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Homogenizer

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Homogenizer
  • Homogenizer

    Homogenizer

  • Homogenizer

  • Homogenizer

  • Homogenizer

  • Homogenizer

  • Homogenizer

  • 150-300KG
    Weight(Specific to actual production)
  • 500-5000L/h
    Production capacity
  • 5.5-55kw
    Equipped with power
  • 2000×1480×1600mm
    Dimensions(Specific to actual production)
Homogenizer
  • Homogenizer

    Homogenizer

  • Homogenizer

    Homogenizer

Product video
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Product parameter


Model
Flow (L/h)
Maximum pressure MPa Rated pressure MPa
Matching power kw Dimensions mm




GJJ 500/25
500
25
20
5.5
960×540×980




GJJ 500/60
500
60
50
11
1315×1100×1300




GJJ 1000/25
1000
25
20
7.5
1030×650×1120




GJJ 1000/40
1000
40
35
15 1315×1100×1300




GJJ 2000/25
2000
25
20
15
1315×1100×1300




GJJ 2000/40
2000
40

35

30
1315×1480×1400




GJJ 5000/25
5000 25
20
45
1630×1480×1600




GLJ-550
5000
40
35
55
2000×1480×1600



Product details


When the machine is working, the processed material is sent to the homogenization valve in a high-pressure form through a three-plunger reciprocating pump, so that the material flows through the tiny gap between the valve disc and the valve seat and is subject to overflow, cavitation, shear, etc. Function to achieve the purpose of homogenization and emulsification. It is widely used in food, dairy, beverage and other industries.



Figure 1  Schematic diagram of the whole machine A


1. Foot    2. Outlet   3. Lapa    4. Inlet    5. Ammeter    6.Voltmeter  7.Nameplate   8.Pump nut   9.Pump body    10.Pressure transmission cylinder    11. Pressure gauge   12. High pressure pistol    13. Low pressure pistol      14. Gland    15. Overflow valve pistol    16.Upper cover    17. Sign    18. Overflow valve body    19. Power switch     20. Electrical box door lock      21. Housing

Figure 1  Schematic diagram of the whole machine B


Figure 2  Homogenizer head assembly drawing A

1. Feed inlet coupling plate   2. Feed inlet joint   3. Stud bolts   4 .Screw plug    5. Pressure gauge seat    6. Vent screw    7. Pressure transmission piston      8. Pressure transmission cylinder    9. Micro-through screw    10. Micro-port valve     11. Pressure gauge       12.0-ring    13. Bolt, nut  14. Damping 0-ring  &nbsp ;15.0 type ring    16.0 type ring    17. Pressure regulating nut     18. Pressure rod    19. Bearing support   20. Pressure regulating seat&nbsp ;   21. Pressure plate   22. Butterfly spring sheet   23. Homogeneous rod  24. Secondary homogeneous valve body    25. Collision ring    26. Both Quality valve    27. Homogeneous valve seat    28. Gasket
29. Discharge port connector  30. Pressure plate   31. Handle  32. Pump body     33 .Screw plug    34. Gasket

Figure 2  Homogeneous head assembly drawing B


1. O-ring, sealing gasket    2. Lower valve seat    3. Guide rod      4. Lower valve    5. Lower valve spring    6. Lower turnbuckle   7. Plunger   8. Set screw   9. Pressure ring  &nbsp ; 10. Plunger sealing ring (V type or square type, spacer)  11. Positioning sleeve, gasket ring    12. Plunger sealing sleeve    13.Upper valve    14. Upper Lanhua      15. Pressure plate    16. Upper valve spring      17. Bolt, nut        18. Bolt, nut      19. Pressure rod nut     20.O-ring, sealing ring    21.A homogeneous valve body    22.Homogeneous rod, O-ring    &nbsp ;   23. Flat bearing        24. Pressure rod    25. Pressure rod nut       26. Pump body nut    27. Lower valve sealing ring

Figure 2  Schematic diagram of the pump body C

1. Pressure gauge assembly  2. Meter seat gasket  3. Gauge seat gland  4. Gland  5. Cone column 6. Gland gasket  7. Lock nut  8. Adjust nut  9. Lock nut with hole    10. Cone valve core   11. Upper cone Valve seat   12. Limit sleeve   13. Lower cone valve seat     14. Adjusting gasket  15. Screw plug   16.O-type rubber sealing ring  ;   17.Pump body      18.Piston seal sleeve  19.Pump body seal ring  20.Set screw  21.Pressing ring   22.Piston seal Ring (V type or square type) 23. Spacer  24. Seat ring  25. Plunger 


1. Working principle and purpose
GJJ series high pressure Homogenizer is a kind of superfine crushing, emulsification and homogenization equipment, which uses the suspension under high pressure to pass an adjustable The comprehensive effects of pressure loss, expansion, explosion, shear and high-speed impact in the flow-limiting gap process smash particles and oil droplets in the liquid into small sizes, with a diameter of Ø0.1-2um, and an average of Ø≤1um, and establish at the same time Ideal emulsion or dispersion. This process integrates the functional principles of ultrasonic pulverizer, colloid mill, ball mill, jet machine, etc. (Figure 3). Product stability, consistency, mixing, easy absorption, nutritional value, shelf life, taste, color and active retention can all be achieved in Homogenizer.

