"Science and technology are primary productive forces". The effective use of foreign advanced technology and equipment for production can not only increase the output and quality of products, promote the development of enterprises, but also greatly enhance and accelerate China's modernization. Imported equipment plays an important role in the production of enterprises because of its advanced technology. The technology of imported equipment is more advanced, mostly for numerical control equipment. Due to the rapid development of computer technology, the renewal of product production structure and the requirements of processing precision and geometric shape required for industrial development, the application of numerical control technology in the industrial field is extremely widespread. In the 1980s, our company introduced the Austrian Sierle diesel engine project, and imported equipment was used in large quantities to carry out the production of closed processes. In recent years, a lot of work has been done in the maintenance of the imported equipment, as well as in the maintenance of equipment, technical transformation, and the localization of imported equipment spare parts, and valuable experience has been gained. It has been applied productively and has achieved remarkable results. Obvious economic and social benefits. Second, the transformation of equipment 2, a reasonable implementation and verification. Third, the research and application of localization of imported equipment spare parts. Expanded Sheet Mesh,Expanded Metal Wire Mesh,Expanded Sheet Metal Wire Mesh,High-Rib Mesh Expanded Metal Sheet Anping County Zhuodi Wire Mesh Products Co.,Ltd , https://www.hebzhuodi.com
First, equipment maintenance
In order to adapt the maintenance of imported equipment to the needs of the development of modern enterprises, improve the quality of imported equipment, and improve the brand name effect of the company's products, we have achieved the principle of three-place in the maintenance of imported equipment.
1. Analysis of faults in place In past maintenance work, people were accustomed to finding faults and rectifying faults as the contents of maintenance work. In fact, this was only part of the maintenance work. In the maintenance of imported equipment, it is more important to analyze and determine the cause of the failure, so as to avoid countermeasures to prevent the recurrence of similar failures. Due to the shortage of imported equipment drawings and random data, maintenance personnel have little experience in the maintenance of imported equipment, and more careful and careful failure analysis is needed to avoid unnecessary equipment stoppages and wasted maintenance time. For example, after the K4960 twin-shaft hole boring machine imported from Austria was put into use, the spindle hole did not cross and the cross-cut unevenness occurred in our company. Due to the unfamiliarity with the machine tool, after the analysis and study by experts, it was decided to dismantle the import mast. Conduct targeted inspections and repairs. After dismantling the mast, it was found that the corrosion of the slider in the cross-cutting knife was serious, and the feed was uneven when the knife was raised. The fundamental reason was the unreasonable proportion of the cutting fluid and the poor lubrication of the slider inside the mast. If you do not carry out in-depth targeted fault analysis, blind inspection and repair, not only can not solve the root cause of the machine failure, but also will cause equipment failure, shorten the life of the machine tool, reduce the machining accuracy.
2. The measures in place The so-called measure is to completely eliminate the cause of the failure, so that similar failures no longer occur. In place of measures, it means that measures are effective and reliable. To use mature technology or structural principles based on existing conditions, do not appear new unreliable links and sources of failure. Given the many economic and feasible measures in the above examples, which one is better? It is necessary to consider the solution to the problems of the machine tool, but also to consider the cost of the consumption, if the daily cost of using imported chip liquid will be tens or even several hundred times higher than the cost of using domestic high quality chip liquid. Based on the above reasons, the measures we have taken are the use of domestically produced high-quality chip liquids to rationally match and enhance the mast seals and lubrication of mast slides. Through the use of high-quality oil seals for chip liquid protection, the sliders are lubricated with Mobil 3# Lubricating Oil, and these failures no longer occur after prolonged use.
3, maintenance records should be in place.
Taking this unit as an example, we monitor these imported equipment as bottlenecks in the production process and set up equipment maintenance records such as equipment maintenance records and equipment maintenance notices. The equipment maintenance records include: 1) equipment name 2) fault location 3) fault cause 4) fault category 5) solution 6) replacement spare part name and model 7) legacy problem 8) maintenance personnel 9) date and downtime . It is very convenient for each maintenance person to fill in carefully and make it easy for the maintenance of this equipment in the future. Equipment maintenance notices are filled out after maintenance of each shift so that they can be summarized. In addition, the maintenance center set up imported key equipment failure files, network management. Complete equipment maintenance records are an important guarantee for quickly finding faults and shortening maintenance time.
4, to strengthen the equipment inspection, pre-check pre-repair, so that the equipment predictive maintenance time cost is the weight of machine tool equipment maintenance costs, import CNC machine tool shutdown losses are generally 100 ~ 500 yuan / hour, large-scale machine tools even thousands of yuan / hour. In order to better save time and cost, pre-inspection and pre-repair of imported equipment, to achieve predictable maintenance, to solve the fault in the bud, is the future direction of equipment maintenance work.
In the late 1980s, imported equipment was at the international and domestic level both in terms of machining accuracy and processing efficiency, and automation. The imported equipment has made great contributions to our company's high-quality, high-volume products and has become a major supplier of high-speed diesel engine production bases in the fierce market competition.
However, with the passage of time and long-term use, the accuracy of some machine tools has dropped significantly, failing to meet the accuracy requirements of the products. In addition, the loss of various parts of the organization is also very serious. There are many problems and defects in the machine tool and the accuracy of new products cannot be met. After many years of experience in the maintenance of imported equipment, in order to make better use of imported equipment for production, we have gained valuable experience in the transformation of imported equipment.
