The efficient and stable operation of the gypsum board equipment production line highly relies on scientific and systematic maintenance. Based on industry practical standards and the characteristics of desulfurization gypsum raw materials in Linyi area, the core maintenance techniques are systematically summarized as follows:
1、 Molding system maintenance: mold and vibration core
Anti sticking treatment of molding molds
Release agent usage: Special non wax release agent is used to ensure that the mold surface is clean and dry before spraying. It is recommended to use the "3-4 layer cross spraying" process, with an interval of 10-15 minutes between each layer, and wait for the solvent to completely evaporate before spraying the next layer.
Spray repair cycle: Local spray repair is carried out every 5 products produced; When the demolding resistance significantly increases, immediately re spray the entire mold to avoid damage caused by forced demolding.
Cleaning standard: After daily production, use low-pressure air or ultrasonic cleaning machine to remove residual gypsum powder; It is strictly prohibited to use metal brushes or strong acid-base cleaning agents to prevent surface scratches or corrosion. It is recommended to use dry ice cleaning technology for high-end production lines, which has no residue and does not damage the mold substrate.
Vibration system maintenance
Vibration exciter bearing lubrication: using a thin oil lubrication system, the lubricating oil must be replaced after the first 40 hours of operation, and then it must be forcibly replaced every 800 hours of operation thereafter. The type of grease should comply with the equipment manufacturer's recommendations (such as ISO VG 68 or 100).
Frequency calibration: Use a laser level (accuracy ≥ 0.01mm/m) every month to calibrate the levelness of the vibration platform, ensuring that the vibration direction is vertical. Every quarter, use a standard vibration calibrator (such as BZ-1 type) to compare the accuracy of the accelerometer. Professional calibration is required when the deviation exceeds ± 5%.
Tightening inspection: Before starting up daily, check whether the anchor bolts of the exciter and the coupling bolts are loose. After running for 4 hours, they must be tightened again and equipped with anti loosening spring washers.
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2、 Drying system maintenance: key to temperature control and crack prevention
Accurate control of temperature and humidity
The temperature fluctuation inside the drying kiln should be controlled within ± 3 ℃, and the relative humidity should be maintained at 15% -25%. The system should be equipped with multi-point temperature and humidity sensors and PLC closed-loop control to avoid local overheating causing cracking or deformation of the board.
Insulation layer and cleaning
Regularly inspect the insulation cotton of the kiln body for collapse or damage, conduct infrared thermal imaging testing every six months, and promptly fill in areas with heat loss.
Clean the gypsum dust on the surface of the drying roller conveyor every month, using soft bristled brushes and dust collection devices to avoid dust accumulation that affects thermal conductivity efficiency.
It is strictly prohibited to rinse the structure inside the kiln with water to prevent moisture from infiltrating the insulation layer and causing a decrease in thermal resistance.
3、 Raw material system maintenance: specialized practical operation of desulfurization gypsum/phosphogypsum (suitable for Linyi area)
Corrosion prevention and scaling prevention
Pipeline blockage prevention: The pipeline for transporting desulfurization gypsum slurry should maintain a flow rate of ≥ 1.5m/s to avoid sedimentation at low flow rates. At the end of each shift, rinse the pipeline with clean water for at least 10 minutes to completely drain the slurry.
Scale cleaning: For pipelines that have already formed scale, priority should be given to using high-pressure water guns for flushing (pressure ≤ 15MPa); The stubborn scale layer can be cleaned by circulating citric acid or dilute hydrochloric acid (concentration ≤ 5%), and after cleaning, it must be thoroughly neutralized with clean water and drained.
Online scale inhibition: Special scale inhibitors (such as polyacrylic acid) are added before the slurry enters the pipeline, and the dosage is automatically adjusted according to pH and conductivity through an intelligent dosing system to achieve "prevention is greater than cure".
Equipment anti-corrosion
All metal components (pumps, valves, pipelines) that come into contact with desulfurization gypsum slurry should be made of 316L stainless steel or lined with rubber/glass flake coating.
Conduct thickness testing on key areas every quarter, and if the corrosion rate exceeds 0.1mm/year, immediately replace or strengthen the anti-corrosion coating.
4、 General maintenance principles
Frequency of maintenance category operation points
Clean and remove dust from equipment surfaces, transmission components, and electrical boxes, and maintain ventilation and heat dissipation after each shift
Lubricate all grease fittings, bearings, and chains by adding lithium based grease according to the manual. Do not mix different models every week
Tighten and inspect all bolts, nuts, and couplings to prevent loosening due to vibration before starting up each day
Check whether the monitoring motor current, bearing temperature, hydraulic pressure, and sensor signals are abnormal and record them every hour
Record the establishment of an electronic maintenance log, documenting details of lubrication, replacement, calibration, and fault handling on a continuous basis
5、 Visualization supplement of frontline practical experience
Linyi Jinhao Machinery Co., Ltd. is a manufacturer mainly engaged in the production, sales, and service of complete sets of gypsum board equipment, gypsum powder equipment, and other mechanical equipment.