is abnormal noise, check for component collisions or loose bolts, and promptly tighten or adjust the position of the components.
- Load Debugging (7-Day Transition Cycle)
- ① Gradual Loading Process Of Materials
Load debugging should start from a low load: on the first day, load at 30% of the rated processing capacity and run for 4 hours before stopping to check; on the second day, load at 50%, run for 8 hours; from the third day onwards, gradually increase to 80%, and reach the rated processing capacity on the seventh day to avoid sudden full load causing equipment shock damage.
During the loading process, it is necessary to control the uniformity of the materials to avoid local overloading. The particle size of the input material should comply with the equipment requirements (such as 0-300mm), and prevent oversize materials from blocking the sieve holes.
② Screening Efficiency Testing
After each loading, the screening efficiency of the upper screen surface should be tested ≥ 95%, and that of the lower screen surface ≥ 90%. By collecting the materials on the screen surface and the screen bottom, the particle size distribution can be calculated to confirm the screening effect; if the efficiency is not up to standard, the amplitude (by adjusting the eccentric block of the vibration exciter) or the inclination angle of the screen surface (such as adjusting to a range of 10°-30° to adapt to the material characteristics) should be adjusted.
③ Verification Of Coordinated Operation Of Each System
Observe the transmission system: V-belts have no slipping or deviation, and the temperature rise of the pulley is normal; the vibration system: the equipment runs smoothly, with no obvious resonance, and the springs have no abnormal deformation; the sealing system: there is no material leakage at the input and output ports, the dust cover is well sealed, and there is no coal dust spillage.
④ Response To Abnormal Working Conditions
If there is a blockage of materials, immediately stop the machine for cleaning, check whether the sieve holes are blocked or the input volume is too large, and adjust the input speed or clean the sieve plate; if there is a deviation of materials, adjust the position of the input chute or the inclination angle of the screen surface to ensure the uniform distribution of materials; if the noise suddenly increases, check whether the sieve plate is loose or the bearing of the vibration exciter is faulty, and promptly tighten or replace the components.
- Production Capacity Assessment
After the load debugging is qualified, a 24-hour continuous operation assessment under the rated load will be conducted. This assessment will be carried out 3 times, with an interval of 2 days each. During the assessment period, the processing volume needs to be recorded and it must reach the design value (such as ≥ 420t/h), and the single fault shutdown time should not exceed 2 hours, and the cumulative time should not exceed 6 hours.
During the assessment, the screening efficiency, bearing temperature, noise and other indicators need to be continuously monitored to ensure stable compliance throughout the process. If the assessment fails (such as insufficient processing volume or excessive faults), the core components (such as the exciter and screen plate) need to be disassembled for inspection, and design or assembly problems need to be eliminated. After repair, the assessment will be conducted again until compliance is achieved.
Common Problems And Solutions For Banana Sieve Installation And Commissioning
Uneven Vibration
Reason: The static compression height error of the vibration damping spring is too large (exceeding 3mm); the balance of the eccentric block of the exciter is unbalanced; the side plate of the screen frame is deformed, resulting in uneven force distribution.
Solution: Use a spring gauge to measure the compression amount of each spring, replace or adjust the position of the spring to ensure the symmetry point error ≤ 3mm; disassemble the exciter to inspect the eccentric block, adjust the weight to be balanced on both sides; use a level gauge to detect the flatness of the side plate, if the deformation is severe, replace the side plate, and if the deformation is slight, repair it by cold correction.
Screen Plate Loosening Or Material Leakage
Reason: The slot is not firmly fixed; there is no buffer rubber plate between the screen plate and the support beam; the gap between adjacent screen plates is too large.
Solution: Re-tighten the polyurethane wedge block and the side pressure strip to ensure that the screen plate is not loose; add a 5-8mm thick rubber buffer plate to enhance the adhesion; replace the screen plate with a size deviation exceeding the limit, adjust the gap between adjacent screen plates ≤ 1mm, and if necessary, add a sealing rubber strip at the gap.
Excessive Bearing Temperature Rise
Reason: The lubricating oil type does not match (such as not using vibration machinery-specific lubricating oil); the V-belt tension is too high; the bearing is assembled too tightly or worn.
Solution: Replace with the appropriate thin oil or lubricating oil (such as 320 number gear oil for the exciter); adjust the V-belt tension, control the depression amount at the middle part to be within 15-20mm; disassemble the bearing for inspection, if the assembly is too tight, reassemble it, if worn, replace the bearing (select vibration machinery-specific bearings).
Excessive Noise
Reason: Component collision (such as collision between the screen plate and the side plate); wear of the internal gears of the exciter; damage to the sealing piece causing dust to enter.
Solution: Check the side pressure strips on both sides of the screen plate, add or replace polyurethane side pressure strips to avoid metal collision; disassemble the exciter to inspect the gears, replace the worn gears when the wear exceeds the limit (ensure the gear accuracy reaches grade 6); replace the damaged sealing piece, add a dust-proof cover to prevent dust from entering the equipment interior.
Maintenance And Precautions After Installation And Commissioning Of The Banana Sieve
Key Points For Initial Operation And Maintenance
After successful commissioning, within 1 month, daily inspections are required: check all fastening bolts, especially those of the exciter, motor, and crossbeam, and tighten once a day; replenish lubricating oil; check the oil level of the exciter every 8 hours of operation, and add oil if insufficient; clean the surface debris of the sieve plate to prevent sieve holes from getting clogged.
Suggested Maintenance Cycle
Based on the operating time, formulate maintenance plans: inspect the wear of the sieve plate every 3 months; replace when the wear exceeds 1/3 of the original thickness; disassemble the exciter every 6 months to check the bearings, clean the internal oil stains, and replace the lubricating oil; test the elasticity of the damping spring annually; conduct a comprehensive flaw detection on the sieve frame every 2 years to check for cracks in the welds and side plates.
Safety Operation Norms
During equipment operation, do not open the protective cover; if maintenance is needed, disconnect the power supply and hang a "Do Not Close" sign; when lifting components (such as the exciter and motor), use the built-in lifting hooks of the equipment; when working inside the equipment, build a safety support to prevent the sieve plate from deforming or components from falling.
Long-Term Operation Optimization Suggestions
Adjust operating parameters according to material characteristics: if the material moisture content is high, appropriately increase the amplitude or adjust the sieve face inclination to 22°-26° to improve the screening efficiency; when the processing capacity fluctuates, adjust the motor speed through the frequency converter (compatible with frequency motor) to avoid overload; regularly clean the dust around the equipment to prevent component corrosion and extend the overall equipment lifespan.
The installation and commissioning of the Banana Sieve is a systematic project. From site preparation to phased commissioning, each step must strictly follow the specifications in order to fully utilize its multi-angle inclined screen surface advantages and achieve high screening efficiency and long service life.
For industries such as coal and mining, standardized installation and commissioning not only can reduce equipment failure rates but also can reduce maintenance costs in the later stage and improve production continuity.
If you encounter any technical difficulties during the installation and debugging of the banana sieve, such as deviations in the base positioning calibration, assembly problems of the exciter, or if you need professional teams to provide on-site guidance or full-process commissioning services; or if you have any equipment selection inquiries, later maintenance planning needs, etc., please feel free to contact us at any time.
