Pneumatic vibrators use compressed air as their power source, resulting in low air consumption, safety, and energy efficiency. They are ideal for use in cold or high-temperature environments, and are compact, trouble-free, and easy to install and maintain. Pneumatic vibrators are widely used in powder processing industries, including food, pharmaceuticals, chemicals, pesticides, feed, ceramics, glass, cement, and fuel. They are suitable for fatigue testing of parts and structures; shaking and compacting hoppers; linear and bowl feeders, sieves, and filters; and vibrating tables and mixing equipment. Pneumatic vibrators are manufactured from a variety of materials, including carbon steel, cast iron, bronze, stainless steel, aluminum alloys, and extruded aluminum. For specialized applications, such as the pharmaceutical industry, the housing can be made of stainless steel.
Core Operating Principle of a Pneumatic Vibrator
The core power of a pneumatic vibrator is compressed air, and its operation can be divided into three stages. First, the intake phase involves high-pressure gas from an air compressor, which is introduced through a pipe into the vibrator's inlet, pushing the piston or rotor to initiate movement. For example, in the DAR series roller vibrator, this gas directly drives the rotor to rotate at high speeds, with frequencies reaching 8.000 to 38.000 min⁻¹, generating centrifugal force. Next comes the generation phase, where different vibrators generate vibration in different ways. Rotational vibrators (such as the GT series) use centrifugal force from the rotation of the eccentric rotor, producing a periodic oscillation with a frequency proportional to the rotational speed. Linear vibrators (such as the FP series) use high-pressure gas to reciprocate the piston, which impacts the target surface (such as the hopper wall) as it descends, generating a linear impact force. Compound vibrators (such as the FKL series) combine rotational and linear motion, using a special airway design to achieve single or intermittent impact modes to accommodate different material characteristics. Finally, the exhaust and circulation phase occurs. When the piston reaches its upward endpoint, the gas automatically switches direction through internal grooves and airways, entering the next cycle. This process requires no external control; vibration is maintained solely by a continuous air supply.
Correct Installation Methods for Pneumatic Vibrators
Proper installation of pneumatic vibrators requires a series of steps: First, determine the installation location. Select the appropriate installation location and quantity based on the model and specifications of the pneumatic vibrator, ensuring that the vibrator and the mechanical equipment work well together to achieve optimal vibration performance. Next, install the mounting base. Securely fasten the pneumatic vibrator's mounting base to the mechanical equipment, ensuring a secure connection between the base and the mechanical equipment to prevent loosening during vibration. Then, install the vibrator. Accurately mount the pneumatic vibrator on the mounting base. Adjust the amplitude and frequency to the desired values based on the model and specifications of the vibrator. Connect the power cord to the mechanical equipment, ensuring that the power cord is properly connected and secure to avoid short circuits or open circuits. Finally, test the vibration performance. After installation, perform a vibration test to ensure that the pneumatic vibrator's vibration performance meets your requirements. Further adjustments and optimization may be required, if necessary.
Before installing the vibrator, ensure that the mounting location is carefully selected to ensure optimal performance. The mounting surface must be clean and flat. Uneven mounting surfaces can cause the vibrator to malfunction due to torsional vibration of the vibrator body. The vibrator should be installed so that the rotation direction of the ball and roller supports the flow of the material as much as possible. The air intake direction can easily determine the correct installation position. It is recommended to use hexagonal or hexagonal screws with a grade of 8.8 or above. Use toothed locking washers or spring locking washers. Vibrators installed at high locations should be equipped with safety bolts to prevent the vibrator from falling and injuring people. Confirm that the vibrator is securely installed. It is recommended to retighten the screws after the vibrator has been operating for a few minutes. Vibrators installed on hoppers or material channels should not be operated when the hopper or material channel is empty, as this may cause structural damage.
Maintenance
If pneumatic vibrators are operated correctly, they require no maintenance. However, frequently operating pneumatic tools above the operating pressure will significantly reduce the tool's lifespan, so proper care and maintenance are essential. Pneumatic tools should be lubricated before and after use. Air motors should be lubricated daily, but not too frequently; weekly lubrication is sufficient.
How should pneumatic vibrators be maintained? Under normal circumstances, if pneumatic vibrators are operated correctly, they require no maintenance. We recommend regular inspections of the vibration system to ensure proper function. The system's frequency can be measured using a vibration meter. A change in frequency is always the first sign of reduced vibration energy.
Note: The frequency of a vibrator will vary depending on the size of the air compressor and the pressure storage tank. Please ensure that the measured frequency and energy are obtained with the pressure storage tank fully filled.
Regular maintenance of compressed air supply systems includes the following:
1. Check the air filter for dust and dirt. A clogged air filter will reduce the vibrator's energy. If clogged, clean or replace it.
2. Check the muffler for dust. A clogged air filter will reduce vibrator power. If clogged, clean or replace it. The FF muffler (for piston vibrators) can be disassembled into two parts and cleaned with compressed air.
3. Check the lubricator for sufficient oil.
Note: Vibrators often suffer damage from operating without oil in the lubricator. Therefore, someone should be responsible for refilling the lubricator and regularly checking its condition.
Pneumatic Vibrator Troubleshooting
If a vibrator fails to start, different methods are used depending on the type of vibrator: For piston vibrators, remove it from its mounting position, hold it upright, and turn on the air supply. If it works, check the internal starting spring. If the lubricant has dried out and caused parts to stick (primarily for FP- or DAR-type vibrators), add ten drops of kerosene (or gasoline) to the air inlet to dissolve the dried-on lubricant. If the air supply is suspected to be clogged, remove the muffler or exhaust pipe and turn the vibrator on. If it works properly, inspect the muffler or exhaust pipe. If clogged, clean it with kerosene or replace it. Also, check the air pressure to determine the source of the blockage. The blockage may occur in the compressor, the three-way connection (filter-regulator-lubricator), or the hose end.
When the vibrator cannot start every time, if it happens on a piston vibrator, it is because this type of pneumatic vibrator needs a few seconds of downtime before it can be started again. Too short a downtime will cause difficulty in starting. The time required for the piston to be pushed back to the starting position by the spring depends on the installation method. The longer the air supply pipe between the valve and the vibrator, the longer the downtime. A clogged muffler will delay the exhaust time. During testing, the muffler can be removed to make the vibrator work. If it works, clean or replace the muffler; if a short downtime is required (less than 4 seconds), it is best to use a three-way valve to ensure that the air supply pipe from the valve to the vibrator is quickly emptied when it is shut down; when using a manual valve, if the air pressure cannot be switched quickly, it will cause starting failure. It is recommended to use an electric or pneumatic valve; in addition, the diameter of the pipeline or valve is not large enough may also cause similar failures.
