To crush waste polystyrene foam, a foam crusher is used, the designs of which include a shaft crusher, a hammer crusher, a rotary crusher, and an installation that operates on the grater principle. This makes it possible to process materials of varying strengths. Regulating the operation of installations makes it possible to produce fractions of various sizes.
The principle of operation of a do-it-yourself foam crusher
In the production of foam chips the following is used:
- production of granules of a given size using a special technology by foaming polystyrene balls;
- waste recycling - shredding polystyrene foam residues in special structures for shredding polystyrene foam.
Crushed material is used in construction as a component of cement mortar to level the surface and form concrete floor screeds. The recycled foam product is the basis for the production of polystyrene concrete.
The expanded polystyrene shredder consists of the following components:
- grounds;
- motor casing;
- bunker;
- tank;
- damper handles.
The crushing chamber structure includes a body, a base, a knife plate and a mesh. Using an adjusting mechanism and a spring block, the distance between the rolls is set.
Waste foam is loaded into a tank, from where it enters the work area. During rotational movements, the shaft passes through the axes of the drum, the foam falls between the knives and is cut into fractionated parts.
The crushed material is removed from the working area for sorting onto a mesh with air. Large pieces of waste are again returned under the knife for grinding, and the crushed foam is fed into the dispensing hopper.
Cutting technology
Cutting technology and all the tools that are used for these purposes can be divided into two large groups:
- mechanical tool;
- electric.
Each method is worth considering separately.
Mechanical method
The mechanical method of cutting foam plastic involves the use of the following tools:
- knife;
- jigsaw;
- saws.
The first cutting method requires a sharp knife. Most often, a shoemaker's knife made of rapid is used for these purposes. Its advantage is a durable handle and a special sharpening angle. But this option is only suitable for those cases when it is necessary to cut foam plastic with a thickness of up to 4 cm. If we are talking about sheets with a greater thickness, then a blade of greater thickness will be required, because too thin can bend, which will lead the cutting line away. In addition, during the cutting process you will need to periodically adjust the blade, so you need to keep a stone of the required grain size on hand. After marking the foam sheet, you need to move the knife along the cutting line towards you, holding it at an angle. In some cases, you will need to make several passes to achieve the desired result. The blade needs to be adjusted every two meters of the cut.
Another tool that is great for cutting foam but produces a lot of waste is a hacksaw. In this case, it is necessary to choose a product with a fine tooth. A metal blade will not cope with the task effectively, so a hacksaw is used. Thanks to the longer length of the hacksaw blade, you can cut sheets with greater thickness. In this case, the best solution would be a hardened tooth without a large set, which will make the cutting line thinner. The advantage of using such a tool when cutting foam is greater safety, since the sharp part of the blade is not directed towards the body.
The power tool is also suitable for cutting foam. Excellent tools in this regard are the reciprocating saw and jigsaw. The difference between them is the speed and depth of cut. The effect is in many ways comparable to that achieved when working with a hacksaw. For work, it is better to purchase attachments with a minimum tooth blade for wood. Using a jigsaw gives you greater freedom when it comes to making shaped cuts. This is easy to do because the width of the canvas is small. The cut is more accurate by adjusting the speed of the blade. It is recommended to turn off the pendulum stroke that is applied to the wood during the process to reduce waste.
Note! If you don’t have any other tool at hand, you can use a grinder with a diamond blade to cut foam. In this case, the rotation speed must be selected so that it does not melt
Nichrome thread
The most comfortable way to cut foam is with a hot nichrome thread. With the correct selection of speed, it is possible to achieve a minimal seam and not melt the ends. The essence of cutting is that the sheet is passed through a wire along a marked line. You can make such a cutting device yourself. To do this you will need:
- LATR or transformer;
- nichrome thread;
- insulators;
- holders.
The thickness of the tungsten filament that will be used to cut the foam is 0.2 mm. It can be purchased at a specialty store or removed from household appliances. The first step is to install two posts, between which the thread will be stretched. This can be done in any convenient way that makes cutting easy. Insulators are fixed to the racks, which will prevent them from heating. Springs are mounted to the insulators to ensure constant thread tension. You can connect wires to them that will come from the LATR or from the step-down transformer.
A rheostat is a better source than a conventional transformer, since the power consumption, and therefore the heating temperature of the filament, can be easily adjusted depending on the thickness of the foam. A car battery can be used as a power supply if foam cutting is rarely done. In this case, the cutter acquires a certain autonomy and additional safety.
