common problems

1. Large-scale construction machinery and mining equipment

This is the primary and most demanding application area for large nylon dust rings.

• Large Mining Excavator(e.g. Liebherr R 9800, Caterpillar 6090): the bucket cylinders and bucket rod cylinders are huge, and the dust rings are correspondingly huge.

• Ultra-large hydraulic supportIn coal mining, the hydraulic support columns that support the roof plate have huge cylinder diameters and require large dust rings to withstand the high dust and humidity of the underground environment.

• Large mining dump truck(e.g. Buellas, Komatsu 930E): the huge lifting cylinders that lift the carriages, working on the bumpy, dusty roads of the mines, the dust rings are vital.

• Tunnel boring machines (shield machines): Its main propulsion cylinder group and cutter shield cylinder, working in the harsh environment of mud, water and slag, the reliability of the dust ring is directly related to the digging efficiency.

2. Large-scale water conservancy and hydropower and gate opening and closing equipment

• Giant hydraulic cylinder for sluice gate/boat gate openerFor example, the hydraulic cylinders of the Three Gorges Dam locks are huge in size and are exposed to the outdoors for a long period of time, which requires the dust ring to have excellent weather resistance and durability.

• Large hydraulic dams: The hydraulic cylinders that control the lifting of the dam surface are immersed or exposed to water for a long period of time, and need dust rings to effectively prevent the intrusion of mud and sand.

3. Heavy metallurgical equipment

• Hydraulic cylinders for rolling mill press down device: Working in a high temperature, iron oxide filled environment, the dust ring needs to be resistant to high temperatures and effective in scraping away hard particles.

• Hydraulic cylinders for steel furnace tilting mechanism: Withstand high temperatures and heavy loads in extreme working conditions.

4. Marine and offshore engineering

• Hydraulic cylinder for ship's rudder: The rudders of large ships are so powerful that hydraulic cylinder dust rings need to resist marine salt spray corrosion.

• Hydraulic Cylinder for Offshore Platform Lifting System: e.g. hydraulic cylinders for lifting and lowering the pile legs of jack-up drilling rigs, exposed to harsh marine environments.

• Synchronized lifting hydraulic system for ship locks and floating docksThe

5. Special equipment and heavy vehicles

• Large military equipment: e.g. suspension and turret hydraulics for tanks and armored vehicles.

• Special Transportation Vehicle: e.g. hydraulic suspension systems for heavy hydraulic flatbed trucks (SPMT) carrying rockets, bridge modules.

I. Core performance advantages (why use nylon slider)

• Self-lubricating and low friction: Nylon itself has a low coefficient of friction, allowing it to operate with no or little oil lubrication and reduced maintenance.

• High abrasion resistance: Withstands frequent sliding and vibration and has a long service life.

• light weight: The density is only about 1/7 of that of metal, which effectively reduces the inertia of the moving parts of the equipment.

• Impact resistance and vibration absorption: It can effectively absorb vibration and noise, making the equipment run more smoothly and quietly.

• corrosion resistance: Good resistance to most chemicals such as alkalis, alcohols, oils and fats.

• Easy Installation: Easily machined into a variety of shapes and at a low cost.

II. Main applicable categories of equipment

1. Material handling and conveying equipment

This is one of the most widely used areas for nylon sliders.

• belt conveyor: Used asGuide Chute SlidemaybeSweeper sliderIt protects the conveyor belt from abrasion and effectively scrapes away adhering material.

• chain conveyor: Acts as a sliding block in the rail, reducing metal friction between the chain and the rail, reducing noise and wear.

• forklift trucks: For sliding pads on the gantry to make fork lifting and lowering smoother.

• Elevator/Stacker: As a guide slide in a guideway system.

2. Construction machinery and heavy equipment

• bulldozers: Widely used in buckets, buckets and other connection parts of thebushingcap (a poem)bushings, reducing pin wear.

• Bulldozers/loaders: Sliding support points for shovel blades, tracks, etc.

• crane: Acts as a liner in the sliding mechanism of the telescopic arm to ensure smooth telescoping.

3. Automated production lines and industrial robots

• Linear Modules: It can be used as a light-duty slide or limit block in applications where precision is not required to be extremely high.

• Flow line workbench: For sliding parts of fixtures and positioning mechanisms.

• Robot end-effector: Serves as a cushion or sliding part to avoid hard collisions with the workpiece.

