1.1 Turntable The rotary table of the rotary tablet press is a circular disk, and the punch holes and the middle die holes are evenly distributed around the periphery. When it rotates under the driving of the main shaft, each punch moves up and down along the curved guide rail, thereby completing the pressing process. The turntable is the main working part of the tablet press. In the continuous work process, the analysis and solution of common faults are as follows:
(1) The long-term wear of the punch hole or the middle die hole causes the coaxiality of the two holes to meet the requirements: during the use, the punch and the middle die hole may have different shaft phenomena due to different degrees of wear, so that the punch The frictional resistance of the up and down movement increases, and in severe cases, the film cannot be normally pressed. If the wear is not serious, the coaxiality can be restored by reaming the rod hole with a reamer, and the turntable needs to be replaced when the wear is severe.
(2) The upshift of the turntable affects the filling or filming: the upshift of the turntable is generally caused by the looseness of the taper locking block of the fixed turntable, which can be solved by tightening the taper locking block. If there is a problem with the fastening screw, replace it immediately.
(3) The loosening of the middle die top wire causes the middle die to move up, and the feeder is worn out: the middle die moves up, mostly due to the looseness of the middle die top wire, and the middle die top wire can be solved. The middle die top wire is a wearing part, which can not be tightened by long-term wear and should be replaced in time.
1.2 Guide rail part rail is an important part to ensure the trajectory movement of the ram, most of the faults are caused by the lack of lubrication. Its common fault analysis and solutions:
(1) Guide rail wear: The punch is curved on the guide rail and works normally by sliding friction, so the wear of the guide rail is one of the common maintenance faults of Zui. The guide rail is divided into the upper rail and the lower rail assembly, and the punch and the guide rail are worn. The lighter can be restored to normal with the oil stone grinding guide rail, and the wearer is only solved by replacing the guide rail.
(2) Loose rail components: The rail components may loosen after continuous operation, and should be tightened in time, and attention should be paid to make the guide rails smooth and smooth.
(3) The lower guide rail wears over the bridge plate, causing the punch to wear the guide rail main body: the lower guide rail crosses the bridge plate to protect the main body of the guide rail. If it is worn, the light is repaired with the oil stone, and the wear is severe and can only be replaced.
1.3 Part of the pressure roller part of the pressure roller can be divided into an upper pressure roller and a lower pressure roller, which is also a device for adjusting the pressure of the tablet and increasing the protection. Its common fault analysis and solutions:
(1) Wear of the pressure roller: The outer circle of the pressure roller is seriously worn, which will cause the resistance of the tail of the punch to be large, and the pressure roller must be replaced again. When the inner hole of the pressure roller and the pressure roller shaft are seriously worn, the pressure roller or the pressure roller shaft must also be replaced. In addition, the pressure roller shaft sometimes breaks and deforms, mainly due to excessive pressure. Most of them are caused by excessive adjustment of the material due to difficult pressure. At this time, the pressure roller shaft needs to be replaced, the material is adjusted, and the pressure is adjusted again.
(2) Oil roller shaft bearing lacks oil or damage: Regularly lubricate and maintain the pressure roller shaft bearing, and replace it in time for damage.
1.4 adjustment system (pressure regulation, filling adjustment)
The adjustment system includes pressure regulation system and filling adjustment system, common fault analysis and solution:
(1) Adjustment failure: Under normal circumstances, the adjustment failure is caused by the looseness of the handwheel screw, which makes the handwheel adjustment not work, or the adjustment of the worm wheel is stuck. In this case, check the adjustment handwheel and the worm wheel, and tighten the screws. Lubricate the rotating worm gear and other measures to solve.
(2) Unstable filling, the main reasons are: 1) material factors, uneven granulation or poor material flow; 2) stencil wear caused by different types or total height difference; 3) improper adjustment of hopper height, behind the feeder Insufficient grid packing; 4) The filling front rail in the filling rail assembly is seriously worn, and the jump is generated. At this time, the filling rail assembly should be replaced; 5) the lifting rod in the filling rail assembly is seriously worn, resulting in large adjustment gap and filling rail jitter. At this time, the filling rail assembly should be replaced; 6) the bottom surface of the feeder is seriously worn, resulting in uneven gap between the bottom surface of the feeder and the turntable; 7) the scraping board is seriously worn, resulting in poor powder scraping effect, and the scraping board should be replaced at this time; The under-crushing effect is poor, resulting in a plug.
