Analysis and troubleshooting for the double-row furnace quenching platform not being in place?

(1) It could be due to internal jamming. You can eliminate the jamming points—for example, if the material tray doesn't push in far enough or if the turning of the tray causes the quenching platform's lifting and lowering mechanism to get stuck.

(2) It’s possible that the brake is too loose and sinks slightly after being fully engaged. In this case, you’ll need to adjust the brake.

(3) It’s possible that the chain has reversed direction. In this case, an electrician needs to adjust the limit switch or perform the reverse operation (continue lowering).

(4) It could be a limit switch issue; an electrician can make the necessary adjustments.

(5) It is also possible that the limit bolts on the quenching platform were improperly adjusted after the furnace was shut down.

Analysis and troubleshooting of the main push rod in the heating furnace failing to fully extend or retract?

Possible causes include: Inside the furnace, if a part or other object becomes jammed, or if the main push rod itself is damaged—for example, due to the detachment of small shafts, ball bearings, or guide keys, or deformation of the push rod, or loosening of the back cap. Additionally, malfunctions in the coupling or limit switches of the reducer can also result in the push rod failing to fully retract.

The soft chain behind the heating furnace has become jammed. Analyze the various possible causes and corresponding solutions.

Possible causes include:

1) The in-furnace guide rail is damaged and jammed, or foreign objects or other debris have become lodged and are causing a blockage.

2) The soft link itself can become jammed if it suffers severe long-term wear and tear.

3) Sometimes, problems arise due to electrical issues, and if the flexible chain isn't removed from the furnace in time, prolonged exposure to heat can cause it to expand and become stuck.

4) After replacing the H-shaped guide rails, if the gap between the two sections of rail becomes too large due to thermal expansion, it can also cause jamming.

5) If the pusher head is replaced without properly rounding off the corners, it may also cause jamming. When addressing this issue, use appropriate methods—such as prying or lifting—to loosen and restore normal operation. Alternatively, remove the pin from the pusher head and carefully unwind the flexible chain. If the problem lies with the chain itself, take the corresponding corrective measures. If the issue stems from the guide rail, you can temporarily replace the damaged rail with a suitable heat-resistant steel bar or plate if repair is feasible. If the damage is irreparable, the furnace must be shut down for repairs; in such cases, the pusher head itself can also be re-ground and refurbished.

The rear chamber door of the heating furnace’s flip-type door cannot be closed. What are the possible causes and how can this issue be addressed?

Possible causes include: The flip-style rear compartment door is driven by a cylinder.

1) Cylinder issues, such as air leakage from the cylinder rod or gas bypassing the piston.

2) Valve issues, such as gas leakage or stuck valve core.

3) The furnace door lug is cracked open or the shaft is worn.

Handling method:

1) Cylinder issue—cylinder can be disassembled and repaired.

2) For valve issues, the directional control valve can be adjusted or replaced.

3) If the furnace door’s lifting lug or shaft is worn, appropriate measures can be taken.

The shot blasting machine has insufficient abrasive flow rate. What are the possible causes and how can they be addressed?

May have:

1) The lifting mechanism is experiencing issues, resulting in a small sand-lifting capacity. This could be due to an insufficient number of sand buckets, which can be supplemented.

2) The sand-dividing mechanism is obstructed by foreign objects; please clean and remove them.

3) The sand-control pipe is blocked and can be cleaned and addressed.

4) If the sand-sweeping plate on the rotary table is severely worn and deformed, obstructing the sand circulation, this phenomenon may occur. The plate can be replaced or corrected accordingly.

The vibration of the bottom furnace is poor, and parts aren't being fed down—what’s the analysis and how should we handle it?

Possibly:

1) The cam is severely worn; replace the cam.

2) If the baseplate is deformed, replace it. Alternatively, if there are too many components attached to the baseplate, they may produce viscous substances at high temperatures.

3) The ball bearings are not suitable; replace them.

4) The pillow is improperly positioned; correct the positioning.

5) The guidance is inappropriate; perform correction processing.

