Debugging and installation of wind selection machine

As a key equipment in the field of material sorting, the wind separator is widely used in industries such as construction waste recycling, mineral processing, and environmental sorting. Its installation and commissioning quality directly determine the sorting accuracy, processing efficiency, and equipment service life. Currently, some enterprises have caused unstable equipment operation, poor sorting efficiency, and even safety hazards due to non-standard installation processes and unreasonable debugging parameters. To solve this pain point, this article focuses on the structural characteristics and practical application scenarios of the wind selection machine. From pre installation preparation, core installation process, precise debugging steps to safety maintenance standards, it provides a systematic and practical operation guide to assist technical personnel in standardizing operations, ensuring that the wind selection machine quickly reaches the design capacity and sorting standards, laying a solid foundation for efficient and stable operation of the production line.

A.Preparation before installation: lay a stable foundation for operation

The installation quality of the wind selection machine directly affects the subsequent operational efficiency and stability. Before installation, sufficient preparation in terms of site, equipment, and personnel is required to avoid potential hazards.

Site and foundation preparation

The site needs to meet the requirements of equipment operation space, reserve at least 1.5 meters of maintenance access, have a flat ground and meet the bearing capacity standards (according to the equipment model, small wind selection machines need to be ≥ 5t/㎡, and large wind selection machines need to be ≥ 10t/㎡). The foundation construction needs to be carried out according to the equipment installation drawings, using concrete of C30 or above for pouring, pre embedded anchor bolts (made of Q235B material, with specifications matching the equipment base aperture), and a horizontal error of ≤ 2mm/m on the top surface of the foundation. The equipment can only be installed after the concrete has been cured for more than 7 days and the strength has reached 80% of the design value. At the same time, ensure that the site is powered (voltage fluctuation ≤ ± 5%), has good ventilation conditions, and is away from flammable and explosive environments. If it is used in dusty scenarios such as construction waste disposal, the installation location of dust removal equipment needs to be planned in advance.

Equipment inspection and accessory inventory

After opening the box, carefully inspect the main body of the air separator (air duct, sorting room, fan, discharge port), transmission system (motor, reducer, pulley), control system and other components for integrity, whether there is any deformation or damage caused during transportation, and whether the key welds are free of cracks or detachment. Check the list of accessories, confirm that the supporting parts such as anchor bolts, gaskets, belts, lubricating oil, etc. are complete, and the model matches the equipment (such as the fan motor power needs to be adapted to the processing capacity of the air selection machine to avoid power shortage or waste). Pre check vulnerable parts (such as impellers and deflectors) to ensure no burrs, deformation, and flexible rotation without jamming.

Personnel and tool preparation

Installation personnel need to have mechanical installation qualifications, be familiar with the structural principles and safety operating procedures of wind selection machines, and conduct technical briefings in advance. Prepare necessary tools: level (accuracy 0.02mm/m), torque wrench, lifting equipment (selected according to the weight of the equipment, manual hoist can be used for small wind selection machines, and truck crane can be used for large ones), wrench, screwdriver, etc., and also equip with safety protective equipment such as insulated gloves, safety helmets, and anti slip shoes.

B. Core installation process: Standardized operation to ensure accuracy

The installation of the wind selection machine should follow the principle of "main body first, accessories later, fixed first, and connected later", and follow the following steps in an orderly manner to strictly control the installation accuracy.

Positioning and fixing of main equipment

Use lifting equipment to steadily lift the main body of the wind selection machine onto the foundation, adjust the equipment position to align the base bolt holes with the pre embedded anchor bolts, and preliminarily tighten the nuts (not yet tightened to the rated torque). Use a spirit level to check the levelness of the equipment, measure the longitudinal and transverse levelness separately, and calibrate by adjusting the shim (thickness 0.5-5mm) under the base to ensure that the levelness error is ≤ 1mm/m. After the calibration is completed, tighten the anchor bolts in diagonal order, with torque values according to the equipment manual requirements (usually 40-80N · m). After tightening, recheck the levelness to avoid equipment displacement during the tightening process.

