I. Assessment of Abnormal Mechanical Operation
1. Abnormal Noise and Vibration: Unusual noises from the circulation pump or fabric guide wheel, or abnormal machine body vibration-distinct from the sound of smooth, normal operation-indicate potential faults in the pump or transmission components.
2. Leakage and Seal Issues: Dye liquor leakage at flange connections, valve shaft seals, or pipe joints, or unexplained fluid accumulation at the machine base, indicates loose or worn sealing components.
3. Abnormal Shutdowns: Unexpected automatic shutdowns without programmed commands, or a noticeable slowdown in fabric circulation speed (or the fabric stalling in the viewing port), indicate faults in the power or transmission systems.
4. Abnormal Nozzle Pressure: Nozzle pressure readings deviating from the process set range, or sudden pressure drops/instability, indicate insufficient pump power, pipeline blockages, or foreign objects obstructing the nozzle.
II. Assessment of Process Parameter Instability
1. Excessive Temperature Deviation: A deviation of more than ±2°C between the actual displayed temperature and the set process temperature, or a noticeably slow heating rate/localized overheating, indicates a clogged heat exchanger or a faulty temperature sensor.
2. Abnormal Liquid Level and Circulation: Unexplained fluctuations in the dye vat liquid level, or interrupted flow and uneven turbulence in the dye liquor circulation, indicate leaks in the circulation system or a clogged filter.
3. Excessive Foaming: A rapid buildup of foam that does not dissipate naturally, or fabric floating out of its normal operating path, indicates faults in the circulation system or issues with auxiliary agent compatibility.
III. Assessment of Abnormal Finished Product Quality
1. Regular Defects on Fabric Surface: Scuff marks or pilling appearing at fixed intervals on the fabric surface indicate burrs on the fabric guide wheel or nozzle edges, or misalignment of components.
2. Batch-wide dyeing defects: If large areas of the same fabric batch exhibit color spots, uneven coloring (mottling), or crease marks-and errors in process parameter settings have been ruled out-it can be concluded that the equipment has latent faults such as clogged dye piping or oligomer deposits.
3. Excessive color difference: If color variations between the left and right sides or the beginning and end of the fabric exceed standard limits-and factors related to dye uptake have been ruled out-it can be concluded that equipment malfunctions are present, such as uneven nozzle pressure or unsynchronized rotation speeds of the fabric guide rollers.
