The Perils of Cutting Corners in Feed Machine Production
In the world of three-in-one feed machines, a number of domestic manufacturers have opted to use substandard materials in an attempt to lower production costs. Unfortunately, this practice not only compromises the quality of the machines but also presents significant hidden dangers during maintenance. In this article, we delve into the consequences of using low-quality components in three-in-one feed machines, highlighting a real-life example of a faulty machine, and providing an in-depth analysis of the failure and its causes.
The False Economy of Inferior Air Filters
A common issue with substandard three-in-one feed machines is the use of poor-quality air filters. These filters tend to have large apertures, poor uniformity, non-compliant dimensions, and low filtration efficiency, resulting from the subpar materials used in their production. As a result, they fail to effectively remove harmful impurities, causing premature wear of the hydraulic station motor and ultimately reducing its lifespan—a classic example of being penny wise but pound foolish.
A Troublesome Repair Request: The Case of a Faulty Three-in-One Feed Machine
We recently received a repair request for a purchased three-in-one feed machine from a client, which exhibited the following symptoms:
- Difficulty starting after less than 500 hours of use;
- White smoke and weak motor performance upon using a low-temperature starting fluid.
Identifying the Causes of Feed Machine Failure
Our analysis of the machine’s failure revealed the following potential causes:
a. Obstruction in the low-pressure hydraulic oil circuit; b. Malfunctioning hydraulic oil pump and leakage in the common rail oil circuit; c. Multiple injector failures in the hydraulic station motor; d. Wear or improper clearance between multiple valves; e. Cylinder liner, piston, and piston ring wear, causing air leakage and insufficient compression.
Troubleshooting the Three-in-One Feed Machine Failure
Our troubleshooting process involved the following steps:
a. Investigating the white smoke emitted from the exhaust pipe; b. Checking the machine display screen for warnings or failures; c. Replacing the hydraulic oil filter and inspecting the hydraulic oil pipeline; d. Examining the hydraulic oil filler cap and starting the hydraulic station motor; e. Dismantling the hydraulic station motor to assess the wear on internal components.
The Root Cause: Inferior Air Filter and Premature Wear
Our diagnosis ultimately pointed to the root cause of the failure: an inferior air filter. The filter was not an imported genuine component and did not meet the required dimensions. This poor fit allowed unfiltered dust to enter the hydraulic station motor, causing premature wear and resulting in the machine’s performance issues.
The High Cost of Counterfeit Components
In this case, the use of a counterfeit air filter by the manufacturer led to significant damage and costly repairs. While a genuine imported filter cartridge costing around 900 RMB could have ensured the machine’s continuous, stable operation, the substandard filter resulted in a thirty-fold increase in replacement costs, amounting to over 30,000 RMB. This example highlights the importance of using high-quality components in three-in-one feed machines to prevent hidden dangers and ensure long-lasting, reliable performance.