In numerous fields with strict requirements for fluid purity, the brush self-cleaning filter of Xinxiang Lifilter has become a crucial piece of equipment. A deep understanding of its working principle, common fault analysis, and troubleshooting methods is essential to ensure the efficient and stable operation of the equipment.
The operation of the Xinxiang Lifilter brush self-cleaning filter is based on two closely coordinated processes: filtration and self-cleaning.
Filtration Process
Under the pressure of the pump, the fluid to be filtered flows in from the inlet of the filter. The fluid first comes into contact with a high-precision filter screen. Based on its fine pore size design, the filter screen can accurately intercept various impurities ranging from micrometers to millimeters, such as sediment, rust, suspended solids, and microorganisms. As the fluid continuously passes through, impurities gradually accumulate on the surface of the filter screen, while the clean fluid smoothly passes through the filter screen and flows out from the outlet to meet the requirements of subsequent processes or systems for pure fluid.
To meet different flow rate requirements, the filter screen is designed in a cylindrical or sheet shape. The cylindrical filter screen provides a large filtering area and is suitable for high-flow working conditions; the sheet filter screen is convenient for installation and maintenance and is often used in space-limited situations. The filter screen material is selected from corrosion-resistant and high-strength materials such as stainless steel and nylon to ensure long-term stable operation in complex fluid environments. At the same time, the surface of the filter screen has been specially treated to enhance the adhesion of impurities and ensure the reliability of the filtering effect.
Self-cleaning Process
When the impurities intercepted by the filter screen reach a certain level, preset cleaning conditions are triggered. There are usually two triggering mechanisms: differential pressure and timed. The differential pressure type is based on the pressure difference before and after the filter screen. When the pressure difference rises to the set threshold, it indicates that the filter screen is severely clogged and needs to be cleaned. The timed type starts the cleaning program periodically according to the preset time interval, which is suitable for situations where the impurity content in the fluid is relatively stable.
After the cleaning is started, the motor quickly rotates and drives the brush holder to rotate. The bristles closely attached to the brush holder, relying on their flexibility and toughness, sweep down the impurities accumulated on the surface of the filter screen during the rotation process. At the same time, the drain valve opens. With the assistance of the scouring force of the fluid itself, the impurities swept down are discharged out of the filter through the drain pipe, completing an efficient self-cleaning cycle. The entire self-cleaning process is fast and smooth and will not interrupt the normal filtration process of the fluid, ensuring the continuous and stable operation of the system.
Poor Filtration Effect
Regularly check the integrity of the filter screen. If damage is found, replace it with a high-quality filter screen of the same specification in time. When replacing, ensure correct installation and that the filter screen and the filter housing are sealed tightly without leakage points.
For situations where the impurity content is abnormally high, consider adding a pre-filtration device at the front end of the filter to preliminarily remove large particulate impurities and reduce the burden on the main filter; or adjust the cleaning frequency in a timely manner according to the actual working conditions to ensure that the filter screen always maintains a good filtering state.
Filter screen damage: Long-term impact by the fluid, abrasion by impurities, or aging of the filter screen material may cause holes or cracks in the filter screen, allowing some impurities to directly pass through the filter screen.
Improper installation: If the filter screen is not sealed properly during installation and there are gaps, the fluid will bypass the filter screen, resulting in incomplete filtration.
Impurity content far exceeding the design load: If the impurity concentration in the fluid flowing into the filter suddenly increases significantly and exceeds the processing capacity of the filter screen, a large amount of impurities will penetrate the filter screen.
Possible Causes
Troubleshooting Methods
Self-cleaning System Failure
If the motor fails, first cut off the power supply and use a multimeter or other tools to check the resistance of the motor windings to determine whether the motor has burned out. If it has burned out, replace it with a motor of the same model; if the starting capacitor is damaged, replace it with a capacitor of the original specification. After motor repair or replacement, conduct a no-load test run to ensure that the motor runs smoothly and without abnormalities.
Regularly check the condition of the bristles. When the bristles wear down to a certain extent, replace the brush holder assembly in time. If shed bristles are found, carefully clean them up to prevent further damage to the equipment.
For drain valve clogging, close the inlet and outlet valves of the filter, disassemble the drain valve for cleaning, remove the internal impurities, and ensure that the valve opens and closes flexibly. After cleaning, reinstall it and conduct a sealing test to ensure there is no leakage.
Motor failure: The motor may experience problems such as burnout and short circuit after long-term operation, resulting in the inability to normally drive the brush holder to rotate; damage to the starting capacitor of the motor will also cause difficulties in starting the motor.
Bristle wear or shedding: Frequent cleaning operations cause the bristles to gradually wear down and become shorter, losing their sweeping ability, and even shedding and getting stuck between the filter screen and the brush holder, preventing the brush holder from rotating.
Drain valve clogging: After long-term use, the drain valve may be clogged by the accumulation of impurities and cannot be opened or closed normally, affecting the discharge of impurities.
Possible Causes
Troubleshooting Methods
Excessive Pressure Loss
Immediately start the self-cleaning program. If the pressure difference still does not return to normal, manual forced cleaning can be carried out multiple times until the pressure difference is reduced to a reasonable range. At the same time, analyze the source of fluid impurities and optimize the front-end treatment process to reduce the impurities entering the filter.
Check the pipeline connection, correct the bends to ensure that the pipeline is straight; for the problem of sudden changes in pipe diameter, redesign the pipeline layout to meet the requirements of fluid mechanics and reduce resistance.
Severe filter screen clogging: Long-term failure to clean or excessive impurities in the fluid cause the pores of the filter screen to be filled with a large amount of impurities, and the resistance to fluid passage increases sharply.
Poor pipeline connection: Improper installation of the inlet and outlet pipelines of the filter, such as bends and sudden changes in pipe diameter, increases the flow resistance of the fluid.
Possible Causes
Troubleshooting Methods
The Xinxiang Lifilter brush self-cleaning filter achieves precise purification through a scientific and reasonable working principle. At the same time, mastering the analysis and troubleshooting methods of common faults can enable timely response to problems that occur during operation, ensuring the long-term stable operation of the equipment and providing solid support for the fluid treatment needs of various industries.
