礦用空壓機(jī)故障原因分析與解決方法

任何機(jī)械產(chǎn)品在使用一段時(shí)間以后，難免會(huì)出現(xiàn)各種各樣的故障，從大故障到小故障，一是使用方法，二是機(jī)械所在的環(huán)境，都有可能造成機(jī)械的損害，空壓機(jī)也不例外，而且礦用空壓機(jī)的故障比一般的空壓機(jī)發(fā)生故障的頻率要高，因?yàn)榈V用空壓機(jī)的環(huán)境粉塵比較多，下面我們給大家分析一下常見(jiàn)的故障。

Any mechanical products in the use of a period of time, it is inevitable that there will be a variety of failures, from the big fault to the small fault, one is the use method, the other is the environment where the machinery is located, all may cause mechanical damage, air compressor is no exception, and the failure frequency of mine air compressor is higher than that of general air compressor, because the dust of mine air compressor is relatively high More, let's give you an analysis of common faults.

1、常見(jiàn)故障及其原因

1. Common faults and their causes

排氣量不足：排氣量不足是與壓縮機(jī)的設(shè)計(jì)氣量相比而言的。主要可從下述幾方面考慮：

Insufficient displacement: the insufficient displacement is compared with the design gas volume of the compressor. It can be considered from the following aspects:

（1）進(jìn)氣濾清器的故障；積垢堵塞，時(shí)排氣量減少，吸氣管太長(zhǎng)，管徑太小，致使吸氣阻力增大影響了氣量，要定期清洗濾清器。

(1) Air intake filter failure; fouling blockage, when the exhaust volume is reduced, the suction pipe is too long, the pipe diameter is too small, resulting in increased suction resistance, affecting the gas volume, to regularly clean the filter.

（2）壓縮機(jī)轉(zhuǎn)速降低使排氣量降低：空氣壓縮機(jī)使用不當(dāng)，因空氣壓縮機(jī)的排氣量是按一定的海拔高度、吸氣溫度，濕度設(shè)計(jì)的，當(dāng)把它使用在超過(guò)上述標(biāo)準(zhǔn)的高原上時(shí)，吸氣壓力降低等，排氣量必然降低。

(2) The reduction of compressor speed reduces the displacement: improper use of air compressor, because the discharge capacity of air compressor is designed according to a certain altitude, suction temperature and humidity. When it is used on the plateau that exceeds the above standards, the suction pressure will be reduced, and the exhaust volume will be reduced.

（3）氣缸、活塞、活塞環(huán)磨損嚴(yán)重、超差，使有關(guān)間隙增大，泄漏量增大，影響到了排氣量。屬于正常磨損時(shí)，需及時(shí)更換易損件，如活塞環(huán)等。

(3) The cylinder, piston and piston ring are seriously worn and out of tolerance, which makes the relevant clearance increase, the leakage increases and the exhaust volume is affected. In case of normal wear, it is necessary to replace the vulnerable parts, such as piston ring, etc.

（4）填料函不嚴(yán)產(chǎn)生漏氣使氣量降低。其原因是填料函本身制造時(shí)不合要求；其次可能是由于在安裝時(shí)，活塞桿與填料函中心對(duì)中不好，產(chǎn)生磨損、拉傷等造成漏氣；一般在填料函處加注潤(rùn)滑油，它起潤(rùn)滑、密封、冷卻作用。

(4) The stuffing box is not tight, resulting in air leakage, which reduces the gas volume. The first reason is that the stuffing box itself does not meet the requirements when it is manufactured; second, it may be due to the poor alignment between the piston rod and the stuffing box center, resulting in wear and tear, resulting in air leakage; generally, the stuffing box is filled with lubricating oil, which plays the role of lubrication, sealing and cooling.

（5）壓縮機(jī)吸、排氣閥的故障對(duì)排氣量的影響。閥座與閥片間掉入金屬碎片或其它雜物，關(guān)閉不嚴(yán)，形成漏氣。這不僅影響排氣量，而且還影響間級(jí)和溫度的變化，閥座與閥片接觸不嚴(yán)形成漏氣而影響了排氣量，一個(gè)是制造質(zhì)量問(wèn)題，如閥片翹曲等，第二是由于閥座與閥片磨損嚴(yán)重而形成漏氣。

(5) The influence of the failure of suction and discharge valves of the compressor on the displacement. Metal fragments or other foreign matters fall between the valve seat and the valve plate, and the valve is not tightly closed, resulting in air leakage. This not only affects the air displacement, but also affects the change of interstage and temperature. The loose contact between the valve seat and the valve plate results in air leakage, which affects the air displacement. One is the manufacturing quality problem, such as the valve plate warping, and the other is the serious wear of the valve seat and valve plate.