(3) The tablet is loose or the appearance quality of the tablet is not good: the tablet is loose or the appearance quality is not good, mainly caused by small pressure, uneven particles, low water content or difficult to press the material composition. The solution is to adjust the pressure hand. The wheel increases the pressure, adjusts the particles and the ingredients of the excipients, and the particles are dried to be sprayed with 75% ethanol.
(4) When the tablet is pressed, the vibration of the machine has a loud sound: when the tablet is pressed, the machine has a loud sound due to the uneven pressure on both sides, and the adjustment pressure is solved.
1.5 Feeding part The feeding part includes two parts, the feeder and the hopper. The frequently occurring fault analysis and solution are as follows:
(1) Leakage powder: The phenomenon of powder leakage is generally caused by the excessive gap between the bottom surface of the feeder or the scraper plate and the turntable. Adjusting the gap between the feeder or the scraper plate and the plane of the turntable will solve the problem. There must be a gap between the scraper and the turntable, which is usually measured with a feeler gauge. When installing the screws, it must be flat, to ensure the installation accuracy, to prevent the gap from being too large or too small to cause leakage or grinding the rotating table. You can pad a piece of paper when it is fixed, and then pull it out after fastening.
(2) Insufficient flash or material: The reason for the occurrence of flash or insufficient material is mainly due to the mismatch between material flow rate and turntable speed. When the rotation speed of the turntable is low and the material flow rate is fast, the flashing phenomenon occurs; when the rotation speed of the turntable is high and the material flow velocity is slow, the shortage of the material occurs. At this time, the material flow rate should be properly adjusted according to the rotation speed of the turntable.
1.6 Overload protection system overload protection system common fault analysis and solution: the main reason for frequent alarm is the pressure of the tablet pressure overload or the overload protection spring setting pressure is too small, the solution is to adjust the pressure hand wheel, reduce the pressure or increase the overload The protection spring sets the pressure.
1.7 Reducer box is composed of worm gear, worm and box. The common fault analysis and solution: the oil leakage of the gearbox is mainly caused by the looseness of the flange screw or the aging of the oil seal. The solution is to tighten the flange screw or replace the oil seal. And apply sealant.
1.8 Tablet press The mold presser often needs to change the mold during use. The abrasive tool is directly related to the quality of the product. Many equipment failures are caused by improper adjustment of the mold replacement. Before installing the tablet press, the power of the tablet press must be cut off, the cover plate, the lower rail, the hopper, and the feeder should be removed. Open the right door, gradually clean the working surface of the turntable, the die hole and the die for installation, and apply some vegetable oil outside the middle die and the punch to adjust the thickness of the film to a position above 5mm.
1.8.1 Before installing the die, the power supply must be cut off, the hopper, the feeder, the front cover, the front cover, the front door, and the test wheel roulette during the installation process must be removed. The specific installation is as follows: (1) Medium mold installation. Loosen the middle mold fastening screw (screw the outer circle of the turntable 2mm), but the head of the middle mold fastening screw should not expose the outer surface of the turntable; use the middle mold to clean the knife to remove the dirt in the middle film hole; For a little lubricant, place the middle film on the middle film hole and align it with a hand hammer (copper) first, so that the middle film is correctly introduced into the 2/3 depth, and then add the mounting pad (rubber plate) to make it in place. Use the ruler to check the middle film end face and the intermediate film work surface 0~-0.05mm; tighten the die to tighten the screw. (2 undershoot installation. Clean the undershoot and oil; insert the lower punch into the lower punch, press the tablet with the left hand, push it on the right hand, make the lower punch into the middle film hole; adjust the lower punch column to make the next The punching movement is flexible, and it is not free to slip. (3) Install the upper punch. Clean the upper punch and apply oil; insert the upper punch into the punching hole at the notch of the guide plate.
1.8.2 Installation of profiled die (1) Medium die installation. Loosen the middle mold fastening screw, but the head of the middle mold fastening screw should not expose the end surface of the punching disc; use the middle mold to clean the knife to remove the dirt in the middle mold hole; remove the upper punch loading and unloading rail and the cover plate, and use the upper punching guide The key is positioned and cannot be rotated, so the middle and upper punches must be installed synchronously. Put the upper punch into the upper punching hole, and insert the upper die into the die hole first, then insert the upper punch into the middle die hole, then use the bar to drive the middle die, and the above punch is used as the guide bar to make the middle die into the middle die. When the hole is 2/3, use the middle die bar (copper) to hit it in place. Then use the punch to test the mold, if it is normal, put the upper punch on the guide plate. If it is not normal, remove the middle mold and reinstall it; use the knife edge to check the middle mold end face and the middle turntable work surface 0~-0.05mm; tighten the die to securely combine. (2) Undershoot installation. Clean the lower punch and apply oil; insert the lower punch into the lower punch, push the tablet with the left hand, push it on the right hand, and push it into the middle die hole; adjust the top post to make it move flexibly, not free. Sliding down (after all the molds have been installed, check the die-tight combination again to ensure that the middle mold is fastened properly).
