Piston Air Compressor Is Easy To Fault And Analysis

Piston Air Compressor Is Easy To Fault And Analysis

The cause of air compressor failure is multi-faceted, and should be determined according to the site conditions and failure mechanism analysis. The troubleshooting method for each fault is not necessarily unique. It should be based on actual conditions, comprehensive comparison, and take effective measures.

The crankshaft fractures the crankshaft to break. The crankshaft fracture is mostly at the rounded corner transition between the journal and the crank arm.

1. Analysis of the cause 

(1) Cracks are generated at the oil hole of the crankshaft, and the penetration of the lubricating oil causes the crack to gradually expand, eventually causing the fracture.

(2) The crankshaft transition fillet is too small. When heat treatment, the rounded corners are not treated in place, resulting in stress concentration at the junction.
(3) The equipment is overloaded for a long period of time, which deteriorates the stress state of the crankshaft, resulting in a decrease in fatigue life.
(4) The material itself is defective, which reduces the actual bearing capacity of the crankshaft.

(5) The crankshaft fillet is irregularly machined, the radius is not equal, and the stress is concentrated due to excessive unevenness.

2. Treatment measures 

(1) Strictly control the processing technology and quality of the crankshaft oil hole to prevent cracks, and remove the burrs in time after processing.

(2) Properly increase the crankshaft transition fillet to maintain uniform heat treatment and eliminate stress concentration.
(3) It is strictly forbidden to overload the equipment. If the fault occurs, it should be shut down for maintenance to avoid the disease.
(4) Improve the level of crank casting technology and avoid defects such as sand holes and shrinkage on the castings.
(5) Ensure the machining quality of the crankshaft fillet, such as shape accuracy and roughness, and improve the fatigue strength of the crankshaft.

Piston stuck
1. Analysis of the cause.
(1) The cooling water supply is insufficient, and the cylinder is cooled after being overheated, causing the cylinder to contract sharply and bite the piston.
(2) The quality of the lubricating oil is inferior, or the fuel supply of the oiler is interrupted, so that the piston is dry and friction in the cylinder, and the resistance is increased to catch and bite.

(3) The clearance between the cylinder and the piston is too small, or the metal piece and other hard objects fall into the cylinder, and the piston hits the cylinder head and is blocked.

2. Treatment measures.
(1) Ensure the water cooling supply. If the cylinder is overheated due to lack of water, stop immediately, and then add cooling water after natural cooling.
(2) Select the air compressor oil of the appropriate grade; always check the working condition of the oiler to ensure that the cylinder is not short of oil during operation.
(3) During assembly and overhaul, the clearance between the cylinder and the piston should be carefully checked to ensure that it meets the standard requirements. Prevent foreign matter from falling into the cylinder and find it in time.

The cause of air compressor failure is multi-faceted, and should be determined according to the site conditions and failure mechanism analysis. The troubleshooting method for each fault is not necessarily unique. It should be based on actual conditions, comprehensive comparison, and take effective measures.