Tongxin Machinery provides high-quality and cost-effective construction equipment, including concrete batching plants and stabilized soil mixing stations. Contact us for customized solutions.
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Introduction: Understanding the Severity of "No Cement Flow" Failures
In the concrete production industry, "no cement flow" failure is widely recognized as one of the most serious production interruption issues. This failure not only leads to complete production line shutdown but can also cause significant economic losses and safety hazards. As a professional manufacturer in the concrete mixing equipment field, Tongxin Machinery will provide a complete technical solution from fault diagnosis to complete resolution, based on 20 years of industry experience.
Chapter 1: In-depth Analysis of Cement Silo Outlet Compaction and Blockage
1.1 Physical Mechanisms of Failure Formation
Cement undergoes complex physical changes during the transportation process. When cement particles fall from a height of 20 meters into the silo, it triggers a chain reaction:
Aerodynamic Effects:
- Air between particles is rapidly compressed during the falling process
- Formation of high-pressure "air wedges" that hinder material flow
- Compressed air at the silo bottom cannot escape in time, creating back pressure
Material Characteristics Changes:
- Static friction between fine particles increases exponentially
- Material angle of repose exceeds critical values
- Formation of stable "arch bridge" structures
1.2 Professional-grade Diagnostic Process
Phase One: Comprehensive Inspection of the Arch-breaking System
Auditory Diagnostic Method:
- Activate manual control mode of the solenoid valve
- Listen at a distance of 1 meter from the equipment
- Normal operation should produce clear, regular "popping" sounds
Tactile Diagnostic Method:
- Manually contact the outer wall of the intake pipeline
- Sense the frequency and intensity of airflow pulses
- Significant vibration should be felt under normal conditions
Instrument Detection Method:
- Check air compressor pressure gauge output
- Standard pressure range: 0.5-0.8MPa
- Pressure fluctuation should not exceed ±0.05MPa
Phase Two: Graded Treatment Solutions
Primary Treatment:
- Use professional anti-static rubber hammer
- Adopt 45-degree angle oblique tapping on the silo cone section
- Control single tap force between 50-100N
Advanced Treatment:
- Replace solenoid valve and inspect circuits
- Adjust air pressure of oil-water separator
- Check for air leakage in pneumatic lines
Chapter 2: Comprehensive Management of Cement Silo Caking and Seal Failure
2.1 Multi-path Analysis of Moisture Intrusion
Top Intrusion Paths:
- Aging and cracking of silo top cover seals
- Seal failure of inlet rain caps
- Poor sealing at dust collector interfaces
Side Intrusion Paths:
- Microscopic corrosion at silo wall welds
- Local detachment of anti-corrosion coatings
- Permanent compression deformation of access door seals
Condensate Formation:
- Condensation due to temperature differences
- Breathing valve function failure
2.2 Systematic Prevention and Treatment Solutions
Preventive Maintenance System
Daily Inspection System:
- Visual inspection of silo top seal condition
- Dust collector pressure differential monitoring
- Silo wall temperature distribution detection
Regular Maintenance Plan:
- Quarterly comprehensive inspection of sealing system
- Semi-annual anti-corrosion layer repair
- Annual overall safety assessment
Chapter 3: Precision Diagnosis of Screw Conveyor System Failures
3.1 Application of Fault Tree Analysis
Using fault tree analysis, we decompose screw conveyor system failures into three main branches:
Power System Failures:
- Motor insulation aging
- Power phase loss
- Control circuit contact failure
Transmission System Failures:
- Reduction gear wear
- Key connection fitting looseness
Mechanical Body Failures:
- Coupling clearance exceeding standards
- Blade wear deformation
- Internal material blockage
3.2 Graded Diagnostic Technology
Level One Diagnosis: On-site Quick Assessment
Sensory Diagnostic Method:
- Vision: Observe motor starting characteristics
- Hearing: Identify abnormal sound types
- Touch: Detect equipment vibration conditions
- Smell: Identify insulation burning odor
Level Two Diagnosis: Instrument-assisted Detection
Electrical Parameter Detection:
- Three-phase current balance testing
- Motor insulation resistance testing
- Starting current characteristic analysis
Mechanical Parameter Detection:
- Bearing vibration velocity detection
- Shaft alignment accuracy measurement
- Reduction gear temperature monitoring
Chapter 4: Preventive Maintenance Schedule
Maintenance Cycle | Inspection Items | Technical Standards | Detection Methods |
Daily | Arch-breaking system function | Arch-breaking system function | Normal operation | Function test |
Weekly | Screw conveyor operation status | Vibration <4.5mm/s | Vibration detection |
Monthly | Silo sealing system | No leakage points | Seal detection |
Quarterly | Electrical control system | Insulation >1MΩ | Megohmmeter test |
Annually | Comprehensive system maintenance | Meets factory standards | Professional inspection |
Conclusion: Establishing a Comprehensive Equipment Health Management System
By implementing the systematic solutions provided in this guide, concrete batching plant operators can:
1. Quickly and accurately diagnose the root causes of "no cement flow" failures
2. Take scientific and effective treatment measures
3. Establish a comprehensive preventive maintenance system
4. Achieve full lifecycle health management of equipment
Tongxin Machinery recommends that customers not only focus on fault treatment but also establish a complete equipment health management system. Through regular training, preventive maintenance, and the comprehensive application of intelligent monitoring systems, equipment reliability can be maximized to ensure production continuity and product quality stability.
This technical guide will be continuously updated. Please stay tuned to Tongxin Machinery's official website for the latest version. For professional technical support, please feel free to contact our engineering team at any time.
