Sand making machines (vertical shaft impact crushers or VSI crushers) are the key equipment in modern aggregate production, artificial sand manufacturing, and mining operations. However, like any high-speed mechanical equipment, they are prone to a range of operational problems that can affect efficiency, product quality, and safety. Below is a detailed look at the most frequent problems encountered during VSI crusher operation and the solutions.
1. Excessive Vibration
Cause: Worn or unbalanced rotor, loose bolts, or blockage inside.
Solution: Stop the machine. Clean the crushing chamber. Replace worn rotor parts in matched sets. Tighten all anchor bolts.
2. Bearings Overheating
Cause: Too little / too much grease, dirty oil, or overload.
Solution: Let bearings cool. Add correct grease or change oil. Reduce feed rate. Check and replace damaged seals.
3. Poor Sand Shape (flaky or too many fines)
Cause: Wrong rotor speed or worn tips/anvils.
Solution: Adjust rotor speed (higher for cubical shape, but watch fines). Replace worn wear parts immediately.
4. Low Output (production drops)
Cause: Worn feed tube or rotor, blocked chute, loose belts.
Solution: Check and replace feed tube / rotor tips. Clean the feed chute. Tighten or replace V-belts.
5. Too Much Dust
Cause: Poor seals or broken dust collector.
Solution: Close all inspection doors, replace rubber seals. Clean bag filters or upgrade dust fan. Use water spray (if allowed).
6. Metallic Clanging Noise
Cause: Loose rotor tip bolts or tramp metal (bolts, digger teeth) inside.
Solution: Stop immediately. Remove foreign metal. Tighten all tip bolts to correct torque. Install a magnet or metal detector on the conveyor.
7. Belts Slipping or Breaking Often
Cause: Wrong tension or misaligned pulleys.
Solution: Adjust belt tension with a gauge. Align pulleys with a laser tool. Replace all belts as a matched set.
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