高压去毛刺清洗机在设备运行过程中，喷嘴系统、传动系统以及电气控制系统常面临各类问题，这些问题不仅影响设备的正常运转，还可能对生产效率和产品质量产生不利影响，以下是对这些系统常见故障的详细分析及针对性解决方案。

During the operation of the high-pressure deburring cleaning machine, the nozzle system, transmission system, and electrical control system often face various problems. These problems not only affect the normal operation of the equipment, but may also have adverse effects on production efficiency and product quality. The following is a detailed analysis and targeted solutions to common faults in these systems.

喷嘴系统问题主要体现在喷雾形态异常和喷嘴快速磨损两个方面。当出现喷雾形态异常时，可依据具体现象判断故障原因并采取相应解决措施。若喷雾发散，通常是由于喷嘴磨损所致，此时需更换硬质合金喷嘴以提升耐磨性；若喷雾不对称，很可能是流道堵塞造成的，可采用超声波清洗的方式清理喷嘴；而流量突变则大概率是密封圈失效引起，应及时更换氟橡胶密封件。针对喷嘴快速磨损的问题，改进方案包括升级为陶瓷喷嘴，其寿命相较普通喷嘴可延长 3 - 5 倍；增加精度≤50μm 的前置过滤器，过滤掉可能磨损喷嘴的杂质；优化喷射角度，避免喷雾反弹对喷嘴造成冲击，从而有效减缓喷嘴磨损速度。

The problems of the nozzle system are mainly reflected in the abnormal shape of the spray and the rapid wear of the nozzle. In case of abnormal spray shape, the fault cause can be judged according to the specific phenomenon and corresponding solutions can be taken. If the spray is divergent, it is usually caused by nozzle wear. At this time, the cemented carbide nozzle needs to be replaced to improve wear resistance; If the spray is asymmetric, it is likely that the flow channel is blocked, the nozzle can be cleaned by ultrasonic cleaning; The sudden change in flow rate is most likely caused by the failure of the sealing ring, and the fluororubber seal should be replaced in a timely manner. To address the issue of rapid nozzle wear, the improvement plan includes upgrading to ceramic nozzles, which can extend their lifespan by 3-5 times compared to ordinary nozzles; Add a pre filter with an accuracy of ≤ 50 μ m to filter out impurities that may wear out the nozzle; Optimize the spray angle to avoid the impact of spray rebound on the nozzle, thus effectively slowing down the wear rate of the nozzle.

传动系统故障主要表现为输送带跑偏和旋转机构卡滞。对于输送带跑偏问题，校正流程需从多个方面入手。首先，调整张紧气缸的压力至 0.4 - 0.6MPa，确保输送带具有合适的张紧度；其次，使用激光校准导轨，将平行度控制在≤0.2mm/m，保证输送带运行的直线性；最后，更换防滑花纹带，使摩擦系数达到≥0.8，防止输送带打滑跑偏。在处理旋转机构卡滞问题时，维护要点包括每月对旋转接头进行清洗，去除可能导致卡滞的水垢；选用 NLGI 2# 食品级润滑脂进行润滑，确保旋转部件的顺畅运转；加装 IP68 等级的防水轴承，防止水分侵入影响旋转机构性能。

The main manifestations of transmission system faults are conveyor belt deviation and rotating mechanism jamming. For the problem of conveyor belt deviation, the correction process needs to start from multiple aspects. Firstly, adjust the pressure of the tensioning cylinder to 0.4-0.6MPa to ensure that the conveyor belt has the appropriate tension; Secondly, use laser to calibrate the guide rail and control the parallelism within ≤ 0.2mm/m to ensure the straightness of the conveyor belt operation; Finally, replace the anti slip patterned belt to achieve a friction coefficient of ≥ 0.8 to prevent the conveyor belt from slipping and deviating. When dealing with the problem of stuck rotating mechanisms, maintenance points include cleaning the rotating joints monthly to remove scale that may cause sticking; Use NLGI 2 # food grade grease for lubrication to ensure smooth operation of rotating components; Install waterproof bearings with IP68 rating to prevent moisture from entering and affecting the performance of the rotating mechanism.

电气控制系统方面，PLC 故障和安全联锁失效是较为突出的问题。在 PLC 故障处理中，针对模拟量干扰，可加装 4 - 20mA 信号隔离器，有效阻隔外界干扰信号；对于数字量抖动问题，通过增加软件滤波功能，设置 50ms 延时，消除信号抖动；当出现通讯中断情况时，改用波特率≥1Mbps 的光纤传输，提升通讯的稳定性和传输速度。针对安全联锁失效问题，改造措施包括构建双回路急停系统，达到 CAT4 安全等级，确保紧急情况下能可靠停机；安装分辨率≤14mm 的光栅保护装置，实时监测工作区域安全；采用机械表与传感器相结合的压力双重监测方式，提高压力监测的可靠性，全方位保障设备运行安全。

In terms of electrical control systems, PLC failures and safety interlock failures are prominent issues. In PLC fault handling, for analog interference, a 4-20mA signal isolator can be installed to effectively block external interference signals; For the problem of digital jitter, adding software filtering function and setting a 50ms delay can eliminate signal jitter; When communication interruption occurs, switch to fiber optic transmission with baud rate ≥ 1Mbps to improve communication stability and transmission speed. Regarding the issue of safety interlock failure, the renovation measures include building a dual circuit emergency stop system to achieve CAT4 safety level, ensuring reliable shutdown in emergency situations; Install grating protection devices with a resolution of ≤ 14mm to monitor the safety of the work area in real-time; Adopting a dual pressure monitoring method combining mechanical gauges and sensors to improve the reliability of pressure monitoring and ensure the safe operation of equipment in all aspects.

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