1. The correct plan is half of the successful transformation.
After a reform project is proposed, a full and in-depth investigation and research is conducted on the objects to be transformed. My company's 4RPL and 5RPL Japanese grinders were introduced in the 1980s and are mainly responsible for the finishing tasks of the mainshaft and connecting rod necks of diesel engine crankshafts. Due to long-term work wear, the automatic grinding wheel dressing mechanism and the finished grinding wheels grind away. The workpiece roughness does not meet the process requirements of the product; R4 and R5 fillets do not meet the design requirements of the original machine tool. According to the above situation, after the argumentation and research of experts, technicians, and maintenance personnel, the selection of multiple sets of renovation programs established a set of programs that can meet the requirements of machine tool processing accuracy and meet the national gold-cutting machine tool standards. We redesigned and improved the working wear parts of the source dressing mechanism, and changed the original diamond grinding pencil to a new wheel-type multi-point particle diamond grinding wheel to improve the dressing accuracy and the R5, R4 forming accuracy. In terms of model reform, scientific calculations and certifications have been conducted on the trajectory of masters. The accuracy and form factor of the mold directly affect the dressing path of the grinding wheel and the accuracy of the machined workpiece. It is a key part of the dressing mechanism. Its success is ensured and the accuracy of the machine tool is ensured.
Determined the transformation of the machine tool program, in practice, installation, commissioning, verification must be in place, can not be a trace of omissions, this is the key to successful technical transformation. Taking the above reconstruction plan as an example, there are special persons responsible for the processing of various drawings of the prepared parts to the processing of the parts, and the quality of the outsourced standard parts must also be the first to meet the national standards. After all the preparatory work is completed, it is the key installation and commissioning phase. During the installation and commissioning process, we must seize the two principles of safety and reliability. In particular, the transformation of imported equipment, the reliability of the machine tool is the first. Without careful consideration in the interlocking of protection and security agencies, it will also lead to disasters. A successful transformation needs to be effectively verified in practice. The results of debugging and test cutting of the machine after the transformation are all in accordance with the theoretical analysis, reaching or even better than the original mechanism, and the equipment fully meets the technological requirements.
3. Revise the equipment data equipment reform Due to the change of function and structure, it is necessary to revise the random data and technical drawings of the original machine tool so that it truly reflects the technological transformation of the equipment. However, in the actual work, it has been found that some of the machine tool equipment transformation, especially some minor changes, did not make corresponding revisions and descriptions on the relevant technical documents, resulting in inconsistent with the actual situation of the file, seriously restricting the maintenance of imported equipment. Therefore, the revision of the revised equipment information is the improvement of the renovation and maintenance work.
The design precision of the imported equipment's components, subsidiary parts and fixtures is high. As computer technology, information technology, and automation technology are widely used in manufacturing, combined with the application of new materials and new processes, the precision of spare parts for imported equipment is very high. Its configuration and design according to systemization, standardization, and generalization are also relatively large. The flexibility and specificity have obvious technical advantages in processing accuracy and process.
With the passage of time, the failures of imported equipment have become more and more frequent. Factors that affect the quality of maintenance and the speed of maintenance mainly include the following aspects: 1) Few stochastic data can not accurately grasp the principle of equipment control; 2) It is difficult to damage parts in China Buy; 3) spare parts accuracy can not meet the requirements and so on. Among them, the most important factor is the spare parts. If spare parts work is done, other aspects are easy to avoid.
Although we have taken corresponding measures for spare parts, we have established special imported spare parts warehouses, set up special personnel management, and maintained contact with imported equipment dealers. However, the spare parts problem still faces three problems: First, our existing spare parts are basically With the purchase of equipment, the number of varieties is limited. In a few years of maintenance, a considerable part of the commonly used spare parts is no longer in stock. Second, some of the spare parts are often due to their speciality, specificity, and the purchase requires a huge investment, blindly Replacement of spare parts will result in high maintenance costs and affect the cost of the product. Third, with the rapid development of science and technology, many spare parts are replaced with new ones, and the purchase channels are not smooth, which will affect the production arrangements.
In light of the above, the localization of components for imported equipment is an urgent task facing us, with far-reaching significance and great development prospects. It is often reasonable and scientific to carry out selection and substitution, which can not only improve work efficiency, but also save a lot of money and achieve significant economic benefits.
Take our factory as an example, Austria's K4950 machine tool, its processing workpiece spindle hole, camshaft hole position degree requirements and coaxiality requirements are relatively high, is a high-precision equipment, respectively position ± 0.02mm, coaxial Degree 0.02mm. Accuracy mainly depends on the front, middle, and rear four molds of the 14th paid German bearing NA4890A/P5 (2 pay), B71930CTP4SDBL (2 pay), B71915CTP4SDBL (8 pay), B71924CTP4S•VT (2 pay) to ensure . In the equipment purchase and use, it cost more than 800,000 yuan to purchase a batch of this bearing as spare parts inventory. Because of the large processing tasks and the aging of machine tools, under normal circumstances, at least two replacements per month, and the high price of standard parts for imported equipment and a long buying cycle will directly affect the output and cost of the product. Therefore, the localization of imported equipment spare parts is very necessary. We tried to use domestic high-precision bearings for replacement. After the replacement, the accuracy, position, and coaxiality of the workpiece reached the process requirements. Through the localization of standard parts, maintenance costs are effectively reduced.
Through the maintenance of imported equipment over the years, our maintenance personnel have trained a large number of maintenance personnel with high-quality and high-tech capabilities from learning and groping maintenance to mastering imported equipment and technological changes. The continuous development of science and technology, let us work together to improve the level of maintenance of imported equipment, and strive to cultivate a high-quality imported equipment maintenance team.