Figure 3  Working principle diagram
Main purpose:
(1) Bio-cells are broken to extract the contents or make new products;
(2) The immiscible two-phase materials (liquid-liquid or liquid-solid) are ultra-finely crushed to make stable emulsion or dispersion Liquid;
(3) Refinement of other various materials.
In short, it is widely used in food, bioengineering, chemical, pharmaceutical and other fields.

3.  The main structure and parts of Homogenizer
    This machine is mainly composed of a base, a motor, a gearbox, a high-pressure pump and a homogenizing part.
3.1   Base and motor
          The base is the foundation of the whole machine and plays a supporting role. It is made of channel steel, and its top Equipped with Y-type three-phase asynchronous motor, the motor has an adaptive displacement on the guide rail to adjust the transmission tension of the triangle belt. Equipped with QC type magnetic starter. For high-power motors, an electrical control box is also equipped to protect the power grid when it starts.
3.2   Gearbox
          The gearbox is driven by a two-stage transmission, and the first stage is driven by a triangular belt to prevent the machine from special circumstances ( Overload) causes unnecessary damage to the machine. The secondary is driven by one or two helical gears, and the helical gear integrated with the crankshaft drives the three-turn or four-turn crankshaft to drive. The crankshaft makes three or four plungers reciprocate linearly in the high-pressure pump through connecting rods, sliding blocks, etc. The high-pressure energy in the high-pressure pump is obtained by the reciprocating movement of the plungers.
           Standard rolling bearings and special alloy materials are used for sliding bearings in the transmission part, and the gearbox is lubricated Large gear splashing, continuous lubrication of each gear bearing through the oil guide hole, plunger high-pressure sealing parts-because the reciprocating movement of the plunger produces a large pressure in the high-pressure pump, the high-pressure seal at the reciprocating movement of the plunger is very good. The prerequisite for high pressure, it is composed of plunger sealing sleeve, set screw, plunger positioning sleeve, backing ring, sealing ring, pressure ring, etc. (Figure 5). This series of plunger seals has two types: V-shaped and square-shaped.
3.3     Pressure pump and homogenization valve (Figure 2-A.B)
        The pressure pump is the heart of the machine and the key component of crushing and emulsification, all made of special corrosion-resistant gao-grade alloy It is made of materials and mainly consists of the following components.
3.3.1   Main pump body (Figure 2-A)   
            It consists of three or four plungers in parallel, it includes a pump body, upper and lower valves , High and low pressure valve, gland, upper and lower turnbuckle, plunger, etc. When the plunger moves backward, the lower valve of the feed is opened and the working fluid is sucked in. When the plunger moves forward, the lower valve is closed, the upper valve is pushed open, and the working fluid is pressed into the area of ​​the high-pressure homogenization valve.
3.3.2   Upper and lower valves and high and low pressure valves (Figure 2-A.B)
        The upper and lower valves are composed of a valve core and a valve seat. There are 6 sets of three-plunger Homogenizer, and three sets of upper and lower valves. They are all made of special high-hardness, high-temperature-resistant, and corrosion-resistant materials. The valve structure is simple in design, has a unique form, is closely matched, is easy to disassemble, and has excellent performance and long service life. When the valve core and the seat mating surface are damaged due to long-term operation, the flow rate decreases or becomes pulse-like. When the pointer of the pressure gauge or the ammeter swings greatly, it should be removed for grinding or replaced with a new one.  
             The homogenization valve part has two levels
            diyiji (high pressure) It is the key part of ultrafine particle crushing and emulsification. The high-energy compressed working fluid enters the small hole of the high-pressure valve seat. The small hole is tightly sealed by the high-pressure valve core (homogeneous rod) through the spring through the ejector rod, and the pressure of the strong spring is arbitrarily adjusted by the hand wheel. When the plunger in the high-pressure pump compresses and the working hydraulic pressure is stronger than the strong spring, the valve core is flushed open, and the working fluid is ejected radioactively from the valve port, and collides with the collision ring with high energy and speed to produce such as (Figure 3) The various complex ultra-fine pulverization and emulsification effects described in. After one action, the working fluid enters the di-level (low pressure) homogenization valve area through the oblique hole in the valve body. The high pressure gasket and the gao pressure shaft sleeve are designed to ensure the high pressure seal between the pump body and the valve body and the hand wheel. of.
di Secondary (low pressure) homogenization valve part
It is composed of a low-pressure valve seat, a low-pressure valve core, a low-pressure gasket, a low-pressure shaft sleeve, a low-pressure handwheel, etc. The working principle is the same as that of di-ji (High pressure) The homogenizing valve is partly the same, mainly for emulsification.
The mating surfaces of the homogeneous valve seat and core valve will be worn out for a long time. When the pressure cannot rise or the crushing effect is not good, they must be removed. Under grinding or replacement.
The yi-level and second-level homogenizing valves have their own characteristics. Different use requirements should choose different homogenizing valve pressure differences. 3) The basic principle described in the above, the greater the pressure difference between the first ji and the second stage of the same material, the better the crushing effect of the material. For most products, the di ji valve P2 establishes a low pressure of 5-10MPa (50-100Bar), It can concentrate the energy of the first-stage homogenization zone, improve the crushing and mixing effect, and reduce the agglomeration of certain materials.
In production practice, the di first and second pressure can be selected appropriately. Within the allowable range of technical indicators, the di second pressure should be selected lower, and still When the selection pressure is zero, select higher di first-level pressure, and finely pulverize particles z. If the process formula is appropriate and the appropriate model is selected, the homogenization effect determined in the working principle must be achieved.
