What are the common faults of pickled cabbage filling machines and their solutions?
Inaccurate Filling Volume
Causes of Faults:
Problems with Metering Devices: The zero point of the electronic scale may drift, resulting in inaccurate weighing. The liquid level sensor may be covered with pickled cabbage residues, affecting the accuracy of liquid level detection. For piston-type filling machines, the wear of the piston's sealing ring will cause leakage during piston movement, thus affecting the filling volume each time. For peristaltic pump filling machines, the wear of the rollers or the decrease in the elasticity of the hose will change the delivery volume per rotation, which in turn leads to deviations in the filling volume.
Faults of Control Valves: If the valves are not tightly sealed or the opening and closing times are inaccurate, the flow control of pickled cabbage will be imprecise. For example, if there are foreign objects blocking the inside of the valve and it cannot be completely closed, the filling volume will exceed the set value.
Solutions:
For metering devices, the electronic scale and liquid level sensor should be calibrated regularly. If the piston sealing ring of the piston-type filling machine is worn, the sealing ring should be replaced in a timely manner. For peristaltic pump filling machines, when the rollers are severely worn, they should be replaced, and when the elasticity of the hose decreases, a new hose should be replaced. For control valves, the inside of the valves should be cleaned regularly to remove foreign objects such as pickled cabbage residues. The sealing parts of the valves should be inspected, and if damaged, they should be replaced in a timely manner. Moreover, the opening and closing times of the valves should be accurately adjusted through the control system.
Clogging of Filling Heads
Causes of Faults:
Problems with the Texture of Pickled Cabbage: If there are many fibers or hard lumps in the pickled cabbage, they are likely to accumulate at the filling head, causing clogging. For example, if the stalk parts of the pickled cabbage are not chopped thoroughly, larger pieces of pickled cabbage may get stuck at the outlet of the filling head.
Mixing of Foreign Objects: During the transportation or storage of pickled cabbage, it is possible to mix in some impurities, such as fragments of packaging materials, detached parts of pickling containers, etc. These foreign objects will cause clogging after entering the filling head.
Solutions:
To address the problem of the texture of pickled cabbage, the pickled cabbage can be screened or further chopped before filling to ensure that the particle size of the pickled cabbage is suitable for filling. For the situation of mixing foreign objects, the management of pickled cabbage raw materials and the production environment should be strengthened. Filtering devices such as strainers should be set at the hopper to prevent foreign objects from entering the storage device and the filling system. Once the clogging of the filling head is detected, the filling should be stopped immediately, the clogging substances should be cleared, and the components should be inspected to see if there are any damaged parts, such as whether the nozzle part of the filling head is deformed. If there is damage, it should be replaced in a timely manner.
Slowing Down of Equipment Operating Speed
Causes of Faults:
Problems with the Power System: Motor faults are one of the common causes. For example, a short circuit or overload of the motor winding will lead to a decrease in the motor's output power, thus slowing down the operating speed of the equipment. In addition, the loosening or wearing of transmission parts such as belts and chains will also affect the power transmission efficiency, making the operating speed of the equipment unable to reach the set value.
Faults of the Control System: Errors in the programs of PLC (Programmable Logic Controller) or single-chip microcomputers may wrongly adjust the operating speed of the equipment. Or sensor faults in the control system, such as faults of photoelectric sensors in the conveying system, which cannot accurately detect the position and movement state of packaging containers, will cause the equipment to reduce its operating speed for safety reasons.
Solutions:
For the power system, the working state of the motor should be inspected, and parameters such as the current and voltage of the motor should be measured to judge whether the motor is working normally. If the motor is faulty, it should be repaired or replaced in a timely manner. For transmission parts, the tightness of belts and chains should be regularly inspected and adjusted, and those that are severely worn should be replaced in a timely manner. For the control system, the program should be inspected to see if there are any errors, and it should be reprogrammed or updated if necessary. For faulty sensors, they should be replaced or recalibrated to ensure that they can accurately detect the operating state of the equipment.
Abnormal Conveyance of Packaging Containers
Causes of Faults:
Faults of the Conveying System: The conveyor belt may deviate, which is caused by the uneven tension of the conveyor belt or the inaccurate installation position of the rollers. When the robotic arm grabs packaging containers, if the joints of the robotic arm are faulty or the grasping force is not enough, it will not be able to accurately convey the packaging containers to the filling position.
Problems with Packaging Containers: The size and shape of the packaging containers do not meet the requirements set by the equipment. For example, if the caliber of the bottle is too small or the size of the packaging bag is too large, it will cause jamming or incorrect positioning during the conveyance process.
Solutions:
For the problem of conveyor belt deviation, the tension of the conveyor belt should be adjusted to make the tension on both sides even, and the installation position of the rollers should be inspected to ensure that the axes of the rollers are parallel. For robotic arm faults, the driving motors, sensors and other components of the joints of the robotic arm should be inspected, and the faulty components should be repaired or replaced, and the grasping force should be adjusted. For problems with packaging containers, it is necessary to ensure that packaging containers that meet the requirements of the equipment are used. The specification range of packaging containers should be determined during the equipment debugging stage, and the quality and size consistency of packaging containers should be strictly controlled during the production process.
Leakage Problems
Causes of Faults:
Damage to Sealing Components: The sealing parts in the filling system, such as the sealing pads between the filling head and the packaging container, the sealing rubber rings at the pipe connections, etc., if damaged or aged, will cause leakage of pickled cabbage.
Abnormal Filling Pressure: For the pressure filling method (such as some piston-type filling machines or peristaltic pump filling machines under special circumstances), if the filling pressure is too high and exceeds the range that the sealing components can withstand, it will lead to leakage.
Solutions:
The state of the sealing components should be regularly inspected, and the aged or damaged sealing pads and sealing rubber rings should be replaced in a timely manner. For the situation of abnormal filling pressure, the pressure control system should be inspected, and the pressure parameters should be adjusted to make them within a reasonable range. At the same time, the pipes should be inspected to see if there are any blockages or other factors affecting the pressure to ensure that the pickled cabbage is filled under normal pressure.
