1、 Daily maintenance matters

1. Cleaning and blockage prevention
   • Cleaning of mixing chamberAfter each use, immediately clean the residual plastic particles, powder, or impurities in the mixing chamber to prevent clogging of the mixing blade or discharge port after solidification. Soft bristled brushes or compressed air can be used to assist in cleaning, avoiding the use of hard tools to scratch the inner wall.
   • Inspection of discharge portEnsure that the discharge valve switch is flexible and free of plastic adhesion. If it is found that the discharge is not smooth, the discharge mechanism needs to be disassembled and cleaned, and a small amount of food grade lubricating grease (such as silicone grease) should be applied to reduce friction.
   • External dust removalWipe the device casing daily, focusing on cleaning the heat dissipation holes, motor surfaces, and control panels to prevent dust accumulation from affecting heat dissipation or causing electrical failures.
2. Lubrication and rust prevention
   • Lubrication of transmission componentsAdd specialized lubricating grease (such as lithium based grease) to the mixing shaft bearings, gearbox, chain and other transmission components every week to ensure smooth operation. Pay attention to moderate lubrication to avoid excessive oil leakage.
   • Rust prevention of metal componentsRegularly apply anti rust oil to unpainted metal parts (such as brackets and connectors), especially when used in humid or corrosive environments, and strengthen protection.
3. Running status monitoring
   • Abnormal sound/vibrationDuring operation, listen to the equipment for any abnormal noise or increased vibration, which may be caused by loose mixing blades, worn bearings, or poor gear meshing. Stop the machine immediately for inspection.
   • Temperature monitoringTouch the motor, bearing seat and other parts. If the temperature is too high (over 60 ℃), it may be due to insufficient lubrication or excessive load, and the lubrication needs to be adjusted or the feeding amount needs to be reduced.
   • current detectionMonitor the operating current of the motor through an ammeter. If it continues to exceed the rated value, it may be due to high viscosity of the mixture or jamming of the stirring blade, and it needs to be promptly investigated.

2、 Regular maintenance items (classified by cycle)

1. Weekly maintenance
   • Mixing blade inspectionConfirm that the mixing blade is not deformed, cracked, or worn, and whether the gap between the blade and the inner wall of the mixing chamber is uniform (generally ≤ 2mm). If the gap is too large, adjust or replace the blade.
   • Seal inspectionCheck if there is any leakage in the shaft seal (such as mechanical seal or packing seal). If any leakage is found, replace the sealing ring or adjust the clamping force.
   • Belt/chain tensionAdjust the tension of the belt or chain between the motor and the reducer to prevent slipping or excessive wear.
2. Monthly maintenance
   • Motor and gearbox maintenance：
     • Check the insulation resistance of the motor (measured with a megohmmeter, should be ≥ 0.5M Ω) to prevent moisture or aging.
     • Replace the lubricating oil of the gearbox (usually every 3-6 months according to the instructions) and clean the impurities in the oil pan.
   • Electrical system inspection：
     • Tighten all wiring terminals and focus on checking the wiring of high-power components such as motors, heaters (if equipped), sensors, etc.
     • Use a multimeter to check the stability of the power supply voltage (such as 380V ± 10%) to avoid voltage fluctuations that may cause equipment damage.
   • Safety device testingVerify whether the emergency stop button, overload protector, limit switch, and other functions are functioning properly to ensure reliable safety interlocking.
3. Quarterly maintenance
   • Calibration of verticality of mixing shaftUse a dial gauge to check the perpendicularity between the mixing shaft and the center of the mixing chamber. If the deviation exceeds 0.5mm, adjust the position of the bearing seat or reducer to prevent eccentric wear of the mixing blade.
   • Mixing uniformity verificationBy sampling and testing the color difference, particle size distribution, and other indicators of the mixed material, if the uniformity decreases, it may be due to the wear of the stirring blade or insufficient speed, and the parameters need to be adjusted or the blade needs to be replaced.
   • Heating system inspection(If equipped):
     • Check the resistance value of the heating tube (measured with a multimeter), and replace it if there is an open circuit.
     • Calibrate the temperature sensor to ensure that the displayed value has an error of ≤± 2 ℃ compared to the actual value.
4. Annual maintenance
   • Equipment overall disassembly and inspectionDisassemble key components such as the mixing chamber and stirring system, clean up internal material accumulation, and check for cracks in the welding parts.
   • bearing replacementConduct a comprehensive inspection of bearings that have been running for over 5000 hours, and replace them immediately if defects such as track peeling or cage fracture are found.
   • performance testRun the standard mixing program (such as mixing time, speed, temperature) to verify whether the equipment meets the design specifications (such as mixing uniformity ≥ 95%).

