Flexible processing production line is an efficient and flexible production method that can quickly adjust the production and output of the production line to meet changes in market demand. However, due to the long-term use and high-intensity operation of production line equipment, the wear, failure and damage of equipment will also increase. In order to ensure the normal operation of the equipment and improve the efficiency of the production line, regular maintenance and repair of the equipment is necessary. This article takes the flexible processing line introduced by our company as an example, combined with our experience in equipment maintenance, to discuss the characteristics of the production line, the purpose of equipment maintenance, maintenance methods, maintenance management, etc.
1. Characteristics of flexible processing lines
The flexibility of the flexible production line is embodied in the co-production of multiple products, and the processed quantity of each product can be adjusted at any time according to changes in demand. The equipment utilization rate is high and a seamless connection can be achieved. It has five processing units, three parts loading and unloading stations and a material storage and transportation system. Compared with rigid automated production lines, flexible manufacturing production lines have relatively centralized processes, no fixed production pace, unified logistics routes and mixed-flow processing to achieve high efficiency and low cost under conditions of production in medium and small batches.
2. Objective of equipment maintenance
Equipment maintenance refers to a series of maintenance measures such as regular inspection, cleaning, lubrication, calibration and shutdown maintenance to extend the life of the equipment, reduce breakdowns and downtime, reduce production costs, ensure stable operation of the production line, and improve production efficiency. . According to surveys, 70% of equipment failures are caused by insufficient equipment maintenance and upkeep. This means that strengthening equipment maintenance and upkeep can reduce most breakdowns, thereby improving equipment reliability and efficiency. Specifically include the following aspects:
(1) Extend the life of the equipment. Through equipment maintenance, equipment faults and problems can be discovered in time and dealt with quickly to extend the service life of the equipment.
(2) Reduce breakdowns and downtime. Through equipment maintenance, equipment can be repaired in time, defects and downtime can be reduced, and the stable operation of the production line can be ensured.
(3) Reduce production costs. Through equipment maintenance, equipment breakdowns and downtime can be reduced, as well as maintenance and production costs.
(4) Improve production efficiency. Through equipment maintenance, the stable operation of the equipment can be guaranteed, the production efficiency and product quality can be improved, and the economic benefits of the production line can be improved.
(5) Avoid accidents. Ensure that the equipment is always in good technical condition to avoid quality and safety accidents during processing.
3. Equipment maintenance methods and content
(1) Equipment maintenance
CNC equipment is a high-tech product that integrates mechanical, electrical, hydraulic, pneumatic, computer control, detection and measurement, electric drag technology and other technologies. Routine maintenance involves a wide range of contents and involves many departments, which requires high technology, knowledge and capabilities of the relevant personnel. Equipment operators should be well aware of the performance status, daily conditions and production phenomena of the CNC machine tools used. Operators must have the ability to perform routine maintenance on equipment.
Equipment maintenance methods mainly include the following aspects:
①Daily maintenance: Daily maintenance is mainly done by visual observation, including cleaning, lubrication, tightening and inspection of equipment. Clean the exterior and interior of the equipment to keep it tidy.
②Regular equipment maintenance: Regularly clean various parts and components of the equipment to ensure the cleanliness of the equipment and reduce damage to the equipment caused by dust, dirt, grease and other impurities.
③ Minor equipment repairs: Shut down the equipment for maintenance and carry out comprehensive inspection, cleaning, lubrication, calibration and replacement of various parts and components of the equipment to ensure the performance and service life of the equipment. the equipment.
④Calibration: Regularly calibrate various parameters and functions of the equipment to ensure the normal operation and accuracy of the equipment.
(2) Content of maintenance
The maintenance content of flexible processing line is divided into two parts: maintenance of processing equipment (NH6300DCG) and maintenance of linear pallet library (LPP) system.
1) Before each shift, it is necessary to confirm that the cutting oil, hydraulic pressure and lubricating oil are sufficient. If the equipment is not started regularly or for a period of time, the spindle should be preheated to make the spindle reach the ideal processing state, ensure the processing accuracy and prolong the service life. The specific spindle speed and warm-up time are shown in Table 1.
Table 1 Spindle speed and warm-up time are shown in the table
During daily maintenance, we often ignore the importance of filters. It is generally believed that a filter and a piece of filter cotton will not play a big role. In fact, the filtering device can not only filter cilia and other debris in the air, but also filter floating fine metal dust, which is especially important for electrical components. The electrical cabinet fan filter adheres to the sealant very easily during use, blocking the normal heat dissipation of the fan. Long-term obstruction will damage the fan and require regular cleaning. When cleaning, use neutral detergent to soak or wipe the dirt, then hold the filter flat and use a vacuum cleaner or high pressure air to clean it. Don’t forget to wash it by hand. The filter life is 3-5 times.