If an overflow valve is installed on the machine, its function is to automatically turn on if the car is stuck or the pressure suddenly rises to protect the machine from use It is accidentally damaged. Its pressure point is set at the factory. The user should not adjust it arbitrarily. Experienced users can also adjust it by themselves if the working pressure changes, but it must be adjusted to be greater than the Pm value, if it is lower than the Pm value The overflow valve is also damaged very quickly, which reduces the rated flow.
3.3.3    Pressure display part (Figure 2-A)
         This machine uses a shock-resistant pressure gauge, and through the gauge seat damping device, installed on the gland to make When the pressure gauge is reciprocating with three plungers, avoid excessive swing of the pressure gauge pointer (usually swing within three divisions); the lower part is equipped with isolation parts to prevent the pressure gauge from leaking and contaminating food. It is suitable for CIP aseptic work. The pressure gauge and the damping device cannot be moved. Otherwise, the oil filling in the damping device will leak or enter air, causing the pressure gauge to fail.
4.       Machine installation and commissioning
         When using this machine, you should be familiar with the working principle, technical performance and function of each part Mutual relations.
4.1      Ann    Install
         This machine does not require foot screw fixation, it can be directly placed on a fixed ground, but the ground is level foundation Must be strong and flat. There are several quick washers under the bottom support feet, and rubber shock-proof pads are used to further reduce noise and improve stability. The inlet and outlet of the pump body are connected with other systems using polyethylene hoses (SG79-75) to observe the inlet and outlet conditions; stainless steel pipes can also be used to connect, and valves are not allowed to be installed on the outlet pipes of the machine to prevent Produce stuffy cars and burst pipes. Determined by the user, the cooling water input adopts polyethylene hose (SG79-75) to connect with the water inlet pipe, accompanied by a switch to control the cooling water flow. After the power supply is connected, the rotation direction of the pulley (standing operation handwheel-side view) must be clockwise, some specifications are counterclockwise, or rotate in the direction of the arrow on the label on the foreign customer to ensure that the rotating parts are fully lubricated. wrong. Before the test run, you can jog it. If the large belt pulley does not rotate in the direction indicated by the arrow on the label on the shell, just connect the two of the three-phase power cords.
4.2      Add   oil
         When the machine leaves the factory, there is no lubricant in the rotating box. Before the test run, you must use high-quality industrial lubricants, such as Mobil gear oil (Mobilgear600), or China-made N68 (GB443-84) mechanical oil, and HJ50 mechanical oil should be used in high-temperature locations. Fill it up to the oil level or the middle of the oil mark (that is, half), otherwise the machine cannot be turned on.
4.3      Try    car
         After the installation and wiring of the machine is completed, or the machine is repaired and maintained, a trial run is required. The key points of the trial run are: (1) Is the power cord connected correctly? (2) Is the machine operating normally? The steps are as follows (see Figure 1. Figure 2)
4.3.1     Slightly loosen the high pressure hand wheel (picture 1-12) and low pressure hand wheel (picture 1) in a counterclockwise direction -13), and at the same time loosen the cap nuts on the two handwheels clockwise (Figure 2-19-25)
4.3.2     Turn on the cooling water, and the water will flow in from the inlet water, and the water will flow slowly, subject to no accumulation of water at the bottom of the box , To prevent the dry friction between the plunger and the sealing ring in the sleeve when the plunger is moving, causing serious wear of the sealing ring.
4.3.3      Open the feed pipe joint, and water can be used as a substitute during the test run.
4.3.4      Before the test run, you can turn the pulley by hand for a few laps. The plunger reciprocates normally without collision.
4.3.5      Start: press the start button (green), run for five minutes under no pressure, so that all parts Enter the lubrication state, and at the same time make the pump body fully feed, exhaust the air in the pump body (Figure 1-9), and the discharge pipe joint (Figure 2-29) will discharge normally, and no pulse shall prevail. The models below 25Mpa and 1500L/H produced by our factory should be screwed with a light bleed screw to remove the air in the feed pipe and pump body. When the material liquid flows out normally in the exhaust pipe, tighten the bleed screw.
4.3.6     Pressurization: Check the allowable pressure Pm.P1 in the technical indicators against the model specifications marked on the machine nameplate .P2 pressure test. Method: Slowly tighten the low pressure handwheel in a clockwise direction (Figure 1-12) until the pressure gauge indicates the value: P2 from 0-5-10, or 20Mpa (50-100 or 200Bar), carefully and slowly clockwise Turn the high-pressure handwheel in the direction (Figure 1-13) until the indicating value P1 of the pressure gauge reaches the maximum working pressure value Pm marked on the nameplate, and run for ten minutes. The machine is operating normally sign:
(a) Stable pressure—The pointer of the pressure gauge can be deflected by turning the hand wheel, and it swings in a stable range of three divisions.
(b) Adequate flow rate-the discharge per minute reaches the rated flow rate marked on the nameplate, which can be obtained by sampling, weighing, and conversion at regular intervals The flow rate shown on the nameplate.
(c) If the machine has no abnormal sound, it can be officially activated.
4.3.7    Always pay attention to the temperature rise of each bearing, fuel tank, noise during operation, and pressure changes.
4.3.8    Stop    machine
                Whenever you are done, release the high-pressure pistol in a counterclockwise direction ( Picture 1-13), release the low-pressure pistol again (picture 1-12), reset the pointer of the pressure gauge, and then clean it with water or shut it down. Make no mistake.
5        Use of Homogenizer
5.1          Use this machine, the particle size of the material entering the pump body Ø<20um is appropriate, the material liquid After the front material is processed, a 60-80 mesh filter can be used to enter the pump body after filtration to prevent large particles from entering and causing a large swing of the pressure gauge pointer.
5.2      The material liquid usually flows into the pump at a high level (the relative height between the inlet of the pump body and the liquid level of the tank is greater than 1m) However, when the material is too thick, viscous, poorly fluid, or the position of the material tank is too low, the low-pressure centrifugal pump can be used to input the pressure (as shown in Figure 4), which is mainly to prevent the formation of partial vacuum in the pump body, suck in air, and make the pump Body pressure is unstable, causing noise and vibration.

