What are the faults of fine mist sprayer

In the field of mechanical structure, nozzle clogging has always been a common problem in the industry. When the viscosity of the paint exceeds the tolerance limit of the equipment, solid particles will form deposits at the nozzle with a diameter of about 0.3 mm, which will lead to a significant reduction in the amount of spray, or even complete failure. Taking a textile factory as an example, due to the accumulation of scale caused by excessive water hardness, 30% of the fine mist sprayers had to be shut down for maintenance. This phenomenon not only affects production efficiency, but also increases maintenance costs. In addition, the solvent erosion problem of the piston sleeve rubber ring should not be ignored. When the operator fails to install the material pot cover according to the specifications, the pigment may penetrate into the sealing structure through the trigger part, causing the rubber ring to expand and deform, and eventually cause airtightness failure, seriously affecting the normal operation of the sprayer.

The failure of the circuit system shows obvious multiple characteristics. In high temperature environment, the sensor signal drift phenomenon is particularly prominent. Data from a production line of an electronics factory showed that when the ambient temperature exceeded 40°C, the error rate of the humidity sensor could be as high as ±8%, which would directly affect the closed-loop control of the spray volume and cause unstable spray effect. In addition, the failure of the overcharge protection of the power module also needs to be solved urgently. In order to improve charging efficiency, some manufacturers simplified the protection circuit, resulting in the battery swelling after two hours of fast charging. This design defect exposes its potential risks in frequent industrial use scenarios, which may cause equipment damage or safety hazards.

The technical bottleneck of the fluid control system is mainly reflected in the synergistic relationship between pressure regulation and atomization effect. When the pump pressure exceeds the design upper limit of 1.2MPa, the atomization angle of the nozzle will shrink from 60° to 35°, which will cause a sharp drop in the spray coverage area by 40%. A cigarette factory once caused a drastic change in the moisture content of tobacco due to pressure fluctuations, which eventually caused 20% of the products to be downgraded. In addition, the lack of adaptability of coating formulas is particularly significant in the beauty industry. The setting spray containing silicone oil components is prone to form an oil film under a specific nozzle structure, which in turn leads to blockage of the spray channel.

Under extreme working conditions, environmental adaptability defects are particularly obvious. In a cold storage environment of -10℃, the plastic shell of a certain brand of sprayer shrinks by 0.3%, which causes a 0.1 mm gap at the connection between the nozzle and the main body, causing continuous leakage. High-dust working environments also pose considerable challenges. A case study at a ceramics factory showed that dust particles accumulated at the atomizer air inlet, forming a filter cake as thick as 0.5 mm, causing the air pump efficiency to drop by 25%. This series of problems not only affected the normal operation of the equipment, but also had a direct impact on production efficiency and product quality.