1.8.3 Punch wear punches and guide rails are frequent parts of the press machine movement, and an effective way to reduce wear is lubrication. The rams and guides should be checked for lubrication every shift. Lubricate with mechanical oil, add a little each time to prevent contamination. The refueling part should be maintained according to the maintenance SOP. The key refueling parts of the upper punch, the lower punch and the track should be added 1 or 2 times per shift. For varieties with relatively high materials and large annual production, the activities of the upper and lower impulses should be checked before leaving work. Clean the die holes and die when it is not easy to move. Pressure rollers and bearings should be refueled regularly.
1.8.4 Pulling (1) When the tablet press is in the normal tableting, due to the influence of the viscosity of the particles, the upper and lower punches cannot move freely during the movement, which is called pull punch (also called lifting). When the tablet press is running, there will be an abnormal sound, and in severe cases, the punch will break and the track will be damaged. Analytical solution: 1) Adjust the humidity in the room, the relative humidity is controlled at 40%~60%; (2) Adjust the viscosity of the particles, replace some auxiliary materials with moisture absorbent or granulate with ethanol; 3) Punch and die hole When the clearance is too large, the die should be replaced in time, and the vacuum cleaner should be cleaned in time.
1.9 Electrical parts (1) Shutdown after a few minutes after starting up: Mostly because of excessive pressure, the overload protection should be reduced and the pressure should be restarted. (2) The oil pump does not oil or supply too much oil: the oil pump does not oil so that the rail guide and the punch are not lubricated. If the oil is too much, the tablet will be contaminated. The reason is mostly because the inverter parameter setting problem, reset the inverter. Parameters, adjust the oiling time. (3) Auxiliary power supply is out of power: mostly because of the line problem, check the line to solve. (4) The tachometer, counter is not displayed, the button is out of order, the panel is broken, the axial fan is broken, the alarm light is broken, the bulb is broken, and the rectifier bridge is burnt out. There is a line problem in the failure of the electrical device. The circuit must be inspected and the damage of the electrical device must be replaced.
1.10 Auxiliary part of the auxiliary machine is mainly vacuum cleaner, and most of its faults are caused by improper connection or misconfiguration with the host. The specific problems can be solved.
(1) The long-term wear of the punch hole or the middle die hole causes the coaxiality of the two holes to meet the requirements: during the use, the punch and the middle die hole may have different shaft phenomena due to different degrees of wear, so that the punch The frictional resistance of the up and down movement increases, and in severe cases, the film cannot be normally pressed. If the wear is not serious, the coaxiality can be restored by reaming the rod hole with a reamer, and the turntable needs to be replaced when the wear is severe.
(2) The upshift of the turntable affects the filling or filming: the upshift of the turntable is generally caused by the looseness of the taper locking block of the fixed turntable, which can be solved by tightening the taper locking block. If there is a problem with the fastening screw, replace it immediately.
(3) The loosening of the middle die top wire causes the middle die to move up, and the feeder is worn out: the middle die moves up, mostly due to the looseness of the middle die top wire, and the middle die top wire can be solved. The middle die top wire is a wearing part, which can not be tightened by long-term wear and should be replaced in time.
1.2 Guide rail part rail is an important part to ensure the trajectory movement of the ram, most of the faults are caused by the lack of lubrication. Its common fault analysis and solutions:
(1) Guide rail wear: The punch is curved on the guide rail and works normally by sliding friction, so the wear of the guide rail is one of the common maintenance faults of Zui. The guide rail is divided into the upper rail and the lower rail assembly, and the punch and the guide rail are worn. The lighter can be restored to normal with the oil stone grinding guide rail, and the wearer is only solved by replacing the guide rail.
(2) Loose rail components: The rail components may loosen after continuous operation, and should be tightened in time, and attention should be paid to make the guide rails smooth and smooth.
(3) The lower guide rail wears over the bridge plate, causing the punch to wear the guide rail main body: the lower guide rail crosses the bridge plate to protect the main body of the guide rail. If it is worn, the light is repaired with the oil stone, and the wear is severe and can only be replaced.