6) The support wheels and the four guide wheels are improperly positioned; adjust and rectify the issue.

7) If the tension of the bottom plate’s tension spring is adjusted too tightly or too loosely, it will result in suboptimal vibration.

The shot blasting machine’s lifting motor frequently burns out—how should we analyze and address this issue?

1) If the belt is misaligned and experiencing jamming or catching, adjust and address the issue.

2) The number of sand buckets is severely insufficient, resulting in a buildup of sand; sand buckets can be replenished.

3) If there are foreign objects jammed in the upper or lower part of the elevator, they can be removed and cleared.

4) Protection against motor overcurrent, overload, and other faults has failed, or the motor selected is too small or is running in reverse.

Analysis and Handling of the Breakage of the Connecting Shaft for the Main Pushrod of American Ball Screw?

1) The limit switch isn’t working properly—when the machine reaches the set position, it doesn’t stop. Adjust the limit switch or replace the small shaft.

2) The main pushrod’s structure is weakest at the connection shaft. When a newly assembled main pushrod is put into use, it may sometimes break at the small shaft if frictional resistance in various parts is too high. The connection shaft features pin holes. Over prolonged use, these pin holes or pins can wear out, leading to poor fit and eventually causing the rod to break.

3) The pusher head may also break if it is severely obstructed in the furnace and forcibly pushed or overloaded.

If the side-push material conveyor chain in the heating furnace fails to fully insert and triggers an alarm, how should we analyze and handle this issue?

1) If the guide rail is damaged and jamming occurs, replace the guide rail. If cooling cannot be achieved, a temporary bridge can be constructed using heat-resistant steel bars or plates.

2) If the chain itself is worn and inflexible, turn it over and replace it.

3) There are parts or other substances in the chain groove.

4) Other electrical-related reasons.

5) The pusher has no chamfer and too many sharp corners.

The 40T (35T) straightening press lacks sufficient pressure. What are the possible causes and how can this issue be addressed?

The main reasons are:

1) The filter screen in the hydraulic oil tank is clogged; it can be cleaned and addressed.

2) If the hydraulic pump malfunctions, it can be disassembled for repair or replaced.

3) For motor failures, repair or replacement is possible.

4) If the relief valve or process control valve malfunctions, it can be disassembled for repair or replacement.

5) If the directional control valve malfunctions, disassemble, repair, or replace it accordingly.

6) If the pressure gauge itself is malfunctioning, disassemble, repair, or replace it accordingly.

7) If the hydraulic cylinder malfunctions, disassemble, repair, or replace it accordingly.

8) The coupling of the motor oil pump is loose, or the key has come loose.

9) The system has leaks or blockages.

What are the reasons why the inner furnace door of a double-row furnace cannot be raised, and how should they be analyzed and addressed?

The reasons are:

1) The furnace door or furnace door frame is deformed.

2) The bearing has seized up.

3) Brick fragments falling or other objects getting stuck.

4) Chain issues on both sides, such as chain breakage or imbalance between the two chains.

Handling: Repair or replace the door and frame, remove debris, replace the bearings, repair the chain, ensure that both chain links have the same number of links, and make sure the connections are secure.

What are the causes of side-fan vibration, and how can they be eliminated?

The fault causes that lead to vibration in the side fan include:

1) Vibration caused by bearing wear.

2) The fan shaft is deformed, causing dynamic imbalance and resulting in vibration.

3) Vibration caused by dynamic imbalance due to corrosion or damage to the fan impeller and blades.

4) The bearing housing—improper coaxiality of the two bearing bores causes imbalance and vibration.

5) The motor shaft head is bent and deformed.

6) Insufficient lubrication can cause bearing vibration or seizure.

7) When the circulating water is interrupted or the water supply is insufficient, it can cause the bearings to overheat and seize up, as well as result in fan vibration.

8) A rockwool baffle in front of the fan base or a thermal insulation bowl at the fan’s front end falling off can both cause fan vibration.

9) Vibration can also be caused by loose connections between the side fan assembly and the furnace body.

