Bearing and Transmission Component Wear Fault
Bearing and transmission component wear is a major cause of vibration, abnormal noise, and efficiency loss in Z-type elevators used in peanut deep-processing lines. If not addressed promptly, it can lead to severe mechanical failure and unplanned downtime.
Fault Phenomena
Typical fault phenomena include a significant increase in equipment vibration during operation, abnormal temperature rise at bearing positions exceeding ambient temperature by more than 40°C, metal friction or impact noise, reduced conveying efficiency accompanied by higher motor current, and oil leakage or dust ingress at sealing points.
Special Cause Analysis in Peanut Processing
In peanut processing environments, fine peanut dust particles smaller than 100 μm easily penetrate bearing seals, mix with lubricating grease, and form abrasive compounds that accelerate wear, while an insufficient sealing design further worsens dust ingress. Lubrication issues include the use of non-food-grade lubricants, improper lubrication intervals, incorrect grease filling volume, and lubricant degradation under high-temperature conditions. In addition, high-impact loads from material drop height, frequent start-stop operations, and uneven load distribution accelerate bearing fatigue and cause localized overload.
Solutions
Sealing improvement measures include adopting multi-layer sealing structures combining contact seals with labyrinth seals, introducing clean air into bearing housings to create a positive-pressure dust barrier, regularly inspecting and replacing sealing elements every 6 months, and keeping bearing housings clean to prevent dust accumulation. Lubrication management should follow a dedicated peanut-processing lubrication plan using NSF H1 food-grade grease, with lubrication every three months for standard bearings and monthly for high-temperature areas; grease filling limited to one-third to one-half of the bearing space, and full lubrication records maintained. Preventive maintenance should include monthly vibration monitoring, weekly infrared temperature checks, planned annual replacement of critical bearings, and sufficient spare parts inventory to minimize downtime.
Electrical Control System Fault
Electrical control system faults can cause sudden shutdowns, unstable operation, and potential safety risks in peanut processing production lines.
Fault Phenomena
Common symptoms include motors failing to start or stopping unexpectedly, frequency converters displaying alarms or fault codes, unresponsive or abnormal control buttons, sensor false alarms or failures, and large speed fluctuations during operation.
Special Cause Analysis in Peanut Processing
Conductive peanut dust can cause short circuits; high temperatures in frying areas reduce component lifespan; and high humidity in cleaning zones can cause moisture-related failures, with oil vapor accelerating contact corrosion. High static electricity generated by dry peanut kernels interferes with sensors; dust accumulation inside control cabinets impairs heat dissipation and insulation; and continuous vibration loosens electrical connections. Operationally, unauthorized parameter changes, insufficient cabinet cleaning, and inadequate protection ratings expose electrical systems to harsh environments.
Solutions
Environmental protection measures include upgrading electrical cabinets to IP65 or higher, installing filtered clean-air systems to maintain positive-pressure ventilation, performing weekly external and quarterly internal cabinet cleaning, and installing temperature- and humidity-control devices. System optimization should adopt redundant designs for key sensors, shielded signal cables with separate routing, optimized inverter parameters based on peanut material characteristics, and comprehensive protection against overload, stalling, phase loss, and overheating. Maintenance management requires daily inspection checklists, six-month sensor calibration, professional electrical training for operators and maintenance staff, and complete fault records for trend analysis.
Z-Type Elevator Common Fault Quick Diagnosis Reference
Typical Fault Types and Emergency Handling
Material blockage or jamming is characterized by increased current, abnormal noise, and material accumulation, usually caused by excessive feeding, material clumping, or unreasonable bend design, and requires immediate shutdown, blockage removal, and equipment inspection. Conveyor belt slippage manifests as speed reduction, current drop, and frictional noise due to insufficient tension, oily rollers, or overload, and should be addressed by adjusting tension, cleaning rollers, and reducing load. Bearing wear shows as increased vibration, temperature rise, and abnormal noise due to dust ingress, poor lubrication, or overload, requiring temperature checks, lubrication, and reduced-load operation. Electrical faults include failures to start, alarms, or control malfunctions caused by dust, short circuits, component aging, or parameter errors, and should be addressed by checking the power supply, cleaning cabinets, and resetting systems. Misalignment faults include belt deviation, casing friction, and material spillage caused by installation deviation or uneven tension, requiring idler adjustment and alignment correction.
Special Faults and Countermeasures in Different Peanut Processing Stages
Raw Material Cleaning and Grading
This stage features high impurity content, heavy dust, and variable humidity, leading to abnormal wear and frequent blockages. These issues can be mitigated through pre-cleaning processes, wear-resistant materials, and anti-wrapping designs.
Roasting and Baking
High temperatures of 150–200°C and dry conditions accelerate material aging and thermal expansion, necessitating high-temperature-resistant materials, thermal-compensation structures, and insulation design.
Peeling and Red Skin Removal
Fine dust, explosion risk, and high static electricity may cause dust explosions and bearing blockages, requiring explosion-proof design, efficient dust-removal systems, and static-elimination measures.
Frying and Seasoning
High oil content, elevated temperatures, and strict hygiene standards lead to oil contamination and material swelling, which should be addressed through easy-to-clean structures, oil-resistant materials, and online cleaning systems.
Packaging and Sterilization
Clean environments with stable temperatures still face cross-contamination and humidity risks, requiring enhanced sealing designs, hygienic materials, and environmental controls.
Special Safety Note: Peanut Dust Explosion Risk
Peanut dust is a combustible material, and when its concentration reaches 30–60 g/m³, it may explode in the presence of ignition sources, while the enclosed structure of Z-type elevators makes them high-risk areas, therefore equipment must comply with ATEX or equivalent explosion-proof standards, use explosion-proof motors and electrical components, ensure reliable grounding to eliminate static electricity, install explosion relief panels, implement dust concentration monitoring and alarms, and maintain excellent sealing to prevent dust leakage.