Figure 4  Schematic diagram of the connection between the pump body and the tank

1. Tank    2. Filter  3. Pipeline  4. Low-pressure centrifugal pump  5. Reversing Valve   6. Pump body


5.3     The pressure of this machine is stepless pressure regulating type
             Continuous working pressure P should be determined according to the process requirements of different materials to achieve z For good crushing and emulsification effects, the low value is appropriate. In continuous production, usually the second-level low pressure P2 is 0.5-10Pa (100Bar), and the first-level high pressure is P1 < 0.8Pm, so as to ensure the light load of the machine and save energy It also improves the service life of mechanical parts, avoids frequent replacement and grinding of vulnerable parts and seals, and reduces production costs.
             Homogenizer crushing effect depends on:
             A. Feeding particle hardness and thickness; B. Homogenizer allows large working pressure It is the key, high and low pressure difference: the larger P1-P2 (when P2=0), the finer particles z will be crushed. For example: coffee, cocoa, soybeans, peanuts, coconuts, almonds, walnuts, lotus seeds and other materials with certain hardness, Pm=70MPa (700Bar) Homogenizer should be used. For pure fruits and dairy products, Pm=400MPa (400Bar) and Pm=25MPa (250Bar).
            During production, professional technologists should repeatedly sample (including increasing or decreasing the ratio of stabilizers) On the basis, determine the best working pressure. The experimental Homogenizer GJJ60-70MPa produced by our factory has a minimum processing capacity of 500ml, which can be used for samples.
             some materials require more than 2 times of homogenization to achieve satisfactory results Ø0.1-2um.  
             If you do not use soy milk, peanut milk, etc., you need to homogenize three times in a row . Fine chemicals, daily-use chemicals, pharmaceuticals, and biological engineering also often require multiple homogenizations.
5.4    Control the feed temperature below 85 degrees, otherwise it will cause the material to be caused in the pump body
       The pressure gauge pointer oscillates greatly, the discharge is insufficient, and gas explosion occurs in severe cases. Made
       It is the phenomenon of gland deformation, bolt breakage, pressure gauge damage, etc., when the feed is not possible
       When the temperature is lower than 85 degrees, just add cooling water to the surface of the pump body to cool down. This is because of the high pressure The energy conversion during homogenization will cause the temperature of the material liquid to rise by 3-15℃ each time. When the pressure of this series of Homogenizer reaches Pm=70MPa (700Bar), the temperature of the homogeneous liquid material will rise up to about 15 degrees each time, and the user must pay attention.
5.5      The production operation sequence is carried out in the order of 4.3.1-2-3-5-6-7, before shutting down and stopping production Apply cleaning liquid or water into the pump body to run without pressure for about 10 minutes, and then shut down the pump body after it is clean.
         The following are general cleaning methods for dairy products for reference.
         a. Wash with hot water (80~90℃).
         b.1.5% nitric acid aqueous solution cleaning (to remove protein gel).
         c. 1.5% caustic soda aqueous solution cleaning (used to neutralize acid lotion and remove remaining oil and lipid ).
d. Wash with hot water (80~90℃) (use hot water to clean and disinfect before each use).
     If this machine is used in the production of food, pharmaceuticals, skin care creams, etc., it must comply with all hygiene regulations and implement wise Cleaning and disinfection procedures.
5.6      Use this machine must pay attention to:
         (1) There is no liquid or water passing through the pump body (i.e. an empty vehicle), and it is strictly forbidden to start operation;
         (2) The plunger cooling water valve is not opened and it is strictly forbidden to start operation;
         (3) If the lubricating oil is not in place or deteriorated, it is strictly forbidden to start up operation, if the oil level is low, it will cause The crankshaft is damaged due to loss of oil.
         (4) This machine is forbidden to start under pressure, so the homogenizer must be set after each shutdown Unscrew the handle.
(5) The internal lubricating oil of this machine is solved by the crankshaft or gear oil distribution, so reverse operation is prohibited.
(6) When operating and maintaining the machine, you should be familiar with the machine’s instruction manual, and illegal operations are prohibited.
(7) Before unpacking the new machine, check that the screws and nuts of each part are not loose, and check once after several shifts.
        (8) The shock-resistant pressure gauge and special pressure gauge seat used in this machine, when the machine is running normally and the pressure When the watch is not working, first check whether there is oil in the watch seat. If it is dry, fill it with cooking oil or glycerin.
