In highly automated wet mixer granulators like the LHSZ20, the precise installation of top cover sensors (such as vibration or condition monitoring sensors) directly impacts the accuracy of data acquisition and the reliability of safety alerts. To ensure perfect rigid contact between the sensor and the equipment from the mechanical foundation, thereby thoroughly eliminating parasitic vibration interference, Hansheng Automation supports the exact manufacturing of high-precision sensor mounting bases, special double-ended stud bolts, and customized flange adapters based on customer design drawings. Leveraging outstanding multi-axis CNC precision milling technology, we strictly control the flatness and thread tolerances of the mounting surfaces, providing exceptionally sturdy non-standard mounting components for granulation machinery.
In practical operations, based on the material characteristics of the LHSZ20 granulator's top cover and on-site working conditions, engineers typically adopt the following three core installation methods:
The first is Drilling and Double-Ended Stud Bolt Fixation. This is the preferred rigid connection method for obtaining the best high-frequency response, applicable to metallic top covers with sufficient thickness that permit machining. During operation, a 5mm drill bit is used to accurately locate and drill a blind hole about 10mm deep at the designated position on the top cover, ensuring all metal debris inside the hole is thoroughly cleaned. Subsequently, one end of the double-ended stud bolt is securely locked into the hole, and the other end passes through the sensor mounting hole. A lock nut is then tightened applying standard torque to ensure absolute physical rigidity of the connection.
The second is Magnetic Base Installation. This approach is suitable for magnetic ferromagnetic metal surfaces and is particularly fitting for temporary monitoring points where the sensor requires frequent removal or regular calibration. Before installation, the paint or oxidation layer on the adsorption surface must be completely ground flat to expose the bare metal. The high-magnetic base should then be slowly and steadily applied to the metal surface at a slight angle. Direct vertical impact is strictly prohibited to prevent the instantaneous impact force from damaging the sensitive piezoelectric elements inside the sensor. In working conditions with severe vibration intensity, industrial-grade casting epoxy can be applied around the edges of the base for additional reinforcement.
The final method is Adhesive T-Bolt Installation. This is the most appropriate solution when dealing with thin-walled stainless steel, non-metallic top covers, or surfaces where penetrating the original pressure vessel structure is strictly prohibited. Operators must use anhydrous ethanol and sandpaper to deeply clean and roughen the bonding surface. Next, a high-strength structural adhesive or casting epoxy, such as DB8118, is evenly applied to the bottom of the T-bolt. It is pressed firmly to expel air from the contact surface and left to cure completely. Naturally, if the top cover material and explosion-proof conditions permit, micro-plasma arc welding or spot welding is highly recommended for securing the T-bolt to achieve superior long-term stability against detachment.
Regardless of the fixation method chosen, the installation location must be selected at a rigid node that truly reflects the vibration characteristics of the equipment's main shaft or chamber. Operators must absolutely ensure there is no looseness at the connection (requiring parasitic vibration displacement to be strictly controlled at ≤ 0.1mm). The total additional mass of the introduced sensor and its machined mounting base must be strictly less than 10% of the measured top cover's local mass to avoid altering the natural frequency of the original structure. Simultaneously, the sensor output cable must be given a buffer bend radius greater than 5cm to effectively withstand cable fatigue stress caused by the equipment's long-term, intense operation.