4. Machining equipment

• CNC machine tools: Used for sliding guides for auxiliary mechanisms such as tool magazine doors and guards.

• Stamping equipment: As a bushing for a mold guide pillar, or as a sliding part of a feeding mechanism.

5. Rail transit and vehicles

• Train/subway doors: Widely used in door slides to ensure smooth and quiet door opening and closing.

• sunroof: Serves as a support block for the sliding sunroof glass.

• Seat adjustment mechanism: In slides used for forward and backward movement of the seat.

6. Warehousing and logistics equipment

• Shelving system: Used on the chassis rails of compact shelves and mobile shelves to make the shelves mobile and lightweight.

• sorter: As wear-resistant liners in chutes, manifolds, etc.

7. Other common equipment

• gym equipment: e.g. seat slides for fitness equipment, weight block guides.

• Door and window hardware: Pulleys and sliders for heavy-duty sliding doors and windows.

• agricultural machinery: Such as harvesters, planters and other parts that require sliding and friction reduction.

I. Core installation process: localized, solid as gold

Ceramic liners can be installed in a variety of ways, depending on the equipment conditions, shape and temperature and other factors to choose the most suitable program.

1. Bonded fixation - the most common and economical choice

• Applicable Scenarios: Flat or large curvature equipment surfaces, such as silos, chutes, flat plates, etc., at room temperature or low to medium temperatures (generally <100°C).

• process::

  • surface treatment: Thoroughly clean the surface of the substrate to remove rust, oil and old coatings and wash with acetone or alcohol to ensure dryness, cleanliness and roughness.

  • Gluing and gluing: Choose special high-strength ceramic-metal adhesive and mix it evenly according to the proportion. The adhesive is applied to the back of the ceramic liner and the equipment substrate by "spot coating" or "full coating".

  • compact: Fit the liner tightly to the substrate, press firmly and tap gently to make the adhesive layer even and full and to expel air.

  • Curing maintenance: Maintain at the specified curing time and temperature, during which movement or vibration is strictly prohibited.

• dominance: Easy construction, lower cost, uniform stress distribution.

• crux: Surface preparation is at the heart of success or failure, and the choice of bonding agent is critical.

2. Welding fixation method - dealing with high temperatures and strong impacts

• Applicable Scenarios: Highly wear-resistant, heavy shock load conditions, such as coal mill outlets, high-temperature air ducts, sintering equipment and so on.

• process::

  • Substrate preparation: Pre-drilled or welded bolts in the equipment substrate or ceramic liner.

  • Liner in place: Slip the ceramic liner over the pre-welded bolts or punched holes.

  • weld fastening: Use special welding rods to securely weld the bolt caps or grommets on the back of the ceramic liner to the equipment substrate.

• dominance: Extremely high connection strength, excellent heat resistance and high impact resistance.

• crux: It needs to be operated by professional welders to ensure the quality of welding and avoid false welding.

3. Tongue & groove (mosaic liner) - ideal solution for complex surfaces

• Applicable Scenarios: Elbows, reducers, cyclone separators and other curved equipment with complex shapes.

• process::

  • Liner in placeThis liner consists of numerous small ceramic pieces connected by a special rubber or fiber backing to form a flexible "blanket".

  • fixed installation: It can be fixed directly to the equipment by pressing strips, bolts or direct bonding, and can easily fit all kinds of complex curved surfaces.

• dominance: Flexible and convenient installation, no installation dead angle, good resistance to impact and thermal shock.

• crux: Installation needs to ensure that the liner fits tightly to the substrate to avoid gaps.

The Universal Golden Rule of Installation::

• logical layout: Pre-layout should be carried out before installation, staggered paste, as in the case of masonry walls, to avoid through-joints, in order to disperse the stress.

• gap control: Leave a gap of 0.5-1cm between boards to cope with thermal expansion and contraction.

II. Guidelines on scientific maintenance: prevention and long-term stability

The completion of the installation is only the first step, scientific routine maintenance and regular inspection is to ensure long-term stable operation of the cornerstone.

1. Daily inspection "look and feel"

• towards: Observe the surface of the liner periodically to check for unusual cracks, large areas of peeling, or signs of severe wear.

• auscultation: Listen to the sound of the equipment running, if there is an abnormal sound of material flushing, it may indicate that the local liner has fallen off.

• grind: When shutting down for maintenance, gently tap the liner with a small hammer to determine whether there is any hollowing or delamination by the sound.