        (9) During use, if the pointer of the pressure gauge stops reflecting (that is, when the handle is used to pressurize, No response from the hands), the inspection must be stopped immediately (see Figure 2)
         A. Remove the pressure gauge, take out the M6 ​​micro-way screw from the micro-way valve, or use M8 Take out the micro-way valve with the screw, use a round rod (4mm) or chopsticks to push the pressure transmission piston in the pressure transmission cylinder to the bottom of the lower end, fill the cylinder with cooking oil, and then screw the micro-way valve or M6 micro-way screw into the valve Add some cooking oil to the seat (not screw tight), and install the pressure gauge. (Be careful not to miss the Ø14×2.4O type sealing ring).
        B. When replacing a new pressure gauge, use a syringe or other tool to insert into the small hole at the lower end of the pressure gauge Fill up with edible oil, and the rest of the operation procedure is the same as A, or after replacing the new pressure gauge, start pressurizing and then stop, repeat method A- for two times until the pressure gauge is filled with oil.
         C. If you find that the pointer does not return to zero after the pressure gauge is tightened, you can turn the pressure gauge Tighten it after loosening it.
             The electrical control box of this machine is equipped with an overload protector, if the pressure exceeds the nameplate When the maximum gap working pressure is Pm, it will automatically stop. According to the local power supply conditions, experienced electrician masters should adjust and calibrate the overload protector accordingly when testing the machine.
             Homogenizer should be equipped with an ammeter, because pressure corresponds to current. When the pressure is determined, the corresponding current value is also determined. In production practice, due to careless use, the pressure gauge components are easily damaged, and the ammeter is more durable as long as it is not immersed in water. Therefore, when the operator uses the new machine, he should write down the current value corresponding to the production pressure, so as to use two kinds of meters to monitor at the same time; when the pressure gauge fails or is damaged, the pressure gauge assembly can be removed, and the gland hole is M20× 1.5 The bolts are sealed and the ammeter is used for monitoring. It can also be equally safe and reliable. The spare pressure gauge assembly can be used to calibrate the ammeter regularly, such as once a month. The transmission box is self-lubricating, and the added oil must be filtered through a filter screen of 150 mesh or more to ensure the cleanliness of the oil. The new machine should be changed once after 100 hours of operation, and the replaced oil should be filtered and reused.
6.       Guarantee   raise
6.1      The lubricating oil should be replaced after 750 operating hours or the color becomes milky white. The replacement method is as follows: unscrew and install in the gearbox Oil drain nut, use plastic pipe to lead the waste oil (place it in the oil drum, after precipitation, the clean oil on it can still be reused), tighten the drain nut, it is recommended to start the machine Flush the gear box with diesel oil at 0 pressure for 5 minutes until all driving parts are thoroughly cleaned, drain the diesel oil and inject new lubricating oil.
6.2      If the machine has been running for a period of time, if there is an abnormal sound, please pay attention to tighten the fasteners of the transmission part and tighten the transmission belt Some (see 7.6 for the method)
6.3      All seals and valves in the pump body are vulnerable parts; after the machine has been used for a period of time, due to the vulnerable parts Leakage causes the pressure gauge pointer to swing large, the flow is insufficient or pulsed, the pressure does not rise, and the crushing effect is not good. This is the normal maintenance range. The maintenance personnel only need to check, replace or grind in time (see 7.2-5 for the method)
6.4      The inner bearing of the motor is assembled with butter, and it is painted by the motor manufacturer when it leaves the factory. It can be as normal as the motor The maintenance method implements maintenance.
7.       Faults and Repairs
7.1      Can’t start: The problem lies in the power supply. Check the incoming circuit, including: contacts, switches, fuses and Relays, etc. can be checked and eliminated one by one.
7.2      Leakage
7.2.1    The plunger part is leaking: this machine adopts a self-tightening sealing device (Figure 5), so as long as the plunger is not Leakage, do not use the set screw (Figure 5-2) to prevent the plunger (5-1) from being over-tightened and causing fuzziness. If leakage is found, the set screw can be properly tightened after stopping the machine. If it does not leak, continue to use it until it does not have a sealing effect. You should add 1-3 new seals or replace with new seals (Figure 5-4). The material liquid is often mixed with hard impurities, such as sand particles, which cause the surface of the plunger to draw grooves and leak, and the plunger must be replaced.

