In the fields of mining, coal, and construction materials, our Mineral Sizers are the core equipment for crushing large pieces of materials in the coarse and medium crushing stages. They are widely used for crushing raw coal, ores, and other materials, capable of reducing pieces of material with a size of ≤1500mm to ≤500mm. They serve as a crucial link connecting mining and subsequent processing, and their stable operation directly determines the production efficiency of the production line. A single machine's downtime for an hour can result in a loss of thousands of tons of production capacity.
However, after new machines are installed, early faults such as abnormal transmission noise and abnormal bearing temperature rise are prone to occur. These problems mostly stem from hidden defects such as insufficient assembly accuracy that were not identified before leaving the factory. This not only delays the construction schedule and increases maintenance costs, but also may cause production to come to a standstill for the customer, resulting in double losses.
Therefore, we insist on conducting no-load tests before each machine leaves the factory not as an unnecessary procedure, but as a "factory inspection" that simulates actual operation. Through dynamic testing, we verify the key performance of each component to ensure that the equipment is delivered in the best condition, thereby avoiding the risk of early faults at the source for the customer.
Mineral Sizer Inspection Dimensions
Stability Test Of Transmission System
- Test Criteria: Continuous no-load operation for ≥ 8 hours. The transmission system should have no periodic abnormal noises, the coupling should show no obvious deviation, the motor's operating current should remain within the rated range without significant fluctuations;
- Key Tests: Monitor the vibration speed of the machine body using a vibration tester, which should be ≤ 2.8mm/s, and there should be no resonance phenomenon; The gear rollers rotate uniformly, without any jamming or skipping teeth issues;
- Core Significance: Early detection of assembly deviations of transmission components to prevent equipment damage caused by poor power transmission during on-site operation by the customer.
Verification Of Bearings And Lubrication System
- Test Standards: Monitor the bearing temperature in real time using an infrared thermometer. The temperature rise should be ≤ 40℃, and the maximum temperature should not exceed 70℃; The oil circuit of the automatic lubrication system is unobstructed, and the grease evenly covers all lubrication points without any leakage;
- Key Tests: The working pressure of the lubrication pump should be stable at around 35 MPa, and the oil tank's storage capacity should meet the demand for 7-15 days of unmanned operation;
- Core Significance: Eliminate bearing damage caused by dry friction, extend the service life of core components, and reduce the frequency of customer maintenance in the later stage.
Sealing And Protection Performance Test
- Test Standards: During the test run, there should be no oil leakage from the bearing end seal or the connection points of the machine body, the dust cover should be tightly attached to the machine body without any sign of dust entering the cavity;
- Key Inspection: The sealing device at the inlet and outlet ports is firmly connected to the flange, the sealing gasket is not loose, meeting the requirements for environmental protection and dust prevention;
- Core Significance: Preventing dust from polluting the lubricating oil and corroding components, ensuring the long-term reliable operation of the equipment under harsh conditions.
Electrical Control System Verification
- Test Standards: The local/remote start/stop functions are normal, the response time of the emergency stop button is ≤ 0.5 seconds, and the interlock functions such as overload protection and stall protection are sensitive and effective;
- Key Tests: The PLC control system communicates smoothly with the upper computer, the signal transmission of sensors (temperature, vibration) is accurate, the dynamic display of the operation interface is clear, and there is no signal loss;
- Core Significance: Avoid "hidden faults" in the electrical system, ensure the safety of on-site operations for customers, and achieve stable interlocking between equipment and the production line.
Verification Of Structural Assembly Accuracy
- Test Standard: Measure the axial gap deviation of the toothed roller using professional instruments, which should be ≤ 0.5mm. The gap across the entire roller surface should be uniform, with no excessive or insufficient areas;
- Key Inspection: The body structure shows no obvious deformation, the bolt tightening torque meets the standard, and there are no signs of loosening; The equipment operating noise should be ≤ 85dB (measured 3m away from the body);
- Core significance: Ensure that the material is uniformly stressed during the crushing process, avoid "over-crushing" or "blockage" problems caused by the deviation of the toothed roller, and guarantee the uniformity of the discharged particle size for the customers.
Value Of Mineral Sizer No-Load Testing
Reduce The Risk Of On-Site Installation And Commissioning For Customers
Our no-load test run can identify and resolve 80% of the assembly and component coordination issues in advance, preventing equipment defects from causing installation delays at the customer site.