Installation and calibration of transmission system

The installation of the transmission system is a critical step that directly affects the efficiency of power transmission. Firstly, install the motor and reducer. The motor base should be firmly fixed to the wind separator base. The parallelism error between the motor axis and the input shaft axis of the reducer should be ≤ 0.2mm/m, and the deviation of the center distance between the two shafts should be ≤ ± 0.5mm. If a belt drive is used, the motor position should be adjusted to align the pulley (deviation ≤ 0.5mm). The belt tension should be lowered by 10-15mm when pressing the midpoint of the belt to avoid bearing wear or slipping caused by excessive tension or looseness; If coupling transmission is used, it is necessary to ensure that the coaxiality error of the coupling is ≤ 0.1mm, the end face clearance is maintained at 2-4mm, and there is no misalignment or jamming when installing the elastic pad.

Pipeline and auxiliary equipment connection

Connect the feed pipe, discharge pipe, and return pipe, and install sealing gaskets (using wear-resistant and corrosion-resistant materials such as rubber or polytetrafluoroethylene) at the pipeline interface. Tighten them with bolts to ensure good sealing and no air or material leakage. The installation of pipelines should be kept smooth, avoiding sharp bends (bending angle ≥ 90 °) to reduce the risk of material blockage. The slope of the feed pipe should be ≥ 30 ° to facilitate material self flow. If supporting dust removal equipment (such as pulse dust collector), it is necessary to connect the dust removal pipeline to ensure that the pipeline direction is reasonable and the resistance loss is small. At the same time, an air volume regulating valve should be installed to facilitate the adjustment of air speed during subsequent debugging.

Electrical system installation

Electrical installation must be operated by professional electricians and strictly follow electrical regulations. Connect the motor and sensors (such as wind speed sensors and material level sensors) to the control cabinet, with firm and standardized wiring. The grounding resistance of the grounding wire should be ≤ 4 Ω to avoid potential leakage hazards. The control cabinet should be installed in a dry and easy to operate location, at an appropriate distance (≥ 1 meter) from the equipment, with neat wiring and clear labeling. After installation, check the continuity of the electrical circuit, test the functionality of the control cabinet indicator lights and buttons, and ensure that the emergency stop button is sensitive and reliable.

C.Accurate debugging steps: achieve efficient sorting

Debugging is the key to achieving the design processing capacity and sorting accuracy of the wind separator. It needs to be carried out in the order of "no-load debugging load debugging parameter optimization", gradually troubleshooting problems and optimizing the operating status.

No load debugging: testing the stability of equipment operation

Before no-load debugging, check again whether the bolts of each connecting part are tightened, whether the lubrication system is filled with qualified lubricating oil (selected according to the equipment manual, such as adding 220 # gear oil to the reducer, with the oil level reaching the centerline of the oil window), and remove any debris inside and around the equipment. Start the power supply of the control cabinet, first jog the motor, and observe whether the direction of rotation of the fan and impeller is correct (consistent with the equipment identification arrow), whether there is any abnormal noise or severe vibration. After the jog is normal, start the equipment and run it continuously for 2-4 hours. Monitor the following parameters: motor current (should be within 30% -50% of the rated current), bearing temperature (≤ 75 ℃), vibration speed (≤ 4.5mm/s). The equipment should run smoothly, without noise or leakage. If there is excessive vibration, it is necessary to check whether the anchor bolts are tightened and whether the impeller is balanced; If the bearing temperature is too high, it is necessary to check whether the lubrication is sufficient or whether the coaxiality of the coupling meets the standard.

Load debugging: optimizing sorting performance

After passing the no-load debugging, perform load debugging and gradually increase the feeding amount to avoid one-time full load feeding. Firstly, feed 30% of the designed processing capacity and run for 1 hour to observe the movement of materials in the sorting chamber: lightweight materials (such as plastic and sawdust) should be able to be smoothly carried away by the airflow and discharged from the lightweight discharge outlet; Heavy materials (such as sand, gravel, and metal) should settle at the heavy discharge outlet without obvious mixing. By monitoring the wind speed inside the sorting room through a wind speed sensor, the wind speed is adjusted according to the characteristics of the materials (usually the wind speed for handling light materials is 3-6m/s, and for heavy materials it is 6-10m/s), and precise control of the wind speed is achieved by adjusting the fan frequency conversion knob or air volume control valve.

