With the high-quality advancement of infrastructure construction in my country, the application scenarios of asphalt mixing plants are continuously expanding, playing a crucial role in everything from expressways and municipal main roads to rural road renovations. As the core equipment for producing high-quality asphalt mixtures, its operating status is closely linked to the efficiency, cost, and quality of construction projects. However, it is important to note that asphalt mixing plants operate under harsh conditions of high temperature, dust, and heavy loads for extended periods. Core components are prone to wear and tear, pipeline aging, and parameter drift. If daily maintenance is neglected, minor problems can easily escalate into major malfunctions, leading to downtime losses and potentially affecting project progress and quality.Therefore, establishing a scientific and comprehensive daily maintenance system is crucial for ensuring the stable operation of equipment, and it is also one of the core focuses of ACE Group’s services to its customers.
Routine maintenance is not simply about “fixing things,” but rather a systematic management process that spans the entire lifecycle of the equipment. Its core value is reflected in the following four dimensions, which also serve as the core principles for ACE Group’s maintenance solutions for its clients:
1. Extend the entire lifecycle of the equipment.
2. Ensure stable production efficiency.
3. Reduce overall operating costs.
4. Ensure the quality of construction work.
1. Precise lubrication and maintenance
• Lubrication of core components: For key moving parts such as the mixing unit bearings, gearbox, drying drum support rollers, and drive chains, use lithium-based grease or gear oil that meets the requirements specified in the equipment manual, and add or replace them periodically (e.g., lubricate the mixing unit bearings every 50 hours, and replace the gear oil in the gearbox every 2000 hours);
• Lubrication System Inspection: Check the oil level and oil quality of the lubrication station daily. If the oil is cloudy, contains impurities, or the oil level is below the warning line, filter or replace the oil promptly. Regularly check the oil pipes and nozzles for blockages or leaks to ensure the lubrication system is functioning properly.
2. Comprehensive cleaning and maintenance
• Screening and Conveying System: Clean the surface and surrounding areas of the screening machine’s screen daily to prevent screen blockage; regularly clean the hoppers and inner walls of the belt conveyors and screw conveyors to prevent material adhesion and accumulation;
• Dust removal and heating system: Regularly clean the filter bags of the bag filter dust collector, check for any damage to the filter bags, and ensure that the dust removal effect meets the standards; clean the caked material and deposits on the inner wall of the drying drum to prevent affecting heating efficiency and drum balance;
• Electrical control and hydraulic systems: Regularly clean dust from inside the electrical control cabinet and check that the cooling fans are working properly; clean oil and dust from the surface of the hydraulic power unit’s oil tank, and check for clogging of the hydraulic oil filter.
3. Thorough inspection and precise adjustment
• Fastening Inspection: Daily check that all connecting bolts, anchor bolts, and fasteners are not loose, especially on components with significant vibration such as the mixing unit and drying drum. Tighten any loose fasteners immediately.
• Transmission system adjustment: Regularly check the tension of the transmission belts and chains; if they are loose, adjust or replace them promptly; check the coaxial alignment of the sprockets and pulleys to prevent misalignment and abnormal noises during operation;
• Weighing System Calibration: The weighing system (aggregate scale, asphalt scale, and powder scale) shall be calibrated at least once a week using standard weights to ensure that the measurement error is within the equipment’s allowable range;
• Combustion system adjustment: Regularly check the combustion status of the burner, observe the flame color and shape, and adjust the air-fuel ratio promptly to ensure complete combustion of the fuel and prevent black smoke emissions and excessive fuel consumption.
4. Replace vulnerable parts promptly.
• Mixing system: Regularly inspect the wear of the mixing blades and liners. Replace them promptly when the wear exceeds the design threshold (e.g., when the blade thickness is reduced by 1/3).
• Conveying system: Check the conveyor belt for surface wear and edge damage. If cracks or delamination occur, repair or replace the belt promptly; check the idlers and rollers for smooth rotation, and replace them immediately if jamming or abnormal noises are detected;
• Screening system: Check the screen for damage and deformation. If there are holes or material leakage, replace the screen immediately;
• Sealing components: Regularly inspect the O-rings and gaskets in the oil and air lines, and replace them promptly if they show signs of aging or leakage.
