Common faults and solutions for customized laboratory rotary furnaces

Common faults and solutions for customized laboratory rotary furnaces

1. Abnormal temperature control
Temperature exceeding or out of control
reason:
Temperature sensor malfunction (such as thermocouple aging, loose wiring) leads to data distortion.
Heating element power is too high or unevenly distributed, resulting in local overheating.
The performance of insulation materials decreases or is damaged, resulting in heat loss.
Control system logic error (such as improper PID parameter settings).
Case: A certain aluminum ash rotary furnace failed to transmit high temperature signals in a timely manner due to a temperature sensor malfunction, resulting in uncontrolled temperature inside the furnace and causing an explosion.
resolvent:
Regularly calibrate the temperature sensor and check for loose or aged wiring.
Adjust the power distribution of heating elements to avoid local overheating.
Replace with high-performance insulation materials to reduce heat loss.
Re adjust the PID parameters of the control system to ensure temperature control accuracy.
Heating rate too fast or too slow
reason:
The power of the heating element does not match the design of the furnace body.
Unstable power supply voltage or circuit failure.
Abnormal pressure inside the furnace (such as insufficient vacuum or excessive gas flow).
resolvent:
Adjust the power of the heating element according to the design requirements of the furnace body.
Check the stability of the power supply voltage and repair any circuit faults.
Adjust the furnace pressure to the normal range (such as vacuum pump pumping rate or gas flow control).

2. Abnormal operation of equipment
Furnace rotation jamming or vibration
reason:
Wear or insufficient lubrication of transmission devices (gears, bearings).
The furnace body is overloaded (such as excessive material accumulation).
Horizontal deviation of furnace installation.
resolvent:
Regularly inspect the transmission system, replace worn parts, and add lubricating grease.
Control the loading capacity of materials to not exceed one-third of the furnace volume to avoid accumulation.
Adjust the installation level of the furnace body to ensure smooth rotation.
Heating system not starting or interrupted
reason:
Power failure (such as unplugged plug or blown fuse).
The heating element is broken or short circuited.
Control system malfunction (such as damaged temperature controller).
resolvent:
Check if the power wiring is normal and replace the blown fuse.
Use a multimeter to check the resistance of the heating element and replace any broken or short circuited components.
Restart the control system and check if the temperature controller is working properly.

3. Atmosphere control malfunction
Gas leakage or abnormal pressure
reason:
Loose gas pipeline connections or aging seals.
Vacuum pump malfunction (such as insufficient oil level, pump body wear).
Calibration failure of gas flow meter or pressure gauge.
resolvent:
Check the gas pipeline connections and replace aging seals.
Regularly maintain the vacuum pump and replenish or replace the vacuum pump oil.
Calibrate gas flow meters and pressure gauges to ensure accurate data.
Incomplete replacement of atmosphere
reason:
Insufficient ventilation time or low gas flow rate.
There are dead corners inside the furnace, and the gas cannot circulate fully.
resolvent:
Extend the ventilation time to 5-10 minutes to ensure complete replacement of air.
Optimize furnace body design, reduce dead corners, or promote gas circulation through stirring devices.

4. Security protection failure
Overtemperature alarm malfunction
reason:
Alarm sensor malfunction or circuit disconnection.
The alarm threshold is not set properly.
resolvent:
Check the alarm sensor and circuit, and repair the fault point.
Reset the alarm threshold according to the process requirements.
Emergency stop button failure
reason:
Button contact oxidation or circuit failure.
The control system did not respond to the emergency signal.
resolvent:
Clean or replace the emergency stop button, and check the wiring connection.
Test the response speed of the control system to emergency signals and upgrade the software if necessary.

5. Maintenance and preventive measures
Regular inspection and maintenance
Check the lubrication system, gas pipelines, and electrical connections weekly.
Clean the residual materials in the furnace every month to avoid corrosion or blockage.
Calibrate temperature sensors, gas flow meters, and pressure gauges quarterly.
Operation specification training
Provide training to operators on equipment principles, fault phenomena, and emergency response.
Develop standardized operating procedures (SOP), clarify the scope of parameter settings and precautions.
Spare parts Management
Reserve commonly used vulnerable parts (such as seals, heating elements, temperature sensors).
Establish a spare parts life ledger and replace components that are close to failure in advance.