It is important for the design to choose the correct length of wire so that it is heated to the required temperature. The assembly process of such a cutting machine is described in detail in the video
Advice! An interesting cutting device can be made from a soldering iron with a power of 100 W. To do this, it is necessary to dismantle the factory tip and install in its place a thin metal plate or blade, which, when heated, will give an effect similar to a machine tool.
Video about making a crusher
To produce foam chips in artisanal conditions, you can make a crusher that works on the principle of a mechanical grater for vegetables. When assembling the crusher yourself, you use a welded metal box, inside of which two shafts with long teeth are mounted.
To make them, you will need two pieces of pipe, 50 cm long, 50 mm in diameter, with a wall thickness of 2.5 mm made of polyethylene. Wooden blocks are placed inside and adjusted to the size of the inside of the pipes.
At the specified distance, screws are not completely screwed into the pipe or rods are installed and secured in the drilled holes. As a result of rotation of the shaft with spikes when feeding foam into the tank, it is crushed.
Rules of operation and maintenance
In order not to encounter situations in which the circulation pump installed in the heating system will require repair, it is necessary to strictly follow the operating rules for such equipment, which are as follows.
- If there is no water in the pipeline, the circulation pump cannot be started.
- The amount of water pressure generated must be within the characteristics specified in the technical data sheet of the circulation pump. If the device produces a reduced or, conversely, increased water pressure, this can lead to its rapid wear and, accordingly, failure.
- During the period when the heating system is not in use, the pump must be turned on for circulation at least once a month for a quarter of an hour, which will prevent oxidation and blocking of its moving parts.
- It is very important to ensure that the water temperature in the heating system does not exceed 65°. In water heated to a higher temperature, sediment begins to actively fall out, which, interacting with the moving parts of the hydraulic machine, contributes to their active wear and, accordingly, failure of the entire device.
The circulation pump should be inspected and checked for correct operation monthly. Such measures make it possible to identify malfunctions in the operation of equipment at an early stage and promptly take appropriate measures.
Periodic checking of the circulation pump will significantly reduce the likelihood of its failure during the heating season
Types of foam shredders
There are several types of polystyrene foam granules, which are also called polystyrene foam balls, crushed foam, recycled material, and crumbs. Crushed foam is a material obtained by grinding. A shaft crusher is used for its production.
The shredder is designed as a grater that is mounted on a shaft. The movement of the drum on the shaft occurs with the help of a motor through a gearbox, which reduces the number of revolutions.
The waste pieces are fed through a guide pipe onto the grater. The adjusted gap between the cutting elements and the float holes determines the fraction of material at the outlet. If such an installation is located indoors and a dust collector is installed on the engine, then you do not need to use a protective casing around the shaft.
The hammer crusher is designed for crushing dense grades of molded foam while maintaining the throughput of the mechanism. A mesh installed at the outlet makes it possible to obtain small particles. The rotary design equipped with sieves has high productivity. The size of the output fraction is regulated by a calibrating grid.
Knife cutting
When insulating a floor or ceiling using foam boards, it is not at all necessary to use special equipment.
To cut polystyrene foam at home you need to have:
- Nice knife.
- A ruler more than one meter long.
- Pencil.
The procedure for cutting polystyrene foam boards in this way is quite simple:
- The starting and ending points of the cut line are first marked on the surface of the material with a pencil.
- Next, a ruler is applied to these marks, clamped, and an incision is carefully made along it with a paint knife (it is not necessary to completely cut off the piece of foam plastic).
- The polystyrene foam plate is turned over to the other side, and a cut is made in the same way, parallel to the cut already made.
- After making the cuts, you just need to break the foam along the line.
This method of cutting material is the cheapest, quietest and fastest, and there is practically no debris after finishing the work. Be sure to check the sharpness of the knife before cutting foam.
The benefits of crushed polystyrene foam
You can stuff upholstered furniture with crushed polystyrene foam.
Polystyrene foam, which is an excellent heat insulator and is produced using the foaming process, is used in crushed form for the following work:
- roof construction;
- insulation of pipes for various purposes;
- leveling the cement surface;
- production of polystyrene concrete blocks;
- increasing the sound and heat insulation qualities of some building materials.
Crushed polystyrene foam is often used as a filler for frameless types of furniture - sofas, armchairs. You can find it inside toys and even pillows.