1.3 Part of the pressure roller part of the pressure roller can be divided into an upper pressure roller and a lower pressure roller, which is also a device for adjusting the pressure of the tablet and increasing the protection. Its common fault analysis and solutions:
(1) Wear of the pressure roller: The outer circle of the pressure roller is seriously worn, which will cause the resistance of the tail of the punch to be large, and the pressure roller must be replaced again. When the inner hole of the pressure roller and the pressure roller shaft are seriously worn, the pressure roller or the pressure roller shaft must also be replaced. In addition, the pressure roller shaft sometimes breaks and deforms, mainly due to excessive pressure. Most of them are caused by excessive adjustment of the material due to difficult pressure. At this time, the pressure roller shaft needs to be replaced, the material is adjusted, and the pressure is adjusted again.
(2) Oil roller shaft bearing lacks oil or damage: Regularly lubricate and maintain the pressure roller shaft bearing, and replace it in time for damage.
1.4 adjustment system (pressure regulation, filling adjustment)
The adjustment system includes pressure regulation system and filling adjustment system, common fault analysis and solution:
(1) Adjustment failure: Under normal circumstances, the adjustment failure is caused by the looseness of the handwheel screw, which makes the handwheel adjustment not work, or the adjustment of the worm wheel is stuck. In this case, check the adjustment handwheel and the worm wheel, and tighten the screws. Lubricate the rotating worm gear and other measures to solve.
(2) Unstable filling, the main reasons are: 1) material factors, uneven granulation or poor material flow; 2) stencil wear caused by different types or total height difference; 3) improper adjustment of hopper height, behind the feeder Insufficient grid packing; 4) The filling front rail in the filling rail assembly is seriously worn, and the jump is generated. At this time, the filling rail assembly should be replaced; 5) the lifting rod in the filling rail assembly is seriously worn, resulting in large adjustment gap and filling rail jitter. At this time, the filling rail assembly should be replaced; 6) the bottom surface of the feeder is seriously worn, resulting in uneven gap between the bottom surface of the feeder and the turntable; 7) the scraping board is seriously worn, resulting in poor powder scraping effect, and the scraping board should be replaced at this time; The under-crushing effect is poor, resulting in a plug.
(3) The tablet is loose or the appearance quality of the tablet is not good: the tablet is loose or the appearance quality is not good, mainly caused by small pressure, uneven particles, low water content or difficult to press the material composition. The solution is to adjust the pressure hand. The wheel increases the pressure, adjusts the particles and the ingredients of the excipients, and the particles are dried to be sprayed with 75% ethanol.
(4) When the tablet is pressed, the vibration of the machine has a loud sound: when the tablet is pressed, the machine has a loud sound due to the uneven pressure on both sides, and the adjustment pressure is solved.
1.5 Feeding part The feeding part includes two parts, the feeder and the hopper. The frequently occurring fault analysis and solution are as follows:
(1) Leakage powder: The phenomenon of powder leakage is generally caused by the excessive gap between the bottom surface of the feeder or the scraper plate and the turntable. Adjusting the gap between the feeder or the scraper plate and the plane of the turntable will solve the problem. There must be a gap between the scraper and the turntable, which is usually measured with a feeler gauge. When installing the screws, it must be flat, to ensure the installation accuracy, to prevent the gap from being too large or too small to cause leakage or grinding the rotating table. You can pad a piece of paper when it is fixed, and then pull it out after fastening.
(2) Insufficient flash or material: The reason for the occurrence of flash or insufficient material is mainly due to the mismatch between material flow rate and turntable speed. When the rotation speed of the turntable is low and the material flow rate is fast, the flashing phenomenon occurs; when the rotation speed of the turntable is high and the material flow velocity is slow, the shortage of the material occurs. At this time, the material flow rate should be properly adjusted according to the rotation speed of the turntable.
1.6 Overload protection system overload protection system common fault analysis and solution: the main reason for frequent alarm is the pressure of the tablet pressure overload or the overload protection spring setting pressure is too small, the solution is to adjust the pressure hand wheel, reduce the pressure or increase the overload The protection spring sets the pressure.
1.7 Reducer box is composed of worm gear, worm and box. The common fault analysis and solution: the oil leakage of the gearbox is mainly caused by the looseness of the flange screw or the aging of the oil seal. The solution is to tighten the flange screw or replace the oil seal. And apply sealant.
1.8 Tablet press The mold presser often needs to change the mold during use. The abrasive tool is directly related to the quality of the product. Many equipment failures are caused by improper adjustment of the mold replacement. Before installing the tablet press, the power of the tablet press must be cut off, the cover plate, the lower rail, the hopper, and the feeder should be removed. Open the right door, gradually clean the working surface of the turntable, the die hole and the die for installation, and apply some vegetable oil outside the middle die and the punch to adjust the thickness of the film to a position above 5mm.
