English (UK) 
简体中文 Why spend a lot of money to replace the roller deformed in less than six months? Old iron, maintenance is not in place is equal to the money thrown into the water ah! This roller looks like an iron lump, but it's actually very delicate--One degree higher, one spoon less grease, one layer of dust.The first thing you need to know is how to maintain your equipment, and how to perform a "strike on the spot" in minutes. Today we will nag through those neglected maintenance details, hand to teach you with theSave 30% per month on maintenance costsof hands-on skills.
I. Daily inspection: don't wait for smoke to call for help
The easiest pitfall for newbies to plant.If the device doesn't alarm, there's nothing wrong with it.. Waiting for bearings to burn red and smoke? The repair bill can scare you to tears! These three items can be avoided by spending 10 minutes a day:
- feel the temperature: Back of hand against the bearing housing shell, over 65 ℃ immediately stop (mobile phone temperature gun more accurate)
- mishear: Hold a screwdriver against the bearing housing and listen with your ear to the handle - crunch = lack of oil, clunk = bearing falling apart!
- Look at the oil level.Lubricating window fluid is less than 1/2? One hour of dry grinding = half a year off your life!
A case of blood and tears: A factory in Jiangsu neglected the gearbox "humming" sound, three weeks later the tooth surface spalling.80,000 in repairs buys lessons.
Second, clean rust: 90% failure is dirty out of the
You think wiping the surface is the end of the story? Wrong!It's the metal shavings in the oil holes that are the hidden killers.. Different sources of pollution are treated:
- tin oxide: weekly withCopper brush + magnetic suction barHollowing out the dead centre of the roll seam (hard scraping of the raceway and waiting for a bearing change)
- Emulsion Residue: Food factory downtime must flush fresh water, acid crystallisation = Roller face perforating machine
- dampness and corrosion: For seafood processing linesStainless steel seal + lithium greaseSalt water? Doesn't exist!
ask and answer questions for oneselfRub the surface with kerosene mixed with pumice powder. Rub the surface with paraffin mixed with pumice powder, the crystalline layer rubbed off immediately restore the grip - this trick has saved the printing plant the entire assembly line!
Third, the science of lubrication: not more oil is enough
Greasing to death? Big mistake!Overfilling with grease and stirring to warm up 15°C, grease carbonisation counters accelerated wear. The golden formula is here:
| take | Type of grease | refill cycle | deadly minefield |
|---|---|---|---|
| High speed light load (>500 rpm) | Synthetic hydrocarbon grease | 400 hours | Mixing different models = chemical reaction |
| Heavy duty impact (mining type) | Extreme pressure grease with molybdenum disulphide | 200 hours | Lipo Injection Ultra Chamber 50% Capacity |
| High temperature rolling (>300°C) | Ceramic Composite Grease | 100 hours | High water temperatures cause grease emulsification |
lazy technique: Take a syringe and fill it with oil quantitatively! For example, for an 80mm diameter roller, each time you replenish the oil, you will need a syringe.120ml just fills 1/3 of the cavity-- both fuel-efficient and anti-overheating.
Fourth, bearing maintenance: change clever than change diligently important
Bearings are not meant to be replaced until they break! Do it as soon as these three signs appear:
- Axial runout＞0.05mm: Percentage meter to hit the end face of the roller shaft, stop immediately if it is out of tolerance (further running may break the shaft)
- Increased clearance can shake the hand: Pinch the roller and shake it from side to side, loose feeling = worn bearing balls
- Seal hardened and cracked: Don't be heartbroken!Half-yearly mandatory replacementDust in bearings = 3 times the wear of abrasive particles.
personal viewpoint: Don't be greedy to replace the bearings with cheap goods! A factory to save 200 yuan with cottage bearings, the result of the rollers holding dead burn motor--The repair cost is enough to buy ten sets of genuine products.
V. Cost control: three-tier maintenance system makes a big difference
Maintenance isn't burning money it's making money! Just do it.It's really not that hard to save $300,000 a year in repairs::
- Daily level (10 minutes for operators)::
✓ Chain sagging ≤ 20mm (over tighten a buckle)
✓ Emergency stop button function test
✓ Hydraulic station oil level over half window - Monthly level (technician specific)::
✓ Laser calibrated roll parallelism (deviation ≤ 0.05 mm/m)
✓ Clear Inverter Cooling Fan
✓ Check fuel tank contamination (within NAS 8) - Annual level (manufacturer's joint inspection)::
✓ Endoscopic view of gear pitting (<5% area can still be carried)
✓ Hydraulic seals mandatory new replacement (mandatory for 8000 hours)
✓ Insulation test earth resistance (≤4Ω for safety)
I'm going to end with the truth.
Maintaining rollers is like car maintenance - theMinor maintenance not done, overhaul shop laughs like a madmanSave your money on grease! Save a little grease money, lost production line downtime losses. Remember, old iron: temperature measurement, grease quantitative play, bearing according to the table change. Can't figure it out? Record a video of the mobile phone rattling, directly @ the factory teacher - professional things to professional people, after all, you are betting on every minute of real money flow ah!
bottom-of-the-barrel advice: Signing a maintenance contract to die forDynamic balance report + hardness test bookNot having either of these? Convert right out of the door!