To make a roof vapor barrier with your own hands, you need to follow the installation technology correctly.
We talked about how to make a vapor barrier for walls in one of the previous articles.
If you need to get enough of this material at home, a foam crusher can easily be made yourself. To create it, regardless of the chosen option, you will need an electric motor with a low rotation speed, a housing and a container for collecting foam chips.
Do I need a stabilizer?
After the parameters of the power supply have been determined, the availability of its stabilized and unstabilized voltage should be considered. The solution to this issue is relevant due to the fact that the network supplying a gas instantaneous water heater must have a stable voltage, without jumps in one direction or another.
Power supply with stabilizer Source oboiman.ru
Important! If there is no suitable power supply and you have to buy one, you can provide for this nuance already at the stage of selecting an adapter. There are models that stabilize the voltage or supply it as received.
The operation of the geyser involves receiving electrical power from batteries. The latter, in turn, (provided they are well charged) are a source of high-quality current and do not require additional stabilizing devices. Manipulations to change the element that powers the heater and does not have a stabilization unit; the piezoelectric element may not operate stably.
Structural elements of a gas flow-through heater Source turbo-yandex-ru.
Types of foam shredders
You can choose the type of crusher for foam plastic based on the amount of material. If the main task is to obtain 1-2 small bags of crumbs, you may not need to assemble a special unit at all to complete it. It is enough to use a metal brush, which is used to rub sheets of foam insulation, or a homemade “grater” from a box with cells. This method will be ineffective, but will avoid costs.
It is better to immediately purchase high-quality material for roof vapor barrier than to redo all the work later.
The method for installing a vapor barrier on the floor is somewhat different from installing it on the roof.
When is a performance check needed?
After another long period of inactivity , the unit needs to be checked; if it is delayed, there is a risk of not only losing heating, but also seriously damaging the equipment.
From the author: Hello, dear readers! The circulation pump plays a very important role in the heating system of almost any private home. Without this device, the coolant flows through the pipeline at a very low speed, resulting in significant wasted thermal energy losses. The result is an unevenly heated house and the danger of freezing of pipes located in non-residential premises - in the attic, basement, etc.
The circulation device easily prevents the mentioned problems. It increases the speed of the coolant flow, thereby giving the liquid the opportunity to quickly run along the route and deliver the required amount of heat to all radiators and other similar equipment. Naturally, to perform this function efficiently, the device must work flawlessly. That's why every homeowner should know how to test a heating circulation pump.
As you know, timely diagnostics can detect a malfunction even in the early stages of development, so a preventive inspection will help protect the device from possible serious damage. The nice thing is that performing the check will not take much of your time and effort, and almost any owner can handle the necessary repairs. Of course, to do this you need to have some information - and you can get it from today's article.
conclusions
Properly configured production of foam chips can bring a certain profit. The main thing is to provide a sufficient amount of raw materials and resolve the packaging issue. The granules are distributed into bags and bags and stored until used or sold. At the same time, the cost of servicing a ready-made crusher is relatively small - the main costs fall on paying for electricity (when connected to the network) or purchasing fuel (when using diesel engines).
Choosing the right adapter
The manufacturing process is simple, the only thing you should pay close attention to is the parameters of the power supply. The main characteristics of the adapter that interest us are indicated under the inscription “Output”. Naturally, they can have different meanings in different devices. In this situation, they must meet the following indicators:
- Input power – 220V.
- Output power – 3V.
- Power 500 mA.
Healthy! The output voltage of most mobile phone chargers is 5V. To lower it to the desired value, use the adjustable stabilizer LM 2596.
Determining the voltage of the power supply Source img.mysku-st.ru
Another situation concerns the moment of determining polarity. Finding the “plus” and “minus” on the outgoing wires of the charger is not difficult. To do this, you need to connect the device to a 220V network, and alternately check the contacts (internal and external) with an indicator. The one that, when touched, will cause the instrument’s light to light up and be “positive.”
How to check the heating circulation pump for serviceability
You can check in the following ways.
Ease of inclusion
To examine the performance of the equipment, it is recommended to check whether it is easy to turn on. After seasonal downtime, the condition of the unit must be checked.
To do this, it is recommended that after switching on, listen to the sounds that the equipment makes during operation. If there is no damage, the unit operates quietly .
If you hear various sounds, you will have to check the contamination of parts , the amount of water in the system, etc.
