In the field of industrial equipment maintenance, as one of the key equipment, the vibrating screen exciter must follow a series of steps and standards during its maintenance process to ensure its reliability and durability. The maintenance process of the vibrating screen exciter includes a series of strict operations, from taking photos and archiving the original condition of the machine after entering the factory, to the comprehensive process of painting and shipping. Each step significantly affects the quality of the maintenance results. In order to ensure the quality of maintenance, various requirements in vibrating screen exciter maintenance are also particularly critical. From bearings to boxes, to gears and other parts, relevant standards and specifications need to be strictly adhered to to ensure that the vibrating screen exciter is maintained during maintenance. Finally, the expected working performance can be achieved.

Vibrating screen exciter maintenance

1. Vibrator maintenance process

Take photos and archive the original condition of the machine after entering the factory → Shot blasting → Spray primer → Disassemble the vibrator → Take photos and archive the parts → Clean the parts → Inspect, test and archive → Issue a test report → The salesperson will confirm the damage with the user Form a damage determination confirmation form → formulate a maintenance plan → receive parts → inspect, record and archive → ultrasonic cleaning → assembly → test and record and file → spray paint → ship

2. Vibrator maintenance requirements

• Bearings

It must be replaced during maintenance, and high-quality SKF special bearings for vibrating screens must be selected to ensure that they can withstand high-intensity vibration working environments and maintain long-term stable operation. Careful installation and adjustment work is also essential to ensure the correct installation position and normal working condition of the bearings.

• Sealing

The replacement of seals is an important guarantee for the normal operation of the exciter. When replacing, it is necessary to select high-quality seals that match the original parts to ensure that they can effectively prevent the leakage of lubricating oil or other substances, thereby protecting the internal parts of the exciter from damage.

• Box

Boxes that are cracked, deformed, thread damaged or worn must be replaced; when the box hole and the bearing outer ring installation position are worn and the bearing does not meet the assembly requirements, they must be replaced. The new box should be replaced with high-strength ductile iron QT400-12 material, which has no defects such as slag inclusions, pores, cracks, etc. and has been inspected by ultrasonic to ensure its durability and stability. During the processing of the cabinet, the precision machining process of the CNC machining center should be strictly implemented to ensure the accuracy and stability of the cabinet.

• Axis

During the maintenance process, shaft replacement is a key link to ensure the normal operation of the vibrator. If there are obvious concave and convex marks on the surface of the shaft, the ovality of the bearing position and gear position is ≥0.01mm, and the assembly dimensions of the shaft and the inner ring of the bearing do not meet the requirements, they must be replaced. The replacement shaft is made of alloy structural steel 42CrMo processed by CNC machine tools, which can ensure good strength and wear resistance. During the installation process, ensure that the assembly dimensions of the shaft and the inner ring of the bearing meet the requirements to ensure the operation of the vibrator.

• Gears

During maintenance, gear replacement is the key to ensuring the normal operation of the transmission system. Gears must be replaced when pitting and broken teeth, excessive surface wear, surface spots falling off, surface creeping deformation, etc., and the accuracy of the replacement gear should be level 5, and the gear meshing clearance should be ≤0.24mm. During the replacement process, the meshing clearance of the gears should be controlled within an appropriate range to ensure the normal operation and efficiency of the transmission system.

• Other parts

Check the parts according to the drawings, and those that are out of tolerance must be replaced. Replacement parts are homemade products to ensure stable operation and long-term reliability of the overall system.

• Standard parts

All standard parts must be replaced with grade 8.8 high-strength galvanized bolts to ensure a stable and reliable connection of various parts of the exciter and to avoid potential safety hazards and equipment failures caused by loosening or falling off.

• Test specifications

After the exciter is repaired, strict tests must be carried out. The test time is ≥36h, the operating temperature rise is ≤60℃, the noise is ≤85db (A), and there is no abnormal sound or oil leakage, it is deemed to be qualified.

• Spray painting specifications

During the painting process, the color code should be confirmed and painted based on the original machine color. The paint film thickness should be ≥0.3mm. Especially if the interior of the cabinet needs to be repaired due to damage to the paint-resistant film, the repair work must be carried out carefully to ensure its durability and cosmetic integrity.

