I. Direct Observation: Visual Signs of Surface Wear
1. Significantly Increased Surface Roughness
A normal roller surface is smooth. Severe wear will result in obvious scratches, pits, or an "orange peel" texture.
A surface roughness comparison sample can be used for preliminary judgment. If the Ra value exceeds 6.3μm, it indicates excessive wear.
2. Large-Area Paint Film Peeling or Bubbling
The paint film on the roller surface not only prevents rust but also reflects the condition of the substrate. If the paint film adhesion decreases and peels off in large patches, it may indicate that the substrate has begun to corrode or fatigue crack.
3. Localized Dents or Uneven Wear
If obvious grooves appear on both sides or in the middle of the roller, it indicates uneven stress, which may lead to "vibration" during compaction or uneven road surface.
II. Structural and Dimensional Inspection: Quantifying the Degree of Wear
1. Wall Thickness Measurement (Key Indicator)
Use an ultrasonic thickness gauge to measure the wall thickness at multiple locations on the roller (especially the high-frequency contact area).
If the thickness of a local area decreases by more than 30% of the original design thickness, it is considered severe wear and poses a risk of structural failure.
2. Radial Runout Detection
Install a dial indicator and rotate the roller to measure the runout.
Acceptance Standard: Radial runout ≤ 0.5mm; if it exceeds 1mm, it indicates that the roller is deformed or the eccentric block is unbalanced, and replacement is required.
3. Roundness and Straightness Deviation
Use a laser alignment instrument or a straightedge + feeler gauge method for detection.
When the roundness deviation exceeds 1.5‰ of the diameter, it will affect the uniformity of compaction, leading to wavy patterns on the road surface.
III. Abnormal Operating Status: Indirectly Reflecting Severe Wear
1. Unstable Vibration or Obvious "Jumping"
Normal vibration should be smooth and powerful. If the machine body shakes violently and the direction is difficult to control during operation, it may be due to uneven roller mass distribution or bearing wear.
2. Abnormal Noises or Metallic Friction Sounds
A "clunking" or "rustling" friction sound during operation, especially at the start of vibration, may indicate severe wear of internal bearings, eccentric blocks, or seals.
3. Decreased Compaction Efficiency
If the compaction degree is substandard with the same number of passes, or if repeated compaction is required to achieve the desired effect, it indicates that the roller surface can no longer effectively transmit vibration energy.