5. Specialized maintenance of electrical systems
• Line inspection: Regularly check the insulation of cables and wires for damage or aging, and check for loose or overheating connections. Repair or replace any faulty components promptly;
• Component inspection: Check the working condition of electrical components such as contactors, relays, and sensors, and clean any oxidation from the contact surfaces to ensure good contact;
• Safety protection: Check that safety devices such as emergency stop buttons, limit switches, and residual current devices are functioning correctly; regularly clean the cooling channels of the electrical control cabinet to ensure the internal temperature is maintained below 40℃.
1. Develop a customized maintenance plan.
2. Strictly implement the maintenance plan.
3. Strengthen professional training for maintenance personnel.
4. Establish a comprehensive equipment database.
5. Conduct regular equipment performance assessments.
1. Do maintenance schedules need to be adjusted under different operating conditions?
Yes, it is necessary. If the equipment is operating in harsh conditions such as high temperatures, high dust levels, and continuous heavy loads (e.g., construction in high temperatures during summer, aggregate processing near mines), the maintenance cycle needs to be shortened (e.g., daily lubrication cycle shortened by 1/3, cleaning frequency increased to twice a day). If the equipment is used infrequently and the operating conditions are good (e.g., intermittent construction in small municipal projects), the maintenance cycle can be appropriately extended under the guidance of professional personnel, but the inspection and calibration of core components cannot be omitted.
2. What key points should be considered when replacing wear and tear parts?
It is necessary to select original or high-quality replacement parts that match the equipment model (such as the dedicated wear parts provided by ACE group) to avoid equipment damage caused by incompatible parts; before replacement, the installation area must be cleaned and polished to ensure a proper fit; after replacement, a test run should be conducted to verify the working condition of the component; at the same time, keep a record of wear part replacements and establish a consumption ledger to facilitate timely replenishment.
3. During the maintenance process, which safety points require particular attention?
Before electrical maintenance, the power must be switched off and a “Do Not Energize” sign must be posted, and the work must be performed by a qualified electrician; for work at height (such as cleaning the drying drum or inspecting the dust collector), safety belts must be worn and safety protection facilities must be erected; when cleaning high-temperature components (such as the drying drum and burner), wait until the equipment has cooled to a safe temperature to avoid burns; during maintenance, keep away from moving parts of the equipment to prevent entanglement and injury.
4. How can we determine if the maintenance work is effective?
This can be verified through three key indicators: whether the equipment failure rate has decreased (e.g., a reduction of more than 50% in monthly failure incidents); whether production efficiency is stable (e.g., achieving the target output of mixed materials per unit time, without production reductions due to equipment problems); and whether the quality of the mixed materials is qualified (e.g., the proportion accuracy and temperature stability meet the design requirements). Simultaneously, by comparing energy consumption and spare parts costs before and after maintenance using equipment historical data, the return on investment of the maintenance efforts can be evaluated.
1. Construction of concrete mixing plants to support the construction of new highways/major municipal roads.
2. Maintenance of upgraded and renovated older concrete mixing plants
3. Concrete mixing plants in remote areas/harsh environments (such as high-altitude or high-temperature desert regions)
4. Batching plants for small-scale municipal engineering projects/rural road maintenance
In the future, Asian Construction Equipment Group Co., Ltd. will continue to provide comprehensive maintenance support to its customers, including customized maintenance plan development, professional technical training, genuine spare parts supply, remote fault diagnosis, and on-site maintenance services. This will help customers maximize the value of their equipment through scientific maintenance management, ensuring the high-quality advancement of infrastructure construction. If you have any questions or needs regarding the daily maintenance of your asphalt mixing plant, please feel free to contact Asian Construction Equipment Group Co., Ltd. professional service team.
Notice: The product case studies, performance data, and customer feedback presented in this article are for industry exchange and reference purposes only, and do not constitute a guarantee of applicability to any specific scenario.
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