Analysis of Common Problems with Oil-Free Air Compressors: How to Avoid Failures and Extend Service LifeIn today's pursuit of efficient and environmentally friendly industrial production, oil-free air compressors have become an important equipment in many industries, but they are not without drawbacks. Oil-free air compressors, as important equipment in industrial production, are highly favored by industries such as healthcare, pharmaceuticals, food, and electronics due to the pure and oil-free compressed air they provide. The gas they discharge contains no oil or oil vapor and will not pollute the end products of users. It is an environmentally friendly and energy-saving product. As the simplest and most ideal equipment for providing high-quality oil-free compressed air, it eliminates the need for complex oil filtration equipment, thereby saving a significant amount of equipment costs and maintenance expenses. However, oil-free air compressors are not perfect. Users often encounter various problems during their use, and only by thoroughly understanding these issues can they better utilize and maintain these devices. 01 The core advantages of oil-free air compressors Compared with traditional oil-lubricated air compressors, oil-free air compressors have significant advantages. They do not require the addition of lubricating oil, and the gas they discharge contains no oil or oil vapor. This fundamentally solves the problem of oil contamination in compressed air affecting product quality. This makes the oil-free air compressor particularly suitable for use in sectors such as healthcare, pharmaceuticals, food and beverage processing, postal and telecommunications, petrochemicals, electronic pneumatic instruments, painting, powder and granular gas transportation, air mixing, film sensitization, construction engineering, materials, and national defense research, where high-quality oil-free compressed air is required. As a general power air source, oil-free air compressors are more convenient to use and have lower maintenance costs compared to oil-lubricated air compressors. At the same time, they eliminate the need for complex oil filtration equipment, saving a significant amount of equipment expenses and maintenance costs. In the long run, this offers remarkable economic benefits. 02 Analysis of Common Faults of Oil-Free Air Compressors Rotor coating detachment
The poor rotor coating will fall off after being in operation for a period of time. The rotor will then be exposed to the air, subject to the influence of impurities in the air and temperature changes. Eventually, this leads to a decrease in operating performance and even causes damage to the machine. This is a drawback that needs to be noted for oil-free air compressors. 2. Lubrication system issues Although it is called an "oil-free" air compressor, some components still require lubrication. An oil-free lubricated air compressor may experience a "wearing out of the bearing" accident due to insufficient oil supply in the lubrication system. Excessive bearing temperature is a major problem for centrifugal oil-free air compressors. The main manifestations are as follows: the main oil pump is damaged while the auxiliary oil pump fails to supply lubricating oil in time; the oil supply system leaks or breaks, or the oil pipes are clogged; the oil level in the oil tank is too low, resulting in insufficient oil supply. 3. Excessive exhaust temperature The water quality of the circulating water system is poor, causing scale formation on the pipe walls and resulting in high exhaust temperatures. Heat dissipation is also a major issue for the oil-free silent air compressor, as it operates at a high speed and generates a large amount of heat during operation. During the operation of the permanent magnet oil-free air compressor, high temperatures may occur due to faults in the frequency conversion non-oil equipment. At this time, it is necessary to check whether the heat dissipation channels of the frequency conversion non-oil device are blocked. Pay attention to whether the heat dissipation fan is damaged and replace or repair it in time to handle the issue. 4. Insufficient exhaust volume Sometimes during the operation, the equipment suddenly lacks sufficient exhaust gas. At this point, you can check the intake filter of the variable-frequency oil-free air compressor to see if there is any dust accumulation or reduced exhaust volume due to it. Or, if the inhalation tube is too long and the cross-sectional area of the pipe is too small, the amount of gas will decrease and cannot pass through smoothly. The exhaust pressure of the oil-free silent air compressor is generally low, and the exhaust volume is usually not large, making it difficult to meet the gas supply requirements over a wide range. 5. Electrical system failure The permanent magnet oil-free air compressor is prone to damage the main board during long-term continuous operation. Once the main board is damaged, the internal components of the equipment cannot function properly and the air pressure cannot be released. During the operation of the variable frequency permanent magnet oil-free air compressor, there is usually voltage instability. Once the voltage becomes unstable, a load phenomenon will occur, and even the variable frequency oil-free air compressor will be unable to change the cylinder pressure. Fast capacitor discharge can cause the click to fail to start, thereby burning out the motor. The motor power of the oil-free silent air compressor may be insufficient, which can easily lead to motor burnout. 6. Wear and tear of mechanical components The piston rings and packing of oil-free air compressors are usually made of polytetrafluoroethylene. However, this type of machine has poor lubrication and a high failure rate. The rubber cups and cylinders are prone to wear and tear. When the bearing clearance is too large, it will generate considerable noise. One-way valves and elbows are usually made of zinc alloy and are one-time use items, and cannot be disassembled and repaired. During long-term operation, centrifugal oil-free air compressors may cause excessive vibration of the bearings. If the impeller becomes bonded or worn, it will disrupt the dynamic balance accuracy of the rotor, thereby affecting the operating accuracy of the bearings. The wear of the journal and the bearing bush causes an excessive or uneven gap between them, resulting in errors and causing vibrations. 7. Surging issue Surge is a unique phenomenon that occurs in centrifugal oil-free air compressors during operation at a certain point.
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