After the test run, we will provide a complete set of test data reports, including key parameters such as current, temperature, vibration, and noise, to provide precise reference for the customer's on-site commissioning and shorten the production cycle.
Extend The Service Life Of The Equipment
If early faults are not promptly identified, they will exacerbate the wear of core components such as gear rollers and bearings. Our no-load test run is equivalent to a "pre-examination before equipment operation", ensuring that all components enter the customer's site for operation in the best condition, effectively extending the major overhaul period of the entire machine to ≥ 8 years, and the lifespan of main structural components to ≥ 20 years.
Ensure Stable Output Of Customer Production Capacity
Our Mineral Sizer is the core equipment of the customer's production line. Each hour of downtime may result in thousands of tons of production capacity loss. Our strict test run of the equipment can reduce the on-site failure rate by more than 60%, significantly reducing production line downtime caused by equipment failures.
Reduce The Customer's Post-Commissioning Maintenance Costs
The on-site repair of early faults requires the customer to invest additional costs such as labor, spare parts, and downtime losses, and the cost is often more than 10 times that of our factory test run cost. We will pre-position the maintenance costs and minimize them. Through one-time thorough inspection before factory delivery, we can reduce the customer's comprehensive operating costs.
Mineral Sizer Test Standards
Strict Test Machine Operation Procedure
- Pre-treatment stage: We will comprehensively check the amount of lubricating oil added, the integrity of electrical connections, and the rationality of the gap between the toothed rollers to ensure that the equipment is ready for the test run;
- Step-by-step startup stage: Start each component in the reverse coal flow direction sequence to verify the start-stop logic; run it at no-load for 1 hour to observe the basic condition, then enter the continuous and stable test run stage;
- Continuous monitoring stage: Run continuously at no-load for ≥ 8 hours, record the motor current, bearing temperature, vibration speed, noise and other data every 30 minutes;
- Qualification determination stage: All indicators meet industry standards and technical requirements, without any abnormal phenomena, generate the "Factory No-load Test Report", and the equipment can be delivered to the customer.
Professional Testing Equipment
To ensure the accuracy and reliability of the test results, we use professional testing instruments for continuous monitoring throughout the process:
- Infrared thermometer: Real-time monitoring of temperature rise of bearings and motors;
- Vibration tester: Verification of the stability of the machine body and transmission system;
- Noise analyzer: Detection of whether the operating noise meets the standards;
- Multimeter and PLC debugging tools: Verification of electrical parameters and interlock logic.
Industry Comparison
In the industry, some enterprises omit the no-load test run process to reduce costs. Although this seems to save time, it actually poses numerous risks for the customers. We will firmly avoid these risks:
- Omission of assembly defects: Issues such as parallelism deviations of the gear rollers and misalignment of the couplings are difficult to be quickly identified on-site, which may lead to early damage of the transmission components and significantly increase the customer's maintenance costs;
- Hidden risks in the lubrication system: Problems such as blocked oil circuits and uneven oil supply become apparent on-site, which may cause bearing burnout. The customer's replacement cost is several times that of our test run cost;
- Failure of electrical interlocks: The start-stop faults or protection functions fail to be detected until the on-site startup, which not only delays the customer's production but may also trigger safety accidents;
- Irreversible production capacity loss: Equipment failures resulting in production line shutdowns can cause an hourly production loss of several thousand tons. This is far more than the cost we invested in the test run, ultimately harming the customer's interests.
The complexity of the structure and the harsh working conditions of our mineral sizer determine that the factory empty-load test run is not an "optional process", but a "necessary defense line" to ensure the quality of the equipment. We insist on conducting the empty-load test run because the essence is to avoid the early failure risks of customers in advance. Through professional testing and standardized procedures, we lay a solid foundation for the stable operation of each piece of equipment.
For customers, a Mineral Sizer that has undergone our strict empty-load test run is not only a "qualified product", but also a "reliable production capacity partner". It means lower installation risks, longer service life, more stable production output, and lower overall costs. In today's pursuit of efficient production, we always believe that only by prioritizing quality control can we truly create long-term value for customers. This is the core original intention that we adhere to for the empty-load test run.
