In daily use, the counting template and vibration feeder of rotary counting filler need to be maintained regularly to ensure its stable operation, accurate counting and extended service life. Here's a detailed maintenance plan for the two core components:
I. Maintenance of statistical templates
1.Cleaning and blocking
Daily maintenance:
Residual Tablet Cleaning: _ Use a soft brush or compressed air to remove tablet powder, debris, or adhesives from the template holes to prevent clogging and counting errors.
Alcohol wipes: Disinfect template surface with alcohol (especially for the pharmaceutical industry) to prevent cross-contamination and remove grease or electrostatic dust.
Weekly maintenance:
Deep Cleansing: After removing the template, soak it in an ultrasonic cleaner with neutral detergent to remove fine particles (such as crystalline drug powder) completely. Make sure it's completely dry before installing.
2.Worn and replaced
Monthly Inspections:
Hole Size Measurement: Use calipers to check if the template hole diameter is enlarged by prolonged friction (standard hole diameter deviation should ≤ 0.1mm). If the aperture exceeds tolerance, it should be replaced immediately to prevent tablet leakage or blockage.
Edge Chamfering Inspection: Make sure there is no chip or burr on the edge of the hole to avoid scratching the surface of the tablet,especially the coated tablet.
Replacement Criteria: templates need to be replaced in the following cases:
hole wear results in a counting error rate greater than 0.5%;
:: Template deformation (e.g. bending > 0.5mm) affecting the fit of dispensing plates;
Surface corrosion (applicable to equipment used in humid environments).
3. Lubrication and rust
Quarterly maintenance:
Light Lubricant Application: Apply food-grade lubricant (such as silicon-based grease) on the contact surfaces between the template and the rotary shaft to reduce friction noise and prevent rust.
Rust control: If the equipment is not usable for a long time, rust inhibitor (e.g. WD-40) should be sprayed on the surface of the template and store in a dry environment.
ii. Vibratory Feeder Maintenance;
1. Vibration Mechanism Inspection and Adjustment
Daily Pre-Start Inspection:
:: Tightening bolts: ensure that the retaining bolts on the base of the vibrating feeder and spring bracket are not loosened to avoid unstable feed due to vibration frequency deviation.
State of spring: Check vibration spring for breakage or permanent deformation. Replace springs if height change is greater than10%.
Weekly Adjustment:
Vibration Frequency correction: The actual frequency of the vibratory feeder is checked with frequency meter (deviation ≤ 5%). Calibration according to eccentric block angle or inverter parameters.
Amplitude optimization: Adjust the amplitude to the shape of the pill (for example, increase the amplitude to reduce overlap of irregularly shaped tablets pills) to ensure a single layer of flow in orbit.
2. Track and Feeder Cleaning
Shift maintenance:
Track cleaning: uses compressed air to blow tablet powder off the track, focusing on removing grime from bends and narrow openings to prevent tablet jamming.
Demagnetization: If the tablet contains a metal component (such as coated tablets), use a magnetic rod to clean iron filings from the feeder to avoid scratching the track surface.
Monthly deep cleaning:
Removal of Trackss: remove the vibratory feeder track, wipe the contact surface with an alcohol swab, remove powder attracted by static electricity and restore smooth flow of tablets.
3. Electrical Component Maintenance
Quarterly inspections:
Sensor Calibration: cleaning transmitters and receivers of photovoltaic sensors. The sensitivity of sensors is tested using standard tablets to ensure that individual tablet signals are accurately recognised.
Line inspection: check whether the power cord and signal wires of vibration feeder are damaged or loose to prevent short circuit or signal interference.
Annual change:
Electromagnet Coil: If the vibratory feeder is electromagnetic driven, check coil resistance (standard ± ±10%). If the tolerance is exceeded, replace the coil to maintain vibration intensity.
III. Maintenance Precautions
Safe operation: disconnect the power supply the equipment before repair, and set up ``do not operate"sign to prevent accidental start and mechanical damage.
Remove electrical components using insulation tools to avoid electrocution risk.
Spare Parts management: Maintain inventory of commonly used spare parts (such as templates, springs and sensors) to ensure rapid replacement in case of damage and minimize downtime.
Record the replacement cycles of spare parts and prepare procurement plans in advance.
Maintenance records: create maintenance files to record changes in the time, content, replacement parts and equipment operating parameters of each repair to provide a basis for fault analysis.