2. Focusing on "critical areas"

• facing the material (e.g. the front face of a building): Areas of direct material impact are where the most wear occurs and should be a top priority for inspection.

• Welds and interfaces: Check for cracked welds and loose bolts at welded fastening points.

• Equipment elbows, tees, and other redirections: These areas are subject to large variations in flow velocity and angle of impact and increased wear.

3. Timely "quick fixes for minor ailments"

• local repair: When a single piece or small area of liner is found to be damaged, stop the machine in time for partial replacement. Remove the old rubber and residual boards and repair them according to the original installation method.

• Avoid running with disease: The loss of a small piece of liner can trigger a "domino effect", resulting in accelerated damage to the surrounding liner as material is washed over it.

4. Establishment of "maintenance files"

• Record the time, location, cause and method of each installation, inspection and repair. This helps analyze wear patterns and provides data to support the next overhaul and spare parts procurement.

I. Core performance advantages (basis for application)

• Extremely high wear resistance: The hardness is second only to diamond, and can effectively resist material scouring and abrasion.

• Excellent corrosion resistance: Resistant to most acids, alkalis, salts and other chemical media.

• High strength and toughness: Higher impact resistance and less fragile.

• light weight: The density is only about half that of steel, which reduces the load on the equipment.

• Low coefficient of friction: Smooth surface, not easy to stick material, can reduce conveying resistance.

II. Main application industries and specific scenarios

1. Electricity industry (coal-fired power plants)

This is one of the most widely used areas for ceramic liners, which are mainly used to solve the severe wear and tear of equipment caused by coal dust and ash.

• coal transportation system: Anti-friction lining for coal fall pipe, hopper, chute, deflector plate, fan snail shell and other parts.

• Powdering systems: Coal mill outlet ducts, separators, primary air ducts, etc.

• Ash removal system: Dust collector hoppers, fly ash conveying piping, valves, air chutes, etc.

• flue system: Anti-friction coatings or linings for induced draft fan impellers and casings.

2. Iron and steel metallurgical industry

The industry has a large number of high-temperature, highly abrasive material conveying and handling processes.

• Raw material transportation and dosage: Lining of blast furnace raw material silo, coke silo, vibrating feeder, sinter chute.

• Blast Furnace System: Piping and distributors for pulverized coal blowing systems, furnace top receiver hoppers, pressure equalizing discharge pipes.

• Steelmaking systems: Dedusting ducts, flues, iron oxide powder conveying equipment.

• Sintering & Pelletizing: Ring cooler chute, vibrating screen, finished ore bin lining.

3. Cement and building materials industry

The entire production process, from raw materials to finished products, is accompanied by heavy wear and tear from dust and particulate matter.

• Raw material preparationRaw material mill, cement mill inlet and outlet ducts, powder selector, V-type powder selector chute lining.

• Clinker cooling and conveying: Skid from grate cooler to clinker storage, clinker crusher inlet, clinker conveyor.

• Pulverized coal preparation: Coal mill system piping, cyclone separator, pulverized coal silo.

• Dedusting and Exhaust Air Treatment: Preheater cyclones, humidification towers, dust collector hoppers.

4. Mining industry

Involved in the mining, crushing and conveying of ores, the wear and tear is extremely severe.

• Ore Crushing: Crusher chamber, impact plate, inlet liner.

• Ore Conveying: Lining of mine silos, chute shafts, vibrating ore dischargers, and chutes in belt conveyor transfer stations.

• Ore sorting: Heavy media sorting tanks, magnetic separator chutes.

• Tailings Transportation: Tailings pipes, cyclone liners.

5. Chemical industry

It mainly utilizes its dual properties of corrosion and abrasion resistance.

• material handling: Pipes, elbows and silo linings for corrosive and abrasive chemical materials (e.g. catalysts, salts, plastic granules).

• Reaction equipment: Anti-friction layer for certain mixing equipment, fluidized bed reactors.

6. Port Terminal and Machinery Manufacturing

• port handling: Hopper and chute liners for ship unloaders, ship loaders, stacker reclaimers, for loading and unloading bulk materials such as coal, ores, grains, etc.

• machinery manufacturing: Used as wear-resistant components on fan impellers, mixer blades, pump housings and other equipment.

7. Other industries

• grain processing: Used for wheat, corn, rice and other grains conveyor skid, elevator base, because of its smooth non-stick, not easy to contaminate the grain.

• paper industry: Lining of pulp conveying pipes and silos.