1.8.1 Before installing the die, the power supply must be cut off, the hopper, the feeder, the front cover, the front cover, the front door, and the test wheel roulette during the installation process must be removed. The specific installation is as follows: (1) Medium mold installation. Loosen the middle mold fastening screw (screw the outer circle of the turntable 2mm), but the head of the middle mold fastening screw should not expose the outer surface of the turntable; use the middle mold to clean the knife to remove the dirt in the middle film hole; For a little lubricant, place the middle film on the middle film hole and align it with a hand hammer (copper) first, so that the middle film is correctly introduced into the 2/3 depth, and then add the mounting pad (rubber plate) to make it in place. Use the ruler to check the middle film end face and the intermediate film work surface 0~-0.05mm; tighten the die to tighten the screw. (2 undershoot installation. Clean the undershoot and oil; insert the lower punch into the lower punch, press the tablet with the left hand, push it on the right hand, make the lower punch into the middle film hole; adjust the lower punch column to make the next The punching movement is flexible, and it is not free to slip. (3) Install the upper punch. Clean the upper punch and apply oil; insert the upper punch into the punching hole at the notch of the guide plate.
1.8.2 Installation of profiled die (1) Medium die installation. Loosen the middle mold fastening screw, but the head of the middle mold fastening screw should not expose the end surface of the punching disc; use the middle mold to clean the knife to remove the dirt in the middle mold hole; remove the upper punch loading and unloading rail and the cover plate, and use the upper punching guide The key is positioned and cannot be rotated, so the middle and upper punches must be installed synchronously. Put the upper punch into the upper punching hole, and insert the upper die into the die hole first, then insert the upper punch into the middle die hole, then use the bar to drive the middle die, and the above punch is used as the guide bar to make the middle die into the middle die. When the hole is 2/3, use the middle die bar (copper) to hit it in place. Then use the punch to test the mold, if it is normal, put the upper punch on the guide plate. If it is not normal, remove the middle mold and reinstall it; use the knife edge to check the middle mold end face and the middle turntable work surface 0~-0.05mm; tighten the die to securely combine. (2) Undershoot installation. Clean the lower punch and apply oil; insert the lower punch into the lower punch, push the tablet with the left hand, push it on the right hand, and push it into the middle die hole; adjust the top post to make it move flexibly, not free. Sliding down (after all the molds have been installed, check the die-tight combination again to ensure that the middle mold is fastened properly).
1.8.3 Punch wear punches and guide rails are frequent parts of the press machine movement, and an effective way to reduce wear is lubrication. The rams and guides should be checked for lubrication every shift. Lubricate with mechanical oil, add a little each time to prevent contamination. The refueling part should be maintained according to the maintenance SOP. The key refueling parts of the upper punch, the lower punch and the track should be added 1 or 2 times per shift. For varieties with relatively high materials and large annual production, the activities of the upper and lower impulses should be checked before leaving work. Clean the die holes and die when it is not easy to move. Pressure rollers and bearings should be refueled regularly.
1.8.4 Pulling (1) When the tablet press is in the normal tableting, due to the influence of the viscosity of the particles, the upper and lower punches cannot move freely during the movement, which is called pull punch (also called lifting). When the tablet press is running, there will be an abnormal sound, and in severe cases, the punch will break and the track will be damaged. Analytical solution: 1) Adjust the humidity in the room, the relative humidity is controlled at 40%~60%; (2) Adjust the viscosity of the particles, replace some auxiliary materials with moisture absorbent or granulate with ethanol; 3) Punch and die hole When the clearance is too large, the die should be replaced in time, and the vacuum cleaner should be cleaned in time.
1.9 Electrical parts (1) Shutdown after a few minutes after starting up: Mostly because of excessive pressure, the overload protection should be reduced and the pressure should be restarted. (2) The oil pump does not oil or supply too much oil: the oil pump does not oil so that the rail guide and the punch are not lubricated. If the oil is too much, the tablet will be contaminated. The reason is mostly because the inverter parameter setting problem, reset the inverter. Parameters, adjust the oiling time. (3) Auxiliary power supply is out of power: mostly because of the line problem, check the line to solve. (4) The tachometer, counter is not displayed, the button is out of order, the panel is broken, the axial fan is broken, the alarm light is broken, the bulb is broken, and the rectifier bridge is burnt out. There is a line problem in the failure of the electrical device. The circuit must be inspected and the damage of the electrical device must be replaced.
1.10 Auxiliary part of the auxiliary machine is mainly vacuum cleaner, and most of its faults are caused by improper connection or misconfiguration with the host. The specific problems can be solved.
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