Figure 5     Piston seal diagram
1. Plunger   2. Set screw  3. Pressure ring  4. Plunger sealing ring (V or Square, spacer) 5. Positioning sleeve, gasket   6. Plunger sealing sleeve   7. Sealing ring
It is specially pointed out that the square seal ring will expand when exposed to water. When installing the set screw (Figure 5-2), just hold it tightly, and do not use a wrench. Tighten. At the beginning of use, allow less leakage. Don’t be busy tightening. If there is leakage after 30 minutes, tighten the set screw 60 degrees. If the leakage does not change within 30 minutes, tighten again 60 degrees. If the leakage is reduced, then No longer tighten the fastening screws, it will naturally stop leaking.
7.2.2    Leakage between the pump body and the transmission case
             with a wrench, just tighten the pump body nut (Figure 2-26) .
7.2.3    Leakage of pump body and valve body:
             After removing the high and low pressure, set the high pressure handwheel seat (Figure 2- 21) Tighten the two hexagon nuts on the top (if necessary, add a long pipe to tighten) until it does not leak. If it still leaks, replace the high-pressure gasket (Figure 2-20). Pay attention to the parallelism of the gap between the valve body and the pump body during operation.
7.2.4    Leakage of pump body and gland:
        (1) GJJ series machine adopts axial end face seal (mainly medium and low pressure Homogenizer), remove the high, After the low pressure, tighten the four hexagon nuts on the gland 14 (if necessary, add a long pipe to tighten) until there is no leakage (Figure 1). If it still leaks, the gland gasket should be replaced and the gap parallelism should be maintained (same as above).
        (2) GJJ series machine adopts radial self-tightening seal—that is, adopts cone hole V-shaped seal assembly, ( Figure 6).
              It has the function of self-tightening static sealing, and the sealing is reliable. If there is leakage after installation, please pay attention to whether there is a gap C between the seat ring and the gland of the component. If not, you can remove the seat ring plane by 2-5mm and continue to use it. If it still cannot be sealed, you need to replace it. Matching into groups.
              Gland V-shaped seal assembly assembly:
              Check that the cylindrical surface must be smooth and free of scratches and burrs. Press (Figure 6) Type V The lower end surface of the sealing component should be about 1-1.5mm higher than the lower end surface of the conical column B1-1.5mm.
              Lock nut (Figure 6-5) to lock the limit column (Figure 6-5) 6-6), so it must be tightened with a wrench to tightly adhere to the lower end of the tapered column, and must not be flush with the lower end of the sealing component, because the sealing component must be lifted after the sealing component is stressed, and the lock nut will not work, that is, it will loosen. The limit column starts to limit the opening height of the upper spine spool, generally controlled at A: about 2.5-3mm. If the lock nut is loose, the opening between the limit column and the upper spool is not suitable. In severe cases, the upper spine spool Cannot be opened or broken.
             The gland and sealing assembly are installed in the pump body because the gland and sealing assembly is stressed The tapered cylinder tends to move upward along the back, the outer diameter of the component is enlarged, and the inner diameter tightly hugs the conical cylindrical surface, which acts as a radial seal. Therefore, when assembling, be sure to pay attention to the gap between the gland and the seat ring of the sealing component. : 5mm. The gland and sealing assembly should be installed into the pump body with a 4.5mm thick process gasket in the gap of C: 5mm, and then gently pressed into the pump body hole, until the gland has not touched the pump body ( 1-2mm), loosen the M12 screw on the gland, remove the process gasket, and then press the gland. The gauge seat gland is basically the same, but the V-shaped seal assembly should be pressed manually or vise as (Picture 6) The gap is installed. To prevent the sealing component from moving up along the tapered cylinder due to the fit when installing the hole, the outer diameter is enlarged, and the hole fit is tighter. After the maximum, although it is installed, there is a 5mm gap It no longer exists, so it affects the sealing performance and life of the gland. The gland nut does not need to be tightened, and the sealing effect is very good.
Note: The gland adopts a V-shaped seal with a tapered hole, which is somewhat reliable and has a long life.
Note that there are two ways to disassemble:
        (1) Loosen the gland nut and move it about halfway, then enter the water to start the Homogenizer, press 5Mpa (50bar ) The complete set of glands are put on top immediately, and then the gland nuts are unscrewed to remove them.
         (2) Unscrew the gland nut, loosen the M12 screw inspection 5mm between the two gland nuts, Use a crowbar or a big screwdriver to pry off the gland to remove it. For the gland of the pressure gauge seat, after removing the gland nut, you can directly use a crowbar or a big screwdriver to remove it. 

