An organic fertilizer granulator is a crucial piece of equipment in the production process, responsible for shaping granular materials into uniform, spherical pellets. Over time, granulators may develop various faults that can impact production efficiency and product quality. Here are some common issues and their solutions.

1. Bearing Overheating

The bearing's temperature rises abnormally during operation, potentially exceeding its normal working temperature and accompanied by unusual noise.

Common Causes:

• Insufficient Lubrication: Prolonged use consumes the grease, and without timely replenishment, friction increases and generates significant heat.
• Improper Installation: The bearing is not installed correctly, leading to uneven internal stress and localized friction.
• Bearing Damage: Long-term wear and tear can cause broken balls or scratched races, increasing operational resistance.

Solutions:

• Regularly check the grease and add or replace it as required by the equipment manual.
• Reinstall the bearing using professional tools and measurement instruments to ensure the concentricity and perpendicularity meet standards.
• If the bearing is damaged, replace it with a new one of the same model and specification, and then conduct a test run.

2. Drive Belt Slippage

The belt slips against the pulley, causing the granulator's speed to drop or even fail to operate. This may be accompanied by increased belt surface temperature and a burning smell.

Common Causes:

• Insufficient Belt Tension: The belt stretches over time, causing a loss of tension and an inability to transmit power effectively.
• Worn Belt Surface: Long-term friction between the belt and pulley makes the belt surface smooth, reducing friction.
• Oil on Pulley Surface: Oil can reduce the friction between the belt and the pulley, causing slippage.

Solutions:

• Adjust the belt tensioning device to increase tension to the proper level. This can be done by adjusting the tensioning bolts or using a tensioning wheel.
• If the belt is severely worn, replace it with a new, high-quality belt of the correct specification.
• Wipe the pulley surface with a clean cloth to remove oil. For heavy oil stains, use a special cleaner and let the pulley dry before re-installing the belt.

3. Poor Granulation Effect

The produced organic fertilizer pellets are irregular in shape, have inconsistent sizes, or fail to meet the required roundness standards, affecting product quality and sales.

Common Causes:

• Improper Granulating Disc Speed: The speed is either too high or too low. A speed that is too high can cause excessive centrifugal force, leading to particle breakage. A speed that is too low prevents the particles from rolling sufficiently, making it difficult to form a regular spherical shape.
• Improper Material Moisture: If the material's moisture is too high, the particles can stick together. If it's too low, there's not enough friction between particles, making it difficult to form pellets.
• Worn Granulating Disc: Prolonged use can cause wear and dents on the disc's surface, affecting the particles' rolling trajectory and force.

Solutions:

• Adjust the granulating disc's speed based on the material's properties and production requirements. Conduct multiple tests to find the optimal speed for good pellet formation.
• Control the material's moisture. Dry or moisten the material as needed before it enters the granulator to keep the moisture within the appropriate range. A moisture content of 15% to 20% is generally ideal for organic fertilizer materials.
• Regularly check the granulating disc for wear. If it is severely worn, replace it with a new one that has good wear resistance and a smooth surface to improve the granulation effect.

4. Motor Overheating

The motor's temperature rises sharply during operation, exceeding its rated working temperature, feeling hot to the touch, and potentially accompanied by unusual noise and a burning smell.

Common Causes:

• Excessive Load: The granulator runs in an overloaded state for a prolonged period. The motor's output power exceeds its rated value, leading to increased current and severe heating.
• Poor Heat Dissipation: The motor's cooling fan is damaged, the heat sink is blocked, or ventilation is poor, preventing the motor's heat from dissipating.
• Motor Winding Short Circuit: A partial short circuit in the winding causes uneven current distribution and overheating in some parts of the winding.

Solutions:

• Plan production tasks to avoid prolonged overloading of the granulator. Check for mechanical faults such as seized bearings or stuck transmission parts, and resolve them promptly to reduce the motor's load.
• Check if the motor's cooling fan is working properly. Clean dust and debris from the heat sink to ensure good ventilation. If the fan is damaged, replace it.
• Inspect the motor winding to locate the short circuit. If the short is not severe, a local repair can be performed. If it's severe, the motor winding or the entire motor needs to be replaced.

5. Outlet Clogging

Material clogs at the discharge outlet, preventing it from exiting smoothly. This increases the internal pressure of the granulator and affects its normal operation.

Common Causes:

• Outlet Size is Too Small: The outlet's design is not suitable for the material's normal discharge, causing it to accumulate at the outlet.
• Blocked Discharge Pipe: Material clumps or sticks inside the discharge pipe. Or, the pipe has too many bends or an unreasonable angle, increasing the resistance of material transport and causing a blockage.

Solutions:

• Adjust the discharge outlet size based on the material properties and production requirements to ensure the material can be discharged smoothly. When widening the outlet, ensure the equipment's structural integrity and sealing are maintained.
• Clear the blockage from the discharge pipe. Adjust the pipe layout to reduce the number of bends and angles, which lowers the material transport resistance. For pipes that are prone to blockages, a vibrator can be installed to prevent clumping and sticking.

To minimize these failures, it's essential to perform routine maintenance, including regular inspections, timely cleaning, and proper use of the equipment. For complex faults, contact a professional technician for repair.