3、 Special maintenance of key components

1. mixing system
   • Selection of blade materialSelect appropriate blade materials (such as stainless steel, chrome plated carbon steel) based on material characteristics (such as corrosiveness, hardness) to avoid premature wear.
   • Dynamic balance adjustmentAfter installing or replacing the mixing blade, a dynamic balance test is required to prevent vibration during high-speed rotation.
   • Adjustment of blade clearanceRegularly measure the gap between the blade and the inner wall of the mixing chamber, and maintain even clearance by adjusting the position of the bearing seat or reducer.
2. Transmission system
   • Gearbox maintenance：
     • Check the oil level of the gearbox every 3 months and replenish the same type of lubricating oil if it is insufficient.
     • Replace the gearbox oil annually and clean the metal debris on the magnetic plug of the oil pan.
   • Belt/chain replacementWhen the belt cracks or the elongation exceeds 5%, it needs to be replaced; When the wear of the chain pitch exceeds 2%, the entire chain needs to be replaced.
3. sealed system
   • Mechanical seal maintenance：
     • Regularly check the wear of the sealing surface, and replace the dynamic ring, static ring, or spring if there is a leak.
     • Ensure that the sealing flushing fluid (such as water or oil) is unobstructed to prevent impurities from entering the sealing surface.
   • Packing seal adjustmentIf packing sealing is used, it is necessary to regularly tighten the packing to prevent leakage, but the clamping force should not be too large to avoid exacerbating wear.

4、 Safe operation and emergency response

1. Operating Specifications
   • No no-load operation is allowedDo not start the equipment when there is no material in the mixing chamber to prevent high-speed rotation of the stirring blade from damaging the bearings or mixing chamber.
   • Standardize start stopTurn on the main power first, then start the mixing motor; Stop feeding first when shutting down, and then turn off the motor after the material in the mixing chamber is emptied.
   • Use of protective devicesEnsure that safety devices such as protective covers and interlocking doors are intact, and do not open the mixing chamber cover during operation.
2. safety protection
   • Grounding inspectionCheck the grounding wire of the equipment every month to ensure it is secure and prevent the risk of electrical leakage.
   • Fire preparednessEquip fire extinguishers around the equipment and prohibit the storage of flammable and explosive materials.
   • personal protectionOperators should wear dust masks, earplugs, protective gloves, etc. to avoid inhaling dust or coming into contact with high-temperature components.
3. Emergency response to malfunction
   • Stirring shaft stuckImmediately press the emergency stop button, cut off the power, and manually turn the machine to check for material clumping or foreign objects getting stuck. After cleaning, restart.
   • Motor overheatingStop the machine and check if the motor fan is running and if the heat sink is blocked. If the temperature continues to rise, check the insulation or load condition of the motor.
   • Sealing leakageIf material leakage is found in the shaft seal, immediately stop the machine and replace the seal to prevent material from entering the bearing and causing damage.

5、 Maintenance records and archive management

1. Establish maintenance ledgerRecord the time, content, replacement parts, and maintenance personnel information of each maintenance to facilitate tracing the historical status of the equipment.
2. Fault AnalysisConduct root cause analysis on frequently occurring faults (such as seal leaks and mixing shaft vibrations) and optimize maintenance plans.
3. File archivingSave equipment manuals, circuit diagrams, and lists of vulnerable parts to ensure quick access to technical information during maintenance.