(a) Correct                       (b) Incorrect
Figure 6    Pump body gland A
1. Bolt   2. Gland   3. V-shaped seal assembly for the vertebral hole (the upper end is the seat ring, the lower end Is the pressure ring)  4. Conical column   5. Lock nut  6. Limit column  7. Upper vertebral valve core


a. Replace the V-shaped square seal assembly as follows:
       After removing the large nut of the pump body (picture 1-26), remove the pump body (picture 1-9) , The plunger seal sleeve (Figure 5-6) of the seal assembly can be taken out of the body, and then the plunger (Figure 5-1) and the set screw (Figure 5-2) can be unscrewed respectively, and then the pressure ring When the V-shaped (or square) seal assembly is pushed out (Figure 5-3-4), it can be assembled in reverse order when replacing it. Be sure to note that when assembling, the pressure ring (Figure 5-3) must be lower than the cutting groove of the seal inner sleeve. In order to ensure the longest service life of the sealing components.
b. Replace the square seal assembly as follows:
       Square seal assembly is composed of high pressure forming sealing ring and isolation ring, add one after every two sealing rings Spacer ring, there is also a spacer ring after the sealing ring.
       Clean the plunger sealing sleeve first, install the square positioning sleeve cushion ring into the sleeve, and then Press the square seal components into the sleeve one by one. There should be no gap between the end faces of each ring. The last seal ring must be lower than the cutting groove of the plunger seal sleeve. Then install the set screw. After the last, coat the surface of the plunger with edible oil, and slowly rotate it into the square seal assembly. After the plunger seal is replaced, the whole machine can be installed.

Figure 6  Schematic diagram of pump body valve structure B
7.3     Internal leakage
7.3.1   Pressure, insufficient flow:
             may be the feed inlet filter mesh or pipeline is blocked, causing suction Insufficiency, it can cause no flow and no pressure when it is serious, the pressure gauge pointer swings too much or does not display, the solution: clear the mesh or pipe blockage (usually do not install a filter, the user configures the external filter is better.
7.3.2   The flow rate is enough, the pressure can’t go up:
            If the high pressure does not go up, the high pressure valve core and valve seat are seriously damaged; the low pressure does not go up It may be that the low-pressure valve core and valve seat are severely worn. The solution: remove and repair or replace. The method is shown in Figure 7. The high-pressure and low-pressure valve seats can be blocked on a surface grinder for grinding; the high-pressure valve core is as shown in Figure 7. Figure 8 Grind the two end faces after clamping with a three-jaw chuck. The chuck must ensure the vertical accuracy requirements. If one end is worn, the other can be used. The low-pressure valve core can be used on the basis of the grinding of the valve seat. 200# green silicon carbide) is relatively grinded. In addition, due to the excessive reversal of the handwheel when the high pressure is released, the diameter of the mantle shaft sleeve on the handwheel is deformed, which is placed on the high pressure valve core, causing the pressure to not rise. The solution is to change The deformed part can be adjusted with a knife. An experienced mechanic will repeatedly grind the high-pressure valve seat until the protruding part is flattened before scrapping, and the high-pressure valve core will also be repeatedly grind until it is more than 1cm shorter, when the top of the rod When the valve core is not available, add a corresponding cylinder at the front end of the top of the rod, and use it as usual. When the ring groove is 1mm deep in the collision ring, it will affect the crushing effect. As long as the high-pressure valve seat is lowered or the collision ring is removed and adjusted To install.

Figure 7   High and low pressure valve seat grinding           Figure 8 High pressure valve core repair Grinding
1. Grinding wheel   2. Fixture  3. Magnetic suction cup      1. Grinding wheel 2. High pressure valve core 3 Clamp. 4. High pressure (low pressure) valve seat                 with (three-jaw chuck) 4. Magnetic suction cup
                
7.3.3    Insufficient traffic
             The discharge is pulse-shaped, and the pressure gauge pointer swings greatly (4-5 divisions ) Reason: (1) Because one of the six valves is not closed tightly and the valve surface is worn, it is necessary to re-grind the valve surface or replace a new valve. Its disassembly method (Figure 10), use a knocking rod (Figure 10-6) (Attachment 4) Knock out the valve seat from the pump body, usually use abrasive (200# green silicon carbide) to coat the contact surface between the valve core and the valve seat for relative grinding. When the valve is repeatedly ground, pay attention to the triangular end surface of the core core. The grinding wheel should be shorter, and the valve seat must not be extended. Do not extend it, otherwise, after installing the pump body, the angle of the vertebral valve assembly will not be closed tightly and leak. (2) The same is true. When installing the valve, you should also use a large force to knock the valve seat tightly, otherwise it will cause internal leakage and blow out the hole in the pump body. At this time, the pump body hole needs to be overhauled. (3) Due to the new machine or shutdown It takes a long time. Because the three lower vertebral valve seats and cores are stuck, you can unscrew the three screw plugs under the pump body (Figure 10-7) and use a screwdriver to poke upwards.

