English (UK) 
简体中文 🤔 Is your conveyor always out of order?
Does it hurt every time you shut down for maintenance? Don't panic! Today we will use the vernacular to talk about this "air porter" how to tame - from installation to maintenance, hand in hand to teach you to avoid the pit, guaranteed to see the end of the tens of thousands of dollars less to pay tuition!
🔧I. Installation: laying a good foundation in order to be as stable as an old dog
1. No slacking on the baseline review
- Track Installation: When measuring the track with a level, the difference in height is more than 1mm (just imagine a mobile phone on a table without shaking). Here is a key point - the track joint gap should be less than 1mm, otherwise the chain runs clicking, like a tractor.
- drive unit: The sprocket and the track must be aligned! Deviation over 1mm? Wait for the chain to derail you.
2. Steel structures are hardcore
If the bracket is crooked, the whole system will have a "herniated disc":
- Vertical deviation of column ≤ 1/1000 (equivalent to a 2-metre-high column with a crookedness of no more than 2mm)
- Horizontal deviation of cantilever bracket ≤ 3/1000 (height difference between the two ends of a 3-metre-long beam within 9 mm)
👉lesson learnt through blood and tears: A factory to save trouble did not measure the level, the chain ran off the track grinding out deep grooves, replace the track cost 80,000 yuan!
🚦Second, the operation of the chapter: the novice must see the life preservation guide
⚠️ The Golden Triple Check before switching on (and saving on medical bills!)
- look up the chain: Hand-carry the middle part of the chain, sagging more than 50mm, quickly tighten! Loose like a trouser belt will derail sooner or later.
- track sth.: Take a torch and shine it on the inside of the track - any cracks or deformations?Shut down immediately.! This thing is as dangerous as a cracked bridge abutment.
- Check the emergency stop button: Press test twice a month, don't wait for something to happen to realise it's just for show.
🚨 Top 3 Runtime Deadly Actions
- Hand extension shields: ⚡️⚡️ Always remember! Last year a dude reached out to reach a stuck part and had two fingers rolled to mush by the chain.
- overloaded transport1.5 tonnes in a nominal 1 tonne? It's not a big deal if the motor burns out, but if the chain breaks, it'll smash through the roof.
- electrified maintenance:: ⚠️The gate must be pulled!A maintenance worker trying to save trouble to adjust the chain with electricity, spanner ride to the conductive rail directly electrocuted.
🛠️Third, the maintenance chapter: the secret of saving 3 hours of downtime per month
📅 Routine maintenance (10 minutes a day = $20,000 annual maintenance savings)
| place | Operating Points | Tools/materials |
|---|---|---|
| sprockets | Touch temperature (alarm if over 60°C) | infrared thermometer |
| fig. conventional way of thinking | Listen for strange noises (crunching = lack of lubrication) | Lithium grease lubricants |
| track roller | Clear gravel (stuck particles accelerate wear) | stiff brush |
🔧 Great Trick of the Month (as easy as fixing your car)
- tensioning device: Adjust the springs every 3 months, using a spanner to the30-50kg pulling force(The equivalent of carrying a bag of rice).
- Bearing oiling: Open the oil filler nozzle.Squeeze for 3 seconds and stop for 1 second-To fill it up too much and it attracts dust.
- trap (computing): 🛡️ This life-saving device is ignored by many! Manual trigger test, slides more than 20cm must be replaced.
💡 Exclusive data: A factory that does maintenance according to national standards can reduce the failure rate by 67%! For example, a car factory insists on monthly maintenance and has not changed a drive wheel in three years.
🤯Fourth, the soul torture: why your equipment always strike?
Q：Why are the bearings still burning even though lubrication is not done?
A: 80% use the wrong oil! You have to use it in high temperature areas.Molybdenum disulphide grease, ordinary grease melts when it gets hot - the same as adding diesel to an oiled car.
Q: What should I do if the chain clicks in winter?
A.Antifreeze + Silicone GreaseDouble-barrelled! Northeast old iron pro-test: -25 ℃ as usual operation, remember not to use water to flush ice.
💎I'll end with something heartfelt.
Zhang, who has been in equipment management for twenty years, told me:"Maintenance isn't about saving money, it's about making money!" Their factory relies on fine maintenance, the conveyor line failure from a monthly average of 8 times to 0.5 times -That's the equivalent of producing an extra 3,000 cars a year🚗.
🔥 The best trick in the book.: Post a note at the drive stationVibration labels(Taobao $10), discoloured labels = internal wear and tear, ten times more accurate than listening! I've avoided three broken chains with this trick.
📢 Call to Action: First thing in the morning shift tomorrow - go and give the chain a "medical check-up" to catch the problem before saving real money!
