Language
In coating production, the mixer is the core equipment, and its stability directly affects product quality and delivery cycle. According to industry data, the downtime caused by failure of paint mixers accounts for as much as 65%, and 70% of the failures are due to lack of daily maintenance. This article combines the latest maintenance cases in 2025 to provide an in-depth analysis of rapid troubleshooting solutions for 12 typical faults of paint mixers to help companies reduce costs and increase efficiency.
In coating production, the mixer is the core equipment, and its stability directly affects product quality and delivery cycle. According to industry data, the downtime caused by failure of paint mixers accounts for as much as 65%, and 70% of the failures are due to lack of daily maintenance. This article combines the latest maintenance cases in 2025 to provide an in-depth analysis of rapid troubleshooting solutions for 12 typical faults of paint mixers to help companies reduce costs and increase efficiency.
Fault scenario: No display on the operation panel, no response from the paint mixing machine
In-depth investigation:
Power supply detection: Use a multimeter to measure whether the voltage is stable within the rated range (such as 220V ± 10%), and focus on checking whether the line connectors are oxidized.
Fuse inspection: If the output fuse (5A) is blown, it is necessary to replace the fuse of the same specification, and check whether the motor load is too heavy (it is recommended that the load rate is ≤ 85%).
Sensor cleaning: If the gap between the photoelectric sensor is too large or dust accumulates, adjust the gap to 1-2mm, and clean the dust in the sensor tank (compressed air purge is recommended).
Maintenance case: A paint factory lost control of the speed due to dust accumulation in the sensor. By cleaning and reinstalling the sensor, the troubleshooting time only took 30 minutes.
Typical symptoms: motor overheating, abnormal noise, frequent tripping
Solution:
Overload protection: Check whether the gap between the stirring blade and the lining plate exceeds the standard (recommended 3-8mm), and adjust the tension of the V-belt to 15-20mm of belt pressure.
Heat dissipation optimization: Clean up the dust in the motor air duct and replace the aging fan. It is recommended to use an axial flow cooling fan (the air volume increases by 30%).
Winding detection: Use a megohmmeter to measure the insulation resistance of the motor. If it is lower than 0.5 MΩ, it needs to be baked (baked at 100 ℃ for 8 hours) or rewound.
Fault manifestations: the equipment shakes violently, accompanied by metal friction sound
Root tracking:
Mechanical wear: Check whether the thickness of the stirring blade is less than 20mm (original thickness 50mm), and whether the wear amount of the liner plate exceeds the limit (allowable value ≤ 5mm).
Dynamic balance failure: Laser centering instrument is used to detect the radial runout of the spindle. If it exceeds 0.3 mm, on-site dynamic balance correction is required (Schmitt balancer is recommended).
Loose foundation: Use a vibrometer to detect the vibration value of anchor bolts. If it exceeds 8mm/s, it needs to be re-grouted for reinforcement (non-shrinkage grouting material is recommended).
Innovative technology: An enterprise uses carbon nanopolymer materials to repair shaft wear, reducing the cost of a single repair by 70% and extending the service life by 3 times.
2.2 Intelligent Correction Of Belt Conveyor Deviation
Frequently Asked Questions: Material Leakage, Belt Edge Wear
Solution:
Automatic deviation correction system: Install ultrasonic sensor to monitor the belt position in real time, and automatically adjust the idler angle through the electric push rod (response time ≤ 0. 5 seconds).
Roller optimization: Conical idler set (taper 1: 100) is used instead, which effectively reduces deviation caused by material accumulation (leakage is reduced by 80%).
Roller coating: Using ceramic rubber composite coating technology, the friction coefficient is increased to 0.35, and the service life is extended to 2 years.
Industry pain points: Traditional floating seal rings are prone to leakage and have high maintenance costs
Innovative solutions:
Combined sealing technology: adopts labyrinth seal + skeleton oil seal double protection (applicable speed ≤ 60 rpm, leakage ≤ 5 ml/h).
Intelligent monitoring: Install a temperature sensor to monitor the shaft end temperature in real time, and automatically start the standby cooling system in case of abnormality (cooling efficiency is increased by 40%).