After each shift, clear the spindle tools, reset each axis, turn off the power, and clean the equipment processing room and tool magazine. Clean the iron filings on the end face of the spindle and wipe the tapered hole of the spindle with a lint-free cotton cloth. High pressure air blowing is not allowed to prevent iron filings from blowing inside the spindle. spindle cleaner for turning and cleaning. Finally, inject Stamina RL2 lubricating oil into the bottom of the spindle hole for 1 second (see Figure 1).
Figure 1 Spindle Lubrication
2) The maintenance content of linear pallet (LPP) warehouse system includes three parts: AGV, loading and unloading station and storage rack.
The AGV (Automated Guided Vehicle) in the flexible processing production line is an efficient automated transportation equipment (see Figure 2). It mainly includes components such as bodywork, wheels, guide rails, transmission devices, sensors, etc. It can accurately transport materials). according to the production plan. Meet at each workstation. In a processing line consisting of 5 processing centers, the total daily transportation time of the AGV exceeds 20 hours, which also involves high maintenance and servicing requirements. In daily work, the iron filings on the guide rails of the AGV transmission should be removed at any time, and grease should be added to each part regularly. Regularly check and replace worn parts such as gears, chains and drive belts.
AGV uses a variety of sensors for automatic navigation and obstacle recognition, such as laser sensors, infrared sensors and ultrasonic sensors. During maintenance, carefully check whether sensors are sensitive or loose and perform necessary calibrations. In short, regular maintenance and repair of AGV is very important.
Figure 2 AGV guided vehicle
The function of the loading and unloading station is to load, unload and clean products (see Figure 3).
Figure 3 Loading and unloading station
When maintaining the loading and unloading station, in addition to the necessary cleaning, special attention should also be paid to the material entry and exit doors as well as the spring detection device located at the bottom of the loading and unloading station. The spring sensing device is always in contact with the cutting fluid and iron filings, and is easily clogged and rusted, resulting in insufficient elasticity to fulfill the sensing function and causing production line failures.
Therefore, it is necessary to regularly clean, wipe, test and add an appropriate amount of lubricating oil; When the materials enter and exit the loading and unloading station door, the cylinder relies on the cylinder to drive the chain to open or close. the door into the guide tray. When operators use a pneumatic gun to clean parts, they often blow iron filings and other debris into the groove of the rear door guide rail, preventing it from opening or closing normally. Debris in the rail must be cleaned regularly to ensure normal operation of the switch door. It should be noted that when cleaning the track, the production line should be placed in the “offline” state and the material door should be opened in manual operation mode. It can be maintained and cleaned at the same time as the AGV.
Flexible in-line pallet racking is an important equipment for material storage (see Figure 4), which is divided into upper and lower layers. The corresponding quantity can be customized as required. In order to ensure its normal operation and prolong its service life, regular maintenance is necessary.
Figure 4 Library structure
Here are some basic steps for maintaining flexline pallet racking:
1) Cleaning: First of all, the pallet rack should be cleaned regularly to prevent dust, dirt and other debris from accumulating and affecting its service life. You can use detergent and cloth for cleaning. It is strictly prohibited to use highly corrosive detergents to avoid damage to the surface of the pallet rack.
2) Lubrication: The flexible line pallet racking should be lubricated regularly to reduce wear and friction and improve the stability and service life of the equipment. It is recommended to use special lubricating oil or grease and replace it regularly depending on the use of the equipment.
3) Inspection: Regularly check the fasteners, axles, brackets and other components of the pallet rack to ensure that they are firm and reliable and avoid loosening or falling.
4) Repair: If the flexible line pallet racking is found to be defective or damaged, it should be repaired or replaced in time.
4. Maintenance management
Maintenance management is an important part of equipment maintenance, including maintenance plans, maintenance records and maintenance training.
Maintenance plan: Develop a maintenance plan according to the characteristics of the equipment and the needs of the production line, formulate maintenance plans such as regular maintenance, fixed-point maintenance, regular inspections and repairs of breakdowns, and adjust and improve them according to the real situation.
Maintenance records: establish equipment maintenance records to record and archive the maintenance status of the equipment, including maintenance date, maintenance content, maintenance personnel, maintenance results , etc., in order to facilitate the monitoring and management of the maintenance status of the equipment.
Maintenance training: organize equipment maintenance training, train equipment operators in maintenance knowledge and skills, and improve the maintenance level and awareness of employees to ensure the quality and effect of maintenance equipment.
5. Conclusion
The purpose of flexible maintenance of processing production line equipment is to extend equipment life, reduce breakdowns and downtime, and improve operational efficiency and product quality. production of the equipment. It is an important way to ensure the stable operation of the production line and. improve production efficiency. It should be carried out in accordance with certain methods and procedures, including inspection, cleaning, lubrication, calibration and shutdown maintenance, etc. Maintenance management is also an important part of equipment maintenance, including maintenance plans, maintenance records and maintenance training. Through scientific management and effective implementation of equipment maintenance, equipment maintenance costs can be reduced, equipment breakdowns and downtime can be reduced, thereby improving the operational efficiency of the production chain and the economic advantages of the company.
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