How can we ensure safety and accuracy during the operation of the corn air screen cleaning machine

During the operation of the corn air screen cleaning machine, to ensure safety and accuracy, systematic management should be carried out from four aspects: pre-operation preparation, in-operation monitoring, safety protection measures, and emergency response mechanisms. The following are the specific measures

I. Preparations before Operation: Conduct a comprehensive inspection to eliminate potential hazards

Equipment status inspection

Structural integrity: Check whether the casing of the cleaning machine, the screen, the fan blades, and the transmission components (such as belts and chains) are in good condition, without cracks, looseness or deformation.

Electrical system: Confirm that the motor and control cabinet are well grounded, and the insulation resistance is ≥0.5MΩ. Check if the circuits are aged or damaged to prevent short circuits or leakage.

Lubrication system: Check whether the oil levels of the bearings and gearboxes are within the normal range (at 1/2-2/3 of the oil gauge), and whether the oil quality is clean and free of impurities.

Air ducts and screens: Clean the remaining corn cobs, broken leaves and other debris in the air ducts to ensure their unobstructed flow. Check that the screens (such as fish scale screens and perforated screens) are not clogged or damaged, and the hole diameters meet the cleaning requirements.

Material and site preparation

Material screening: The impurity content of corn should be ≤5%, and the moisture content should be controlled at 12%-15%(if it is too high, it may stick to the screen mesh; if it is too low, it may produce dust).

Site clearance: Ensure that there are no flammable materials or obstacles within 5 meters around the equipment and that the passageways are unobstructed. The ground is flat to prevent the equipment from vibrating and shifting.

Safety signs: Post warning signs such as "Do Not Touch", "Beware of mechanical injury", and "Dust Mask Must be worn" at the equipment entrance, transmission components, electrical control box and other locations.

Personnel training and protection

Operation training: Operators must undergo professional training, be familiar with the structure, performance and operation procedures of the equipment, and master the emergency shutdown methods.

Personal protection: Wear a safety helmet, dust mask, goggles and anti-crush work shoes. Long hair should be coiled into a safety helmet. Scarves and gloves are prohibited (when approaching rotating parts).

Ii. Monitoring during Operation: Real-time observation and timely adjustment

Parameter monitoring

Motor current: Check every 15 minutes and it must not exceed 85% of the rated current. If the current suddenly rises, immediately reduce the feed rate or stop the machine for inspection.

Fan air pressure: Monitor whether the air pressure is stable through a pressure gauge (usually 0.8-1.2kPa). If the air pressure is too low, it may lead to incomplete cleaning; if it is too high, it may blow away qualified grains.

Screen surface vibration: Observe whether the vibration of the screen body is uniform, without abnormal shaking or offset. If the screen surface is clogged, the machine needs to be stopped for cleaning.

Discharge port: Check the separation effect of light impurities (such as broken leaves, corn cobs), heavy impurities (such as stones, soil lumps) and qualified grains, and adjust the air volume or the inclination Angle of the screen surface in time.

Feed control

Uniform feeding: Use a screw conveyor or vibrating feeder to control the feeding speed to prevent material accumulation from causing screen surface overload or fan blockage.

Foreign objects are strictly prohibited from being mixed in: Metal blocks, wooden blocks, woven bags and other non-sortable items are strictly forbidden to enter the equipment to prevent damage to the screen or fan blades.

Exception handling

Abnormal sound/vibration: Immediately stop the machine for inspection to determine if it is caused by loose screen, damaged bearings or unbalanced fan impellers.

Dust leakage: Check whether the dust removal system is operating normally and whether the sealing parts are aged. Replace the damaged sealing strips or dust removal bags in time.

Excessively high temperature: If the bearing temperature exceeds 70℃, the machine should be shut down for cooling and lubricating grease replenished. When the motor temperature is too high, check whether the cooling fan is operating normally.

Iii. Safety Protection Measures: Multiple safeguards to reduce risks

Mechanical protection

Transmission component protection: Install protective covers on rotating parts such as pulleys, chains, and couplings. The distance between the protective covers and the rotating components should be no less than 50mm.

Screen protection: The screen frame must be firm to prevent grains or debris from splashing and injuring people if the screen breaks.

Feed inlet protection: Install an openable protective door to prevent personnel from accidentally touching the rotating parts inside the feed inlet.

Electrical safety

Grounding protection: Ensure that the metal casing of the equipment is reliably grounded with a grounding resistance of no more than 4Ω.

Leakage protection: Install a leakage circuit breaker with an operating current of ≤30mA and an operating time of ≤0.1s.

Emergency stop device: Emergency stop buttons are set at easily operable positions in the control cabinet and equipment to ensure that the power supply can be quickly cut off in an emergency.

Dust control

Dust removal system: Equipped with pulse bag dust collectors or cyclone dust collectors to ensure that the dust concentration is ≤10mg/m³(below the occupational exposure limit).

Ventilation design: The working area of the cleaning machine should maintain good ventilation to prevent dust accumulation that may cause explosions or occupational diseases.

Iv. Emergency Response Mechanism: Quick response to minimize losses

Emergency response plan

Fire/Explosion: Equip dry powder fire extinguishers or carbon dioxide fire extinguishers and regularly check their validity periods. No open flames are allowed around the equipment. "No Smoking or Open Flames" signs should be set up.

Personnel injury: The operation site is equipped with a first aid kit, which includes items such as tourniquets and sterilized gauze. Regularly organize emergency drills to ensure that personnel master first aid skills.

Equipment failure: Develop a flowchart for troubleshooting and clearly define the handling steps for common faults (such as screen blockage and abnormal noise from the fan).

Shutdown and maintenance

Normal shutdown: First, stop feeding. After the material on the screen surface is completely discharged, turn off the fan and motor. Clear the residual materials in the equipment to prevent mold or corrosion.

Emergency stop: After pressing the emergency stop button, immediately cut off the power supply and hang a "Do Not Close" warning sign. Before maintenance, power-off procedures must be completed and a dedicated person should be assigned for supervision.

Maintenance safety: When entering the interior of the equipment for maintenance, it is necessary to go through the hazardous operation permit procedures and wear protective equipment such as gas masks and safety belts. Use a safe voltage of 36V or less for lighting.

Maintenance record

Establish equipment operation logs to record daily operation time, feed volume, parameter adjustment conditions and abnormal events.

Regularly analyze maintenance data, replace vulnerable parts (such as screens and bearings) in advance, and extend the service life of the equipment.