In addition: First, check whether the installed fan’s static and dynamic balance are within the specified tolerances, and whether the coaxiality of the two shaft holes in the bearing housing falls within the prescribed range. If these conditions are met, the assembled fan unit is considered qualified. Second, during operation, if vibrations occur, appropriate measures should be taken according to the specific situation—such as replacing bearings, impellers, or shafts; replacing the bearing housing; tightening connecting components; and closely monitoring the lubrication and coolant circulation.

What are the causes of insufficient pressure in a hydraulic cylinder-type quenching press?

1) Insufficient pressure caused by oil leakage from the hydraulic system components’ pipelines.

2) The pressure valve and relief valve are not properly adjusted in their positions.

3) The oil pump has excessive wear clearance, resulting in insufficient oil pressure at the pump outlet.

4) The motor speed is insufficient or reversing.

5) Blockages in system components or pipelines, or poor oil flow, can affect the flow rate and lead to insufficient pressure.

6) Insufficient oil level or poor oil quality.

What are the common faults that can occur in shot blasting machines? (Brief answer)

1) The blades, impeller, and guard plates inside the turbine casing are worn.

2) Leaks have appeared in the casing and the sand-flow pipeline.

3) The elevator belt and sand bucket are worn or missing.

4) The turntable guard or bracket is worn.

5) Wear on the elevator pulley and drive shaft.

6) Turbine shaft and bearing housing—bearing wear, turbine vibration.

7) The turntable got stuck due to a dropped part, causing the fuse to blow or the chain to break.

What could cause the cylinder to fail to rise?

1) The piston seals have aged or worn out, causing gas leakage and resulting in insufficient air volume.

2) The system compressed air pressure is insufficient.

3) Deformation or bending of the cylinder rod or cylinder body.

4) Solenoid valve failure.

5) Power off.

6) Lubrication difference.

How do you determine whether the furnace shell is leaking?

Under normal intake conditions, if the furnace pressure is found to be too low or the exhaust port is not venting, it indicates that there is a problem somewhere.

There’s a gas leak. In production, open flames are often used to locate leaks, because the gas inside the furnace is combustible and will ignite when exposed to an open flame.

What are the common faults that can occur in ceiling fans?

1) A common failure is the bearing—either bearing wear or, due to high furnace top temperatures and inadequate lubrication, the bearing can seize up and stop rotating.

2) Due to the excessively high furnace temperature, gas corrosion has caused the fan impeller to become thinner or even break off at the connection between the impeller and the shaft. To address this issue, after lifting out the fan housing, use a long hook and have two people pull upward in a symmetrical manner to remove the fan.

3) Impeller corrosion and wear, or fan shaft wear.

If there is oil leakage from the cylinder in a hydraulic system, what are the possible causes, and how should it be addressed?

Oil leakage from hydraulic cylinders is a common failure in hydraulic systems. The primary causes of this phenomenon are wear and aging of hydraulic components, such as wear on copper bushings and aging and wear of sealing cups and O-rings. The appropriate remedy is to replace the worn parts—including copper bushings, sealing cups, and O-rings—with new ones.

The fan in the well-type furnace exhibits significant vibration. What are the possible causes, and how should they be addressed?

The primary causes of excessive fan vibration are a bent fan shaft or failed bearings. The solution is to replace the shaft and bearings and then readjust and reassemble the components.

What are the causes of gas leakage in a nitriding furnace, and how can this phenomenon be improved?

The nitrogen furnace is leaking, causing unstable operating conditions and environmental pollution in the workshop. This issue should be thoroughly addressed. The primary source of the nitrogen furnace’s leaks is the gap around the shaft hole.

If the possibility of shaft bending is ruled out, the primary cause is likely to be an inadequate seal provided by the asbestos rope. The improved approach involves adopting a double-gland design, with an additional compression mechanism applied in the middle to tighten the asbestos rope.

This improvement method can effectively address the air leakage issue.

The quenching platform of the cyanide furnace cannot be raised or properly positioned. What are the possible causes, and how should they be addressed?

