What to do if the air compressor is operating normally and the supply is insufficient

When the air compressor is operating normally but the air supply is insufficient, it can be checked and dealt with in the following aspects:

1. Check for air leakage

Air leakage is a common cause of insufficient air supply for air compressors. Air leakage may occur at all links of the air compressor, such as external pipes, air supply pipes, check valves, safety valves, pressure switches and other connections.

Processing steps:

1. Switch off the air compressor power: Ensure safe operation.
2. Check the air leakage point: When the air compressor stops running, check whether there is any air leakage at each joint. You can use soapy water to apply on pipe joints and other parts that may leak to observe whether there are bubbles.
3. Repair air leakage problem: Once a leak is found, it should be repaired in time. It may be necessary to replace seals, fasten fittings, or replace damaged parts.

2. Check the air filter

If the air filter is blocked, it will affect the intake air volume, resulting in insufficient air supply.

Processing steps:

1. Switch off the air compressor power: Ensure safe operation.
2. Check the air filter: Check whether the filter is clean and whether there are dust and impurities blocked.
3. Cleaning or Replacing Filters: If the filter is dirty, you can use compressed air for purging. If the filter is already severely blocked, it is recommended to replace a new filter. It is generally recommended to replace the air filter every 1000-2000 hours. If the working environment is harsh, the replacement cycle can be appropriately shortened.

3. Check the air intake valve

If the air intake valve cannot be opened all or there is a fault, it will lead to a decrease in the air intake of the air compressor and insufficient air supply.

Processing steps:

1. Switch off the air compressor power: Ensure safe operation.
2. Check the air intake valve action: Observe whether the air intake valve can be fully opened when loaded. If the intake valve cannot be opened or is not fully opened, it may be a plug-in, a spring failure or a solenoid valve failure.
3. Repair or replace the intake valve: Repair or replace the intake valve according to the specific circumstances. It may be necessary to clean the valve spool, replace the spring, or repair the solenoid valve.

IV. Check the pressure sensor and control system

PressureA sensor failure or improper control system setting may cause the air compressor to fail to operate at the set pressure, which will affect the gas supply.

Processing steps:

1. Check pressure sensor: Use professional tools to check whether the pressure sensor is working normally and whether the output signal is accurate.
2. Check the control system settings: Confirm whether the loading and unloading pressure settings of the air compressor are correct. If the setting is too low, it may cause frequent loading and unloading of the air compressor, affecting the stability of the gas supply.
3. Adjust or replace the sensor: If the sensor fails, it should be replaced in time. If the control system is not set properly, it should be adjusted according to actual needs.

5. Check the operating parameters of the air compressor

The operating parameters of the air compressor (such as speed, pressure, temperature, etc.) are set unreasonably, which may also lead to insufficient gas supply.

Processing steps:

1. Check operating parameters: Use professional tools to check whether the speed, pressure, temperature and other parameters of the air compressor are normal.
2. Adjust operating parameters: Adjust the operating parameters of the air compressor according to the actual gas volume to ensure that the equipment is operating in the best condition. For example, increasing the speed can increase the exhaust volume, but attention should be paid to the load capacity and energy consumption of the equipment.

6. Check the wear of the air compressor

As the use time increases, the components inside the air compressor (such as the head, gearbox, belt, etc.) will gradually wear out, resulting in insufficient air supply.

Processing steps:

1. Regular maintenance: Perform regular maintenance according to the manufacturer’s recommendations and replace parts with severe wear.
2. Inspect the wear of the machine head: If you suspect that the wear of the machine head is severe, you can contact a professional maintenance personnel for inspection and repair. The wear of the machine head will cause serious internal leakage, which is usually accompanied by random head noise.

7. Check the increase in system load

As the production scale expands and the equipment increases, the air demand of the system will also increase accordingly. If the air supply capacity of the air compressor is not improved in time, it will lead to insufficient air supply.

Processing steps:

1. Evaluate the current gas supply capacity: Evaluate whether the current air compressor’s gas supply capacity meets production needs based on the actual gas usage.
2. Increase the number of air compressors or improve operating efficiency: If the gas supply capacity is insufficient, consider increasing the number of air compressors or improving the operating efficiency of existing air compressors. At the same time, production plans should be arranged reasonably to avoid concentrated use of large amounts of compressed air during peak periods.

8. Other precautions

1. Ensure the stability of the power supply: Unstable power supply may cause the air compressor to fail to work properly, affecting the gas supply.
2. Keep the environment clean: The air compressor should be placed in a well-ventilated and clean environment to prevent dust and impurities from entering the equipment.
3. Train operators regularly: Ensure that operators are familiar with the operating methods and maintenance knowledge of air compressors, and can detect and deal with problems in a timely manner.

Through the above steps to check and deal with the air compressor, the problem of normal operation but insufficient gas supply can usually be solved. If the problem persists, it is recommended to contact professional maintenance personnel for further inspection and repair.