Maintenance cycle: Seal inspection is recommended for every 5000 m ³ of paint produced (replacement cycle extended to 12 months).
Key measures:
Screw conveyor: The gap between the blade and the pipe wall is controlled at 2-3mm, and wear-resistant alloy coating is adopted (hardness HRC ≥ 55, wear resistance is increased by 5 times).
Butterfly valve modification: Pneumatic actuator is installed to realize remote control, and the sealing surface of the valve plate is surfaced with Stellite alloy (corrosion resistance is increased by 3 times).
Dust removal system: Equipped with pulse bag dust collector (filtration accuracy ≤ 1 μm, emission concentration < 30 mg/m ³), the filter bag replacement cycle is extended to 18 months.
Core features:
Vibration analysis: FFT algorithm is used to identify the characteristic frequency of bearing failure (such as outer ring failure frequency ≈ 0.4 × rotating speed), and 7 days’ early warning is given.
Temperature warning: Set the motor temperature rise threshold (the allowable temperature rise of F-class insulation is 115K), and automatically reduce the load when it exceeds the limit.
Energy consumption monitoring: Establish a mixer power curve model, and trigger an alarm when abnormal fluctuations occur.
Maintenance periodic table:
|
Component |
Daily inspection |
Weekly maintenance |
Monthly maintenance |
|
Stirring blade |
Visual inspection |
Thickness measurement |
Wear quantity analysis |
|
Triangular belt |
Tension detection |
Surface inspection |
change |
|
Lubrication system |
Oil level confirmation |
Oil quality analysis |
Filter element replacement |
Adaptive modification:
The motor cooling system is upgraded to a water-cooled + air-cooled composite mode (cooling efficiency is increased by 50%).
The hydraulic oil is replaced with VG46 anti-wear hydraulic oil (applicable temperature is-20 ℃ ~ 120 ℃, and the oxidation stability is increased by 2 times).
The stirring arm is made of high chromium cast iron (hardness HRC ≥ 60, impact resistance increased by 3 times).
Special measures:
Install the diesel engine preheating system (start when the ambient temperature is <-10 ℃, the preheating time is ≤ 15 minutes).
The hydraulic system is equipped with an electric heater (keep the oil temperature ≥ 15 ℃ and the heating power is 5kW).
The belt conveyor adopts V-shaped anti-slip idlers (the friction coefficient is increased by 40% and the leakage is reduced by 90%).
Low efficiency: High viscosity materials are unevenly mixed, and the uniformity is difficult to meet the standard (CV value > 5%).
Poor adaptability: abrasive materials lead to rapid equipment wear and frequent maintenance (average annual downtime > 100 hours).
Insufficient intelligence: lack of real-time monitoring and automatic control functions (manual inspection efficiency is low).
Modular design: quickly adapt to different materials by changing stirring parts (such as paddles, dispersion disks) (switching time ≤ 30 minutes).
Wear-resistant material: Silicon carbide ceramic coating (thickness 2mm, wear resistance increased by 10 times) is used to extend the service life of components to 3 times that of traditional materials.
Intelligent control: Industrial automation technology is introduced to achieve fault diagnosis (accuracy ≥ 95%) and automatic parameter optimization (energy consumption reduction by 20%).
Case background: A large paint company has an annual production capacity of 100,000 tons. The yearly average downtime of the original mixer is 120 hours, and maintenance costs account for 8%.
Solution:
Replaced with a modular mixer equipped with an intelligent monitoring system.
Implement preventive maintenance programs with quarterly in-depth inspections.
Results:
The annual unplanned downtime was reduced to 20 hours (83% decrease).
Repair costs were reduced to 3% (down 62.5%).
The uniformity of product quality is improved to CV value ≤ 2%.
By implementing the three-in-one management model of “preventive maintenance + intelligent monitoring + rapid response”, coating companies can significantly improve equipment utilization. In the future, with the popularization of digital twin technology, paint mixer fault diagnosis will enter a new era of “predictive maintenance”, injecting new momentum into the high-quality development of the industry.