2、排氣溫度不正常原因

2. Causes of abnormal exhaust temperature

（1）排氣溫度不正常。從理論上，影響排氣溫度增高的因素有：進(jìn)氣溫度、壓力比、以及壓縮指數(shù)（對(duì)于空氣壓縮指數(shù)K=1.4）。實(shí)際情況影響到吸氣溫度高的因素有：中間冷卻效率低，或者中冷器內(nèi)水垢結(jié)多影響到換熱，則后面級(jí)的吸氣溫度必然要高，排氣溫度也會(huì)高。氣閥漏氣，活塞環(huán)漏氣，不僅影響到排氣溫度升高，而且也會(huì)使級(jí)間壓力變化，只要壓力比高于正常值就會(huì)使排氣溫度升高。此外，水冷式機(jī)器，缺水或水量不足均會(huì)使排氣溫度升高。

(1) The exhaust temperature is abnormal. Theoretically, the factors that affect the increase of exhaust temperature are inlet temperature, pressure ratio and compression index (k = 1.4 for air compression index). In fact, the factors that affect the high suction temperature are: low intermediate cooling efficiency, or more scale in the intercooler will affect the heat transfer, then the suction temperature of the later stage must be high, and the exhaust temperature will also be high. If the pressure ratio is higher than the normal value, the exhaust temperature will increase. In addition, water-cooled machines, water shortage or water shortage will make the exhaust temperature rise.

（2）壓力不正常以及排氣壓力降低。壓縮機(jī)排出的氣量在額定壓力下不能滿(mǎn)足使用者的流量要求，則排氣壓力必然要降低，所以排氣壓力降低是現(xiàn)象，其實(shí)質(zhì)是排氣量不能滿(mǎn)足使用者的要求。此時(shí)，只好換另一臺(tái)排氣壓力相同，而排氣量大的機(jī)器，影響級(jí)間壓力不正常的主要原因是氣閥漏氣或活塞環(huán)磨損后漏氣，故應(yīng)從這些方面去找原因和采取措施。

(2) Abnormal pressure and reduced exhaust pressure. If the air volume discharged by the compressor can not meet the flow requirements of the user under the rated pressure, the discharge pressure must be reduced. Therefore, the decrease of the discharge pressure is a phenomenon, and the essence is that the discharge volume can not meet the requirements of the user. At this time, we have to replace another machine with the same exhaust pressure and large displacement. The main reason for the abnormal interstage pressure is the air leakage of the air valve or the worn piston ring. Therefore, we should find out the causes and take measures from these aspects.

（3）過(guò)熱故障。在曲軸和軸承、十字頭與滑板、填料與活塞桿等摩擦處，溫度超過(guò)規(guī)定的數(shù)值稱(chēng)之為過(guò)熱。過(guò)熱所帶來(lái)的后果：一個(gè)是加快摩擦副間的磨損，二是過(guò)熱量的熱不斷積聚直致燒毀摩擦面以及燒抱而造成機(jī)器重大的事故。造成軸承過(guò)熱的原因只要有：軸承與軸頸貼合不均勻或接觸面積過(guò)??；軸承偏斜曲軸彎曲，潤(rùn)滑油粘度太小，油路堵塞，油泵有故障造成斷油等；安裝時(shí)沒(méi)有找平，沒(méi)有找好間隙，主軸與電機(jī)軸沒(méi)有找正，兩軸有傾斜等。

(3) Overheating fault. In the crankshaft and bearing, crosshead and sliding plate, packing and piston rod friction, the temperature exceeds the specified value is called overheating. The consequences of overheating: one is to speed up the wear between the friction pairs; the other is that the heat accumulated continuously leads to the burning of the friction surface and the burning and holding, resulting in serious accidents of the machine. The causes of bearing overheating are as follows: the bearing and journal fit unevenly or the contact area is too small; the bearing is skewed, the crankshaft is bent, the lubricating oil viscosity is too small, the oil circuit is blocked, the oil pump is out of order due to fault, etc.; during installation, there is no leveling and clearance, the main shaft and motor shaft are not aligned, and the two shafts are inclined.