Gradually increase the feed rate to 50%, 80%, and 100%, and run steadily for 1-2 hours after each increase. Record parameters such as processing capacity, sorting accuracy, motor current, and energy consumption. Detection and sorting accuracy: The content of heavy impurities in light materials should be ≤ 1%, and the content of light impurities in heavy materials should be ≤ 0.5%. If it does not meet the standard, the following parameters can be adjusted for optimization: ① Adjust the angle of the guide plate (angle range 15 ° -45 °), change the airflow distribution, and optimize the sorting area; ② Adjust the height or speed of the feeding port to ensure even distribution of materials and avoid local material accumulation; ③ Replace the impeller speed (through variable frequency speed regulation), adjust the airflow intensity, and adapt to materials of different densities.

Troubleshooting and Adjustment

Common problems and solutions in load debugging: ① Excessive heavy impurities carried by light materials: high wind speed, appropriately reduce wind speed or adjust the angle of the guide plate; ② Mixing light impurities into heavy materials: if the wind speed is too low, increase the wind speed or increase the impeller speed; ③ Material blockage in the feeding pipe: If the feeding speed is too fast or the pipeline slope is insufficient, reduce the feeding amount or adjust the pipeline slope; ④ Motor overload: If the feeding amount is too large or the equipment is stuck, stop the machine to clean up foreign objects, adjust the feeding amount, and check whether the transmission system is stuck.

D.Safety and Maintenance Standards: Extending Equipment Lifespan

After passing the debugging, it is necessary to establish a comprehensive safety operation and maintenance system to ensure the long-term stable operation of the equipment.

Safety operation standards

Operators must be trained and qualified before taking up their posts. They must strictly follow the operating procedures and check the equipment status before starting up. The starting sequence is: start the fan first → adjust the wind speed → start the feeding device; The shutdown sequence is: stop feeding → continue running the fan for 5-10 minutes (remove residual materials) → turn off the fan. When the equipment is running, it is forbidden to open the sorting room door or perform maintenance operations, and it is forbidden to insert hands or foreign objects into the interior of the equipment. If there is an emergency situation, immediately press the emergency stop button, cut off the power and handle it. Regularly check whether the safety protection devices (such as protective covers and fences) are intact, and it is strictly prohibited to dismantle the safety devices for operation.

Daily maintenance and upkeep

Establish a regular maintenance ledger, with daily maintenance focus on: ① checking the tightening of bolts, lubrication system oil level, equipment operation status, and cleaning the surface and surrounding dust of equipment daily; ② Check the tension of the belt and the wear of the impeller every week, clean up residual materials at the inlet and outlet, and inspect the electrical circuit for damage; ③ Replace the lubricating oil once a month (or as required by the equipment manual), clean the oil filter, and check the accuracy of the sensor; ④ Conduct a comprehensive inspection of vulnerable parts such as impellers and deflectors every quarter, and replace them promptly if they are severely worn to ensure sorting accuracy.

Long term shutdown and restart

If the equipment is shut down for a long time (more than 15 days), residual materials inside should be cleaned to prevent moisture and clumping; Cut off the power and turn off the main switch of the control cabinet; Apply rust proof oil to easily rusted parts and cover the equipment with a rainproof cloth. Before restarting, the equipment needs to be rechecked according to the installation and debugging process. After running without any abnormalities for 1 hour, it can be operated under load.

The installation and commissioning of wind selection machines is a systematic project that requires strict adherence to the core principles of "sufficient preparation, precise installation, scientific commissioning, and proper maintenance". During the installation phase, the main body fixation, transmission calibration, pipeline and electrical connections are standardized to ensure the basic operation of the equipment; The debugging process follows the sequence of "no-load inspection load optimization" to accurately adjust key parameters such as wind speed and guide plate angle, achieving efficient sorting; Daily maintenance and safety standards can extend equipment lifespan and mitigate risks. The operation points and standard parameters described in this article can effectively solve common problems in installation and debugging, helping enterprises quickly achieve optimal performance of wind selection machines. Whether it's building new production lines or upgrading equipment, these standardized processes can provide reliable support for improving production efficiency and ensuring sorting quality, helping the industry achieve high-quality development.

Author : Serena Chang

Serena Chang is the writer of blog and news column. With more than 10 years of working experience in the machinery industry, she has a comprehensive understanding of environmental protection machinery and is willing to share useful knowledge of environmental protection machinery.