1、 Precautions for safe operation

1. Equipment installation and debugging

• Site selection requirementsThe equipment should be installed in a well lit and easy to operate location, close to the raw material and finished product warehouses, to facilitate production organization. The motor should be placed in a corner or against a wall, paying attention to waterproofing.
• Stable foundationThe equipment installation must be smooth and firm, with smooth ground drainage to prevent water accumulation from causing equipment damage or personnel slipping.
• Electrical safety：
  • The foundation of the distribution cabinet should be at least 5 centimeters above the ground to prevent water from entering the cabinet.
  • The connection of each terminal post should be firm and correct to avoid short circuits or damage to the circuit.
  • Each device must be equipped with a safety grounding wire, and the grounding point must be effective.
• Transmission components：
  • Correctly select the motor model and the specifications of the pulley V-belt. During installation, the active and passive wheels must be parallel, the V-belt should be moderately elastic, and a protective cover should be installed.
  • Inject 3-10 kilograms of lubricating oil into the reducer (based on the immersion scale or 1/3 position), change the oil after 600 hours of operation, and then change the oil every three or six months (depending on the actual situation).

2. Pre operation inspection

• Device Status：
  • Check if the water, electricity, and gas systems in the equipment are functioning properly, ensuring smooth and leak free water and gas pathways, and reliable electrical systems.
  • Run the auxiliary machine at low speed without load to observe if the equipment is operating normally.
  • Start the shaping table vacuum pump and observe if it works properly.
  • Lubricate the lubrication parts of various equipment with oil.
• Preparation of raw materials：
  • Recycled materials must meet the drying requirements and be further dried if necessary.
  • Clean the various components of the porous plate and machine head, and replace the filter screen.
• temperature control：
  • Before starting the heating system, check whether the set values of the temperature control meters in each area match the temperature requirements of the process.
  • Adjust the filter chamber of the middle plate of the mold head to expose the sealing surface by about 15mm, and do not move the mold head again after starting the heating system.
  • The heating time should be sufficient, and after meeting the process requirements, it should be kept at a constant temperature for 10-15 minutes, with manual turning being more agile and suitable.

3. Monitoring during operation

• Main motor status：
  • Monitor whether the current of the main motor is stable (strictly controlled within the rated current). If the fluctuation is too large or rises sharply, adjust it by controlling the feeding flow rate and stopping the machine for inspection if necessary.
  • Check for any abnormal noise in the gearbox, engine body, and other rotating parts. If any abnormalities are found, stop the machine immediately.
• Temperature and pressure：
  • Monitor the current indication values of the heaters in each area to ensure accurate temperature control.
  • Pay attention to observing or checking whether the fasteners are loose and whether there is any vibration during operation.
• Discharge situation：
  • Check whether the discharge of the granulator is uniform, determine the degree of material plasticization based on the condition of the extruded material, and adjust the screw speed, barrel, and head temperature if necessary.

4. Shutdown operation

• Sequential shutdown：
  • Stop adding materials and squeeze out all the plastic inside the granulator.
  • Turn off the power to the barrel and head, and stop heating.
  • Turn off the power supply of the granulator and auxiliary equipment to stop the operation of the screw and auxiliary equipment.
• Cleaning and maintenance：
  • If it is necessary to remove the machine head, cleaning work should be carried out to prevent damage to the inner surface of the machine head.
  • The remaining material inside the machine head should be cleaned with copper sheets, and then the plastic adhered inside the machine head should be sanded off with sandpaper, polished, and coated with engine oil or silicone oil for rust prevention.
  • After the parking material is crushed into powder and extruded, use compressed air to repeatedly blow out residual granules and powders from the feeding port and exhaust port until there is no residual material in the barrel. Then, reduce the screw speed to zero, stop the granulator, and turn off the main power and cold water main valve.

2、 Preventive measures for faults

1. Common faults and prevention measures

• The screw operates normally but does not discharge：
  • reasonThe feeding of the hopper is discontinuous, there are foreign objects blocking or creating "bridging" at the feeding port, and hard metal objects fall into the screw groove and block it.
  • preventionIncrease the feeding amount to ensure continuous and stable screw feeding; Stop the machine to remove foreign objects from the feeding port and eliminate the "bridging" phenomenon; When it is confirmed that a metal foreign object has fallen into the screw groove, immediately stop the machine and disassemble the screw to remove the metal foreign object.
• The torque of the main motor is too high or too low：
  • reasonMalfunctions in the oil lubrication system, poor alignment between the main motor output shaft and the gearbox inlet/outlet shaft, motor and clutch vibration, excessive feeding load, or poor material melting.
  • preventionRegularly inspect and clean the lubricating oil system, use vibration measuring instruments and infrared thermometers to measure the main motor bearings and form trend charts; Regularly check the alignment between the output shaft of the main motor and the input shaft of the reducer; Ensure that the material is uniformly heated and fully melted.
• The discharge of the machine head is not smooth or blocked：
  • reasonPoor plasticization of materials, malfunctioning heater in a certain section, wide molecular weight distribution of plastics, low and unstable working temperature setting, and presence of foreign objects that are not easily melted.
  • preventionCheck the heater and ensure its normal operation; Verify the set temperature of each section and increase the temperature setting value; Check and replace materials that may cause blockage; Clean foreign objects from the machine head and extrusion system.
• Clutch disengaged：
  • reasonThe instantaneous starting voltage of the main motor is too low, the friction disc and friction plate are overheated or aged, and the air pressure of the friction disc is too low.
  • preventionWhen starting the main motor, avoid peak electricity consumption and reduce the feeding load. The minimum interval between restarts is 30 minutes; When starting the main motor twice or more in summer, extend the interval time or use a fan to force cooling; Use instrument air to blow and wipe off the dust stains on the friction plate and its surface with a cloth. If the wear is severe or there is a "glass like" phenomenon on the surface, the friction plate and friction plate should be replaced; Confirm whether the air pressure value can make the friction disc and friction plate fit together.

2. Key points of maintenance and upkeep

• routine maintenance：
  • Daily inspection of lubrication status of various lubrication parts, temperature rise and noise of bearings in rotating parts, vibration of the unit, current and voltage display of motors and electric heaters, temperature of lubrication cooling water, quality of extruded products, etc.
  • Clean the hopper and other units, inlet and outlet pipes, and check the oil level and lubrication condition of various engine oils, gear oils, and high-temperature butter. The gear oil of the new machine should be replaced at least once every six months, and lubricating oil should be added to the active position at least once a week.
• regular maintenance：
  • Check the wear of screws and barrels every quarter and keep records.
  • Check the gears, bearings, and oil seals of the gearbox once a year.
  • The electrical control cabinet should be purged once a month to clean the electrical dust.
• Long term shutdown maintenance：
  • When the machine is shut down for a long time, measures such as rust and dirt prevention should be taken.