The quenching platform of the cyanide furnace cannot rise or reaches its upper limit only because the piston rod of the oil cylinder has dropped too far, creating a vacuum in the oil-inlet chamber and making it difficult for the oil to return.

The solution is to add adjustment shims under the cylinder to achieve the appropriate speed and height, thereby resolving the issue.

What are the possible reasons why the cyanide furnace lid cannot be lifted?

1) The check valve doesn't work well.

2) The hydraulic system pressure is low (insufficient oil level).

3) Deformation of the guide posts causes jamming.

Causes of air leakage from the door of a box-type furnace and methods for eliminating them.

1) If the furnace door or furnace door frame is deformed, resulting in a poor seal, the furnace door or furnace door frame can be replaced.

2) If the asbestos rope used for sealing has aged or become damaged, causing a leak, replace the asbestos rope.

3) The installation deviation of the roller position, or severe wear of the roller, can lead to poor sealing.

4) Poor sealing caused by positioning errors or wear in the roller guide groove.

For the above-mentioned reasons, the following measures can be taken: replacing worn parts, correcting deformation and errors, replacing asbestos rope, and ensuring proper sealing.

Causes of Fan Failure in Box Furnaces

1) The main reason is poor welding quality of the fan blades, which often results in cracks at the weld joints and subsequent blade detachment.

At this point, if production workers fail to detect it in time, it could lead to deformation of the fan shaft and the detachment of arch-top bricks.

2) Due to the structural design of the furnace, when the front and rear furnace doors are opened in a through-type configuration, cold air can directly enter, which negatively affects the lifespan of both the radiant tubes and the fans, reducing their service life.

3) Since the furnace arch is relatively flat and has lower structural strength, if bricks become loose and fall onto the rotating fan blades, it could also cause the fan to deform. (Vibration is caused because the fan blades and shaft ends become soft and pliable at the high temperatures inside the furnace.)

4) Failure caused by fan bearing wear and inadequate lubrication.

5) The shutdown of the circulating water caused the fan bearing to seize up, leading to a failure.

6) Failure caused by wear on belts and pulleys.

7) Motor failure.

What are the common faults with furnace door mechanisms in box furnaces?

1) Cylinder air leakage, valve blockage, or obstruction in the air circuit can cause the furnace door to fail to rise with sufficient force or not operate at all.

2) The chain breaks, the sprocket shaft is deformed, the bearing is worn, or the bearing seizes up.

3) The furnace door itself is deformed, the guide plates are deformed, or the position of the weld has shifted.

4) Brick fragments or other debris obstructing the furnace door’s lifting and lowering.

Common Faults of Continuous Roller Furnaces

1) The roller speed is unstable.

2) The spiral inside the roller doesn’t work well; wear has caused gaps at the weld points, and the part is stuck and can’t be removed from the furnace.

3) The roller is jammed: The feeding cylinder and the roller’s feed inlet are misaligned, causing the roller to jam; the support wheels are worn and have not been replaced in a timely manner, leading to difficulty in rotation.

The rear discharge port has become jammed due to the evaporation and crystallization of alkaline water, causing significant deformation of the drum and making it difficult or impossible to rotate.

4) The feed slide gate is jammed, and there’s a large gap between the gate and the slot, causing small parts to fall in and get stuck.

What are the causes of the sealing furnace failure?

1) The base plate and the base plate guide block have large machining dimensions, poor material quality, and excessive thermal expansion after use, causing them to become jammed in the guide groove. Additionally, the clearance between the guide rail and the guide groove is too small, and the joints between adjacent guide rails are poorly aligned.

2) The quenching platform fails to rise or fall to the proper position, or the impact force is too high; the cylinder piston doesn’t function properly; and the hydraulic pressure is set improperly.

3) The fan circulation effect is poor, the assembly quality is substandard, the bearing is seized, or the fan has come loose.

4) The part cannot be pushed forward; the rail joints don’t connect properly; there’s insufficient pressure; the check valve isn’t adjusted correctly; there’s pressure relief; and the solenoid valve isn’t working well.