3. Precautions for vibrator maintenance

1. Box

Observe the box for cracks, deformation, thread damage, wear and other defects. If the box has no obvious defects, special tools such as an inner diameter dial indicator and micrometer will be used to inspect the box’s various dimensions. The boxes that pass the inspection will be arranged for ultrasonic flaw detection. The box can be put into use only after passing the flaw detection. For boxes with doubts such as deformation that are difficult to confirm, use three-dimensional coordinates to check and determine the coaxiality of the box. Only qualified boxes can be used.

2. Gears

First observe whether there are pitted teeth and broken teeth, excessive surface wear, surface spots falling off, surface creep deformation, etc.; if there are no problems, use special tools such as inner diameter dial indicators and micrometers to check the dimensions of the gears; the gears that pass the dimensional inspection will undergo magnetic particle inspection. + Ultrasonic flaw detection; only gears that pass the flaw detection can be put into use. For gear arrangements with doubtful deformations that are difficult to confirm, use a gear detector to review and determine the tooth shape, and only qualified gears can be used.

3. Axis

First observe the obvious unevenness and wear marks on the surface of the shaft; if there are no problems, use special tools such as micrometers to check the dimensions of the shaft; after passing the inspection, conduct magnetic particle + ultrasonic flaw detection on the shaft; it can only be used after passing the flaw detection. For shaft parts whose deformation and coaxiality changes are difficult to determine, arrange a three-dimensional coordinate check to check the shaft coaxiality, and only those parts that pass the standard can be used.

4. Assembly

Ensure that the assembly area is clean, and ultrasonic cleaning is required before assembly to ensure that all parts are clean and free of stains; inspect the assembly and press-fitting tools specified and repair them if necessary; assemble and inspect according to process specifications; arrange for qualified vibrators Carry out tests to ensure compliance with the “Hiside Vibrator Test Specifications”.

During the maintenance of the vibrator, in addition to strictly following the maintenance procedures of the vibrator, it is also crucial to observe the precautions. Especially in the monitoring and inspection of boxes, gears, shafts and assembly processes, more accurate and detailed measures need to be taken. This not only includes the verification of various dimensions, but also requires the use of testing tools and technologies, such as magnetic particle + ultrasonic flaw detection and three-dimensional coordinates, to ensure that the repaired exciter can comply with relevant test specifications and standards. Only by strictly following these rigorous maintenance precautions can the reliability and stability of the maintenance quality of the vibrator be ensured, thereby ensuring its efficient and stable operation in industrial production.

A vibrating feeder is a device used to convey bulk materials or granular products through the use of vibrations. It consists of a vibrating tray or chute that is mounted on springs or other vibration isolators to facilitate smooth and controlled movement.

How does a vibrating feeder work

Vibration Generation: The vibrating feeder contains an electromagnet or other type of vibration source that generates periodic vibrations. This vibration is transmitted to the tray or chute, causing it to move in a controlled, linear motion.

Material Loading: Bulk materials or granular products are loaded onto the vibrating feeder tray or chute. The tray may have an inclined or flat surface, depending on the application requirements.

Vibration Transmission: As the vibrating feeder tray or chute vibrates, the material on top of it experiences a series of small jumps or movements. These vibrations help to dislodge any particles that may be stuck together or compacted, ensuring a consistent flow of material.

Flow Control: The rate of material flow is typically controlled by adjusting the amplitude or frequency of the vibrations. By increasing or decreasing the intensity of the vibrations, operators can regulate the amount of material being discharged from the feeder.

Discharge: As the material reaches the discharge end of the vibrating feeder, it may be directed onto a conveyor belt, into a processing machine, or onto another conveying system for further transport or processing.

Adjustments: Operators can fine-tune the operation of the vibrating feeder by adjusting various parameters such as vibration amplitude, frequency, and tray inclination to optimize performance for specific materials and operating conditions.

Maintenance: Regular maintenance of the vibrating feeder is essential to ensure reliable operation. This may include inspecting and tightening fasteners, lubricating moving parts, and replacing worn or damaged components as needed.

Overall, a vibrating feeder operates by using controlled vibrations to convey bulk materials or granular products from a loading point to a discharge point in a continuous and controlled manner. It finds applications in various industries such as mining, quarrying, recycling, and food processing, where a consistent and reliable material flow is required.