Presence of noise during operation
If the circular pump makes noise, it requires diagnostics or complete replacement. Sounds occur due to malfunction of the rotor or impeller , which can render the entire heating system unusable.
Sometimes noise occurs due to voltage drop . This happens due to imbalance and synchronization, which leads to uneven movement of the coolant.
Attention! Diagnostics are carried out only by a specialist .
If operation is stable, but the device still makes noise, it is recommended to check:
- Is the operating power of the unit equal to the initial values? If the calculations are similar, then the coolant moves too quickly or slowly, which leads to noise.
- Is the motor rotor in a horizontal position?
Bearing operation
Bearings tend to wear out and vibrate heavily.
They are responsible for rotating the impeller, so if the part is no longer suitable for use, it needs to be replaced.
Also, bearings sometimes become damaged and make knocking or squeaking noises. To eliminate the problem, disassembly and washing are carried out. A special worker does this.
How long do batteries last and reasons for frequent changes?
The service life of a chemical power source depends on the frequency of switching on the column and the correct adjustment of the equipment. If the standard conditions are met, the shelf life of the batteries reaches 6-8 months. Premature failure of elements is associated with problems with the operation of the electronic unit that generates the spark.
An additional reason for premature discharge of the power source is the low quality of the device (typical for batteries produced by small or little-known Chinese manufacturers).
Signs of a decrease in voltage at the contacts of the current source:
- drop in spark power; when the tap is opened, the burner does not ignite;
- Reducing the brightness or turning off the information display.
An increase in humidity in the room in which the heating device is located negatively affects the battery life. If the distribution valves are clogged or the sensors are broken, a second spark is generated, which leads to the discharge of the power source. The ingress of water vapor onto the contact pads leads to the formation of conductive paths, causing a short circuit and accelerated degradation of the battery.
No circulation, heating failure - why
Failure in the heating system, deficiencies, imperfections, all lead to cold radiators.
If there is no coolant circulation, then the reason needs to be determined. Most often, the answer to why the heating does not work is on the surface, obvious. Let's look in order at the main causes of heating malfunctions, why water does not circulate through the pipes, and what needs to be done first.
Let's start with the simplest and most obvious reasons.
It's clogged and clogged.
Every heating system must have a coarse filter. A very small device with a fine mesh and a sump (installed downwards! or at least to the side) saves equipment, pumps, and the boiler from coolant contamination that will be present in any system. Wood shavings, broken threads, rust, water sediment…. everything is retained by the mesh in the filter.
The sedimentation tank must be periodically untwisted and the mesh cleaned.
If the circulation in the heating system of a private house is disrupted, then the first thing you need to do is check the filter, which should be installed on the return line in front of the boiler.
Air in the system, airing
Airing can occur in any closed piping system where air removal measures have not been taken. Air is always present in the coolant, including in a dissolved state, is released during pressure changes, and accumulates at the highest points. Including in the boiler.
Automatic air vents are installed at characteristic, highest points of the system, as well as on collectors and special separators - the normal circuit is equipped with a special air catching device in which air bubbles are released from the coolant.
In addition, Mayevsky valves (manual air vents) should be on each radiator, and also possibly in other elevated places.
Checking the air supply, bleeding the air, installing air vents are common actions if circulation stops and the batteries are cold.
The circulation pump does not work
In private homes, the reason why the heating system stops working is a breakdown of the electrical equipment that controlled the movement of the coolant through the pipes.
If the heating suddenly stops working, then you need to check the functionality of the circulation pump near the solid fuel boiler or the pump in the automated boiler. In addition, the same unit can be installed in each circuit, which must work properly.
Bad polypropylene pipes
Often the consumer (customer) believes that polypropylene pipes are absolutely reliable and cannot cause heating problems or cold radiators.
But polypropylene is much more insidious than old steel or metal-plastic pipelines. Each place of soldering (welding) is a potential increased resistance in the system or a cause of cessation of circulation (weakened movement of water through the batteries), due to deposits of material inside.
It is impossible to control the quality of connections from the outside; all that remains is to cut out pieces, resolder, and remake polypropylene pipes.
Poor performance of a polypropylene system is a real problem for the home installer. Good professionals don’t take on this material at all.
Bad project
It is not uncommon for poor circulation to occur where there is poor design. Typically, the batteries are not connected correctly, according to some sequential circuit, where the last battery in the circuit receives much less coolant.
Another bad design is single-pipe circuits, where it is also difficult to establish the necessary coolant circulation through each battery.
