In the field of industrial production, air compressors, as key power equipment, their stable operation is crucial to the production process. However, air compressors are inevitably prone to various faults during long - term use. Quickly and accurately determining the fault types has become the key to ensuring the normal operation of the equipment and reducing downtime. Recently, industry experts have deeply interpreted the methods for judging air compressor faults.
Visual inspection is the first step in determining faults. Carefully check each component of the air compressor. If the belt is broken or loose, it will directly affect power transmission; the rupture and air leakage of pipelines, as well as the loosening of connecting bolts, may all trigger operational problems. At the same time, the traces of oil or gas leakage at the fuselage, pipeline interfaces, valves and other parts cannot be ignored. Oil leakage usually appears as oil stains on the surface of the fuselage, while gas leakage is accompanied by a "hissing" sound or obvious air flow. These are all visual signals reflecting the health status of the equipment.
The analysis of operating parameters is even more crucial. In terms of pressure, when the system pressure cannot reach the set value, blockage of the intake system, internal leakage of the compressor, or malfunction of the pressure regulating valve may all be the culprits; and large pressure fluctuations are often related to faults in the pressure sensor, unstable control of the intake valve, or abnormal operation of the unloading valve. Temperature is also important. If the oil temperature or exhaust temperature is too high, it may be due to problems with the cooling system, insufficient or deteriorated lubricating oil, or excessive compressor load; conversely, too low a temperature may be related to a faulty temperature sensor or failure of the heating device. In addition, current parameters can also provide important clues. If the operating current exceeds the rated current, it may be due to motor overload, mechanical component jamming in the compressor, or low power supply voltage; unstable current fluctuations may stem from poor electrical system contacts, motor winding faults, or control circuit problems.
Sound is also an effective way to judge faults. A sharp friction sound is likely to mean that the bearing is worn, the impeller is rubbing against the housing, or the piston is rubbing against the cylinder wall; an irregular impact sound is most likely due to loose or broken internal components, such as loose connecting rods or broken valve plates; and the noise generated by excessive vibration is mostly due to unstable installation of the unit, loose foundation, or unbalanced rotor dynamic balance.
From the perspective of performance, a decrease in gas production capacity, that is, a significant reduction in gas production within the same operating time, is most likely due to wear of internal components of the compressor, blockage of the intake system, or leakage. If the compressed air contains too much oil, water, or impurities and the gas quality deteriorates, factors such as malfunctions of the oil - gas separator, leakage of the cooler, or failure of the air filter need to be carefully investigated.
The control system of modern air compressors provides convenience for fault determination. The fault codes or alarm messages it displays can quickly locate the fault range. At the same time, it is also essential to check the status of control components such as controllers, sensors, and relays to see if there are any damages, short - circuits, or open - circuits.
It is worth mentioning that referring to historical data and maintenance records is also very necessary. Reviewing the past fault records of the air compressor and understanding the treatment methods and results of similar faults can provide experience for the current fault determination. Information such as the maintenance cycle, maintenance content, and the last maintenance time of the air compressor also helps to determine whether the fault is caused by improper maintenance, such as clogged filters or deteriorated lubricating oil.
Experts emphasize that mastering these methods for determining the fault types of air compressors can help enterprises promptly detect equipment problems, take effective maintenance measures, ensure the continuity and stability of production, reduce production costs, and enhance the economic benefits of enterprises.