Vibrating screens are essential equipment in various industries for the screening and classification of materials. They come in several types, each designed for specific applications and requirements.

Vibrating Screen Types

Circular Vibrating Screen

This type of vibrating screen is widely used in the mining and construction industry. It utilizes a circular motion for efficient screening and is suitable for both dry and wet screening applications.

• This type of vibrating screen employs a circular motion for efficient screening of materials.
• It is versatile and widely used in industries such as mining, construction, and aggregates.
• Circular vibrating screens are suitable for both dry and wet screening applications.
• They offer high screening efficiency and are relatively easy to operate and maintain.

Linear Vibrating Screen

Linear vibrating screens use linear motion to screen materials. They are suitable for screening fine to medium-sized materials and are commonly used in industries such as mining, coal, metallurgy, building materials, and chemical engineering.

• Linear vibrating screens use linear motion to screen materials, moving in a straight line.
• They are ideal for screening fine to medium-sized materials in industries such as mining, coal, metallurgy, and chemical engineering.
• Linear vibrating screens offer high screening efficiency and accuracy, making them suitable for precise classification tasks.
• They can handle large processing capacities and are available in single or multiple deck configurations.

Elliptical Vibrating Screen

This type of vibrating screen employs an elliptical motion, which provides high screening efficiency and large processing capacity. It is often used in the classification of various minerals and coal.

• Elliptical vibrating screens employ an elliptical motion, providing high screening efficiency and large processing capacity.
• They are effective in screening various minerals and coal, offering reduced pegging and blinding compared to other types of screens.
• Elliptical vibrating screens are suitable for both dry and wet screening applications, making them versatile for different industries.

High-Frequency Vibrating Screen

High-frequency vibrating screens operate at higher frequencies, typically 3600-7200 RPM, which allows for more efficient screening of fine materials. They are commonly used in the mineral processing industry.

• High-frequency vibrating screens operate at higher frequencies (3600-7200 RPM), allowing for more efficient screening of fine materials.
• They are commonly used in the mineral processing industry for separating particles based on size and shape.
• High-frequency vibrating screens offer improved screening performance for difficult-to-screen materials, resulting in higher throughput and efficiency.

Banana Screens

Banana screens have a banana-shaped screen deck with varying angles of inclination. They are particularly effective for screening fine and sticky materials, as the inclined deck reduces pegging and blinding.

• Banana screens feature a banana-shaped screen deck with varying angles of inclination.
• They are effective for screening fine and sticky materials, reducing pegging and blinding.
• Banana screens offer high processing capacity and are suitable for applications requiring high throughput and efficiency.

Dewatering Screens

Dewatering screens are designed to remove excess moisture from materials, typically achieved by applying a linear motion to the screen deck. They are commonly used in the processing of sand, aggregates, and minerals.

• Dewatering screens are designed to remove excess moisture from materials, typically achieved by applying a linear motion to the screen deck.
• They are commonly used in sand, aggregates, and minerals processing for dewatering applications.
• Dewatering screens improve product quality by reducing moisture content and are available in various sizes and configurations.

Flip-Flop Screens

Flip-flop screens utilize elastic mesh screens that alternate between parallel and perpendicular orientations. This design reduces blinding and pegging, making them suitable for screening difficult-to-screen materials.

• Flip-flop screens utilize elastic mesh screens that alternate between parallel and perpendicular orientations.
• They are effective for screening difficult-to-screen materials, reducing blinding and pegging.
• Flip-flop screens improve screening efficiency and product quality, particularly for high-moisture, sticky, or fine materials.

These are some of the commonly used types of vibrating screens, each designed for specific applications and materials. The selection of the appropriate vibrating screen depends on factors such as the size and nature of the material to be screened, processing capacity, and desired screening efficiency.

Maintaining a vibrating screen is crucial to ensure its efficient operation and longevity. Regular maintenance helps prevent unexpected downtime, reduces the risk of costly repairs, and ensures the screen continues to perform at its best.

Vibrating screen maintenance

Inspect Screen Components: Regularly inspect the screen deck, side plates, cross members, and other structural components for signs of wear, corrosion, or damage. Replace any worn or damaged parts to prevent further deterioration and ensure structural integrity.