If the radiators do not heat up evenly, or there is poor coolant circulation on individual heating devices, first of all you need to consider how the connection corresponds to the classic circuits - shoulder, associated, radial. It is necessary to bring home heating to normal design standards, and then expect good circulation and uniform heating of the radiators.
Small diameter, overgrown pipes
Old steel pipes become overgrown with rust and deposits from the inside, their throughput capacity decreases significantly over time, and there is only one solution - they need to be replaced with modern ones.
But even during installation, for the sake of economy, mistakes can be made with the choice of pipeline diameter - on mains, on groups of heating devices, diameters of 16 or 20 mm can be installed. The result is noise in the pipes, excessive consumption of electricity, and insufficient coolant flow. What pipe diameters should you choose?
A complex system
A type of bad design is an incorrectly designed complex heating system consisting of many heating circuits and several boilers. Here entire circuits will not work correctly if the work of one affects the neighboring one.
As a rule, one boiler (the backup one does not count) and three circuits - boiler, radiators, heated floors with their pumps are coordinated normally, and no questions arise. But if you connect another working boiler plus a circuit (for example, heating a garage and greenhouse), then the system will become complex. It is difficult to say how the coolant will circulate in it without equalizing the pressures at the connection points.
In complex systems, a competent design is important, installing a hydraulic arrow or an equal pressure ring; more information about the hydraulic separator can be found here
No balancing
Many home heating schemes involve balancing; balancing and control valves are installed in them. For example, between floors, between shoulders, and for each radiator. The taps cover the direction with less hydraulic resistance; accordingly, more coolant will flow to other points.
Children can play with the taps. Or the system is initially unbalanced. Setting up, as a rule, is no problem, you just need to find this tap... How to set up home heating
Neighbors don't provide heat
But complex heating project schemes are of little concern to residents of high-rise buildings, who have a separate riser for each radiator in the apartment. And if any radiator stops heating up normally, it means there is no circulation through the riser, therefore...
You need to contact the heating network, housing office (service organization) to adjust the power in the risers, and if this does not help, then with the requirement to check the neighbors.
Often, unauthorized connection or replacement of radiators and pipes in central heating systems leads to a redistribution of pressure, circulation through individual batteries decreases and disappears.
No circulation in gravity system
In gravity systems, the pressure difference is low; they are especially sensitive to air pockets, pipe diameters, and gaps in radiators.
In old circuits, gradual deposits occur in radiators and pipes; circulation may decrease over time, and the only cure for this is replacing everything with a more modern one.
You also need to pay attention to the correctness of the circuit itself - the middle heating line is below the cooling line (the boiler heat exchanger is below the radiators), and also - the hot feed rises up to the highest point, and from there it drops to the radiators... Read more about gravity flow circuits below
Various breakdowns in heating systems
- The taps and valves are closed - check that everything is open to ensure circulation.
- There is a leak in the system - there is not enough coolant, check the pressure, eliminate the leak.
- Installation with flexible pipes - the pipe is pinched.
- Failure of automatic equipment - thermal heads on mixing units, radiators, the mixing units themselves - silting, failure, it is necessary to check the correct operation. Also – electronic failure.
- Incorrect balancing on the distribution collector - in beam circuits, complex systems, collectors with balancing and tuning equipment can cause a lack of circulation anywhere due to breakdowns and incorrect settings.
- Low pressure, no air in the expansion tank - check the pressure in the pipes and the pumping of the tank; automated units will not work at all without the required pressure.
- Violation of the circuit, excess bypass - check that the installation complies with the design, the logic of the circuit, whether there are any short circuits in the jet, parallel branches to radiators and circuits.
How does the circulation mechanism work?
When the pump is turned on, the water in the heating system (in a closed circuit) is drawn into the inlet under the influence of the rotation of the wheel with blades. The water that gets into the chamber, due to the action of centrifugal force, is pressed against the walls of the working chamber and pushed out (into the outlet). Following this, the pressure in the chamber drops, which promotes a new injection of water into the pump reservoir.
Thus, during a continuous cycle of pump operation, the heating system can be in a state of a constant set temperature, which significantly reduces the cost of fuel or electrical energy consumption for heating water.
Important: the circulation pump is capable of processing water up to 95 degrees Celsius, which makes its use even more justified in individual heating systems. But it is not recommended to constantly drive water at this temperature through pipes. This will negatively affect the longevity of the equipment.