Figure 9   Disassembly diagram of valve turnbuckle
Disassembly method of valve and turnbuckle:
1. First remove the pressure plate (Figure 2-15) and then use a turnbuckle remover or screw to take the upper turnbuckle
  out (Figure 2-14).
2. Take the upper valve spring (Figure 2-16) together with the upper valve (Figure 2-13) by hand or with hand pliers
  out, and then use the valve seat remover (special tool) to take out the upper valve seat.
3. Use the valve seat remover to take out the lower turnbuckle (Figure 2-6).
4. With hand pliers, take out the lower valve spring (Figure 2-5) together with the lower valve.
5. After the valve is replaced or cleaned, it is assembled from bottom to top in this order. If the valve and valve seat are removed and cleaned, they should be put together properly Don’t miss it.

The flow is slightly pulsating, which is a leakage of the plunger seal of the pump body or the seal between the pump body and the box. Solution: Refer to 7.2 to eliminate It may also be that one or several valve seats of the six vertebral valves in the pump body are leaking from the mating surfaces of the holes in the pump body. The disassembly method is shown in Figure 10 to thin the adjusting gasket under the lower vertebral valve seat, and the upper vertebral valve The limit sleeve under the seat is ground a little lower to ensure a 0.5mm gap on the bottom surface as shown in Figure 11.12, and then use the tapping rod (Figure 11, 12-8) to tighten it.
Figure 10  Schematic diagram of the disassembly of the vertebral valve            Figure 10-12 Schematic diagram of the installation of the vertebral valve
1. Pump body     2. Vertebral valve core   3. Upper Vertebral valve seat   4. Limit sleeve   5. Lower vertebral valve seat    6. Knock rod      7. Screw plug     8. Knock rod (Attachment 3)       When disassembling or refurbishing the valve seat, please pay attention to the replacement<1> keep the opening height of the original core valve The upper spool is about 2.5-3mm, and the lower spool is 3mm; <2> The number of the spool and the seat must not be specified.
7.4     The pressure display is not normal, in addition to the above reasons, it is mainly caused by improper use
        The pointer of the pressure gauge and the ammeter swings a lot, and the pointer of the pressure gauge exceeds the range of three divisions.
      Reason: <1>When the machine is installed, the ground is uneven, and the machine shakes when it is running (the current meter indicates normal);&lt ;2>The feeding temperature is high, exceeding 85℃;<3>The feeding pipe is not smooth, the feeding is insufficient, and the gas is trapped; <4>The feed particles are relatively coarse and the thickness is uneven;<5> The material is too thick, too thick, and it is not rinsed when the machine is stopped, and the time is long to cause dryness and block the channel in the pressure gauge seat, such as the production of soy milk, starch, plastic, etc.; <6> The high-pressure spring in the handwheel seat is artificially compressed ;<7>Inadvertently moved the pressure gauge, causing leakage at the upper end of the damping device, air entering or insufficient internal damping; <8> Overpressure operation, the pressure gauge has been damaged. 
     <5> and <6> often the pointer does not start to rotate when pressing up, and it suddenly rises when it moves, even Full scale, broken hands.
Solution: 1. Read through the Homogenizer part and operate according to the chapter; 2. For faults <6>
Note that the cap-shaped nut on the handwheel should be loosened clockwise before opening, so that the high-pressure spring is in a natural state; 3. For < 5> Use ammeter to monitor, remove the pressure gauge, close the gland screw hole with M20×1.5 bolts, and use the pressure gauge for regular (usually one month) proofreading; 4. For <7> and <8> The pressure gauge can be disassembled and filled with silicone oil or the pressure gauge assembly can be changed.
7.5     The oil in the transmission box is easy to emulsify or the oil is carried into the sink by the connecting rod. For the former, the main reason is that the cooling water flow is too large. If the oil is brought out by the connecting rod, check the connecting rod rubber skeleton seal ring and its spring for possible damage, just replace it.
7.6     When the pressure is applied, it is found that the linear velocity of the plunger drops or the transmission belt is slipping. The main reason is that the transmission belt is too loose. Remove the rear side plate of the cover and tighten the tightening bolts on the motor base.


Table 3   General troubleshooting methods


Serial number

Failure content

General reasons

Exclusion method

1

Insufficient flow and pressure can’t be high

valve leakage, seal damage, homogenization valve leakage

check, repair, replace

2

The pressure gauge pointer jumps too much

Valve leakage, seal damage

Bad, bad pressure gauge components

Same as above

3

Uneven valve operating sound and large pressure fluctuations

Part of the valve is leaking

Same as above

4

Leaking fluid at the plunger

The plunger seal is worn out

Renew

5

There is an impact sound in the pump body

The plunger is worn, there is gas in the pump, and there is debris in the pump

Using a bleed screw to exclude, disassemble for inspection and exclude

6

There is a knocking sound in the transmission box

The connecting rod bearing bush or bushing is worn, the connecting rod bolt is loose, and the upper valve is leaking.

Replace, tighten, overhaul

7

Crankshaft bearing heats up

The bearing is damaged, there is debris in the bearing, and the bearing is poorly assembled

Replace, inspect, clean, reassemble

8

The slider is hot

There are debris on the working surface of the slider and the box body, and the lubrication hole is blocked

Disassemble, inspect, clean

9

Motor heats up

Damage to electrical appliances, high room temperature

Inspect, repair, take measures, lower the room temperature

 




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