Check Screen Panels: Inspect the screen panels or mesh for tears, holes, or excessive wear. Damaged screen panels can affect screening efficiency and product quality. Replace worn or damaged panels as needed to maintain optimal performance.

Monitor Screen Media Tension: Proper tensioning of the screen media is essential for efficient screening. Periodically check the tension of the screen panels and adjust as necessary using tensioning bolts or other adjustment mechanisms.

Lubricate Bearings: Vibrating screens contain bearings that require lubrication to reduce friction and prevent premature wear. Regularly lubricate bearings according to the manufacturer’s recommendations using the appropriate lubricant.

Inspect Drive Components: Check the drive belts, pulleys, and motor mounts for signs of wear or misalignment. Tighten loose belts, replace worn belts, and realign misaligned components to ensure smooth operation of the screen drive system.

Clean Decks and Screening Surfaces: Remove any buildup of material, debris, or contaminants from the screen decks and screening surfaces. Use a pressure washer, brush, or air blower to clean the screens thoroughly and prevent blockages that can affect screening efficiency.

Inspect Springs and Suspension Components: Check the condition of the springs, coil springs, or rubber mounts that support the vibrating screen. Replace any damaged or worn suspension components to maintain proper screen motion and isolation.

Monitor Motor and Vibration Mechanism: Inspect the motor, eccentric shaft, or other vibration mechanisms for signs of wear, damage, or abnormal vibrations. Address any issues promptly to prevent further damage to the screen and drive system.

Perform Vibration Analysis: Periodically perform vibration analysis or condition monitoring to identify potential problems early. Monitor vibration levels, bearing temperatures, and other indicators of screen health to detect abnormalities and take corrective action as needed.

Document Maintenance Activities: Keep detailed records of maintenance activities, including inspections, repairs, and replacements. Use these records to track the condition of the vibrating screen over time and plan future maintenance tasks accordingly.

By following these maintenance guidelines and performing regular inspections and repairs, you can ensure your vibrating screen remains in good working condition, maximizing uptime and productivity.

Vibrating screens are crucial equipment in the mining industry, used for separating minerals and other materials based on size and particle shape. They are commonly used in various stages of the mining process, including primary crushing, secondary crushing, and final product sizing.

Vibrating Screen Mining Industry Applications

Primary Crushing Stage

In the primary crushing stage, large chunks of mined material are fed into a vibrating grizzly feeder, which screens out oversized rocks and debris before they enter the crusher.

Vibrating screens may also be used after the primary crusher to separate oversize material from the crusher discharge and ensure uniform feed to the secondary crusher.

Secondary Crushing Stage

After the primary crushing stage, the crushed material undergoes secondary crushing to further reduce its size.

Vibrating screens are used to classify and separate the crushed material into different size fractions, ensuring that the final product meets the desired specifications.

Screening and Sizing Operations

Vibrating screens are extensively used in screening and sizing operations to separate materials into various size fractions.

They consist of multiple decks with different-sized openings (mesh or perforated plates) to classify materials into different particle sizes.

Vibrating screens are often equipped with various types of screening media, such as wire mesh, rubber, or polyurethane panels, to optimize screening efficiency and minimize downtime.

Dewatering and Desliming

In some mining applications, vibrating screens are used for dewatering or desliming purposes.

Dewatering screens remove excess moisture from the material to produce a drier product, while desliming screens remove fines and ultra-fines to improve downstream processing efficiency.

Scalping and Pre-screening

Vibrating screens are used for scalping and pre-screening applications to remove oversized or undersized material from the feed stream.

Scalping screens are placed before the primary crusher to remove oversized rocks and debris, while pre-screening screens are used to separate fines and smaller particles from the feed material.

Portable and Mobile Screening Plants

In addition to stationary vibrating screens, portable and mobile screening plants are also widely used in mining operations.

These portable units can be easily transported to different locations within a mining site and are ideal for temporary screening applications or when quick setup and teardown are required.

Overall, vibrating screens play a critical role in the mining industry by efficiently separating and classifying materials, improving product quality, and optimizing process efficiency. They are versatile equipment used in various stages of the mining process, from primary crushing to final product sizing.