English (UK) 
简体中文 Brothers and sisters in factories, is the spring conveyor line in your workshop always out of order? Today the material jam tomorrow broken spring, the maintenance master ran more than the production line is more diligent? Don't be anxious! Let's talk about how to serve this "ancestor of the line", so that it can do more than a few years of work, less swallowed your tens of thousands of maintenance costs!
First, the daily maintenance do not be lazy - save big money on small actions
Guess what? Eighty per cent of the failures are routine maintenance is not done! Just like people have to brush their teeth and wash their faces, conveyor lines have to do basic care:
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Cleaning should be as diligent as washing your face
Dust and oil is the number one killer of conveyor lines! Especially in food factories and powder workshops, the residue sticking to the spring thicker and thicker, the light is jammed material heavy is burned motor.Blow inside the catheter with compressed air at least once a week, stubborn oil stains are wiped with a neutral cleaner. Remember! Don't use a high-pressure water gun on electrical parts, it will short-circuit you in minutes. -
Lubrication is not as good as more lubrication
Have you ever seen a bearing filled with grease? Ouch, that's slimy and attracts dust!Heavy-duty lines (running more than 8 hours a day) are replenished with lithium grease every three months, and half a year is enough for light-duty ones.The main focus is on the bearings, chain joints and other "joints". Focus on taking care of bearings, chain joints, these "joint" parts. Secretly tell you, an auto parts factory adhere to the lubrication, chain life from 1 year to 3 years, saving more than eight hundred thousand! -
Screws have to be "tightened" regularly.
Screws are most likely to come loose in a shop with a lot of vibration. Last week I went to a hardware factory, good guy! The conveyor line shook like a dance, a check is the fixed frame screws fell out three.Tighten the bolts once a month with a spanner.The motor base and drum mounts in particular - you can't save money on this, and dropping a screw could cost you a unit!
Second, the key maintenance of the three tricks of the trade - specialising in all kinds of disobedience
It's not enough to just do the superficial work, these three tricks are the core secrets to extending your life:
▌The first move: there is a way to prevent the spring from breaking.
Spring breaks at the drop of a hat? Seventy per cent of failures in flexible screw conveyors are due to it! There are just two main reasons.Fatigue and impact.
- Selection of materials should be tough enough: Alloy steel springs (wire diameter ≥5mm) must be used for conveying metal parts, ordinary steel wire can't carry the impact.Risk of breakage in 72 hours continuous operation 35%
- You have to spend a lot of money on damping.: Adding a rubber cushion to the bracket eats up 60% of impact. When a mattress factory added the cushion, the spring life was extended from six months to two and a half years
- Fatigue should be detected early: Measure the free height of the spring every month.Compression set exceeds 10% and can be replaced immediately.! Don't wait for the break to stop production and lose even more money
▌The second trick: there is a mystery in the tensioning of the dragon belt.
Dragon belt slipping, running off, wear fast? Ninety per cent is that the tension is not adjusted properly!
- Hand-measured soil methodsTwo fingers under the pressure of the dragon belt mid-point, sinking 3-5mm is ideal. Too loose will slip, too tight motor wailing and power consumption
- Upgraded Black Technology: Flower ten thousand handle block plus automatic tensioning device, ten times more accurate than the manual adjustment. Measured speed fluctuations from ± 15% pressure to ± 3%, the light to save the cost of electricity two years back to the capital!
- Material to see the scene: Stainless steel glossy dragon belt for food factory is good for cleaning, polyurethane anti-slip belt for general workshop is more money-saving -Choose the wrong material maintenance cost difference 60%
▌Third Tip: You have to be smart to prevent jamming.
Card a material delay of half an hour, three times a day card production line will have to curse! Try this:
- Vibrating screen at the feeding port: Shocking out the longitudinal springs like sifting beans and only letting the transverse pieces into the pipe, a certain car company uses this trickJamming rate reduced from 5% to 1 per cent
- Fitting deflectors on corners: 45 degree angled inserted alloy plate guides the material direction, much less effort than hitting the wall of the tube hard.
- Don't go too fast.Conveying speed exceeds 15m/min, be sure to add a bridge plate transition at the exit, height difference ≤ 3mm!
Third, upgrading spend little money to do great things - the old equipment can also be a second spring!
Maintenance done right can extend your life, but you'll have to have some surgery if you want to improve efficiency again. Fear not! These remodelling tricks are more cost-effective than you buying new equipment:
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Shot Peening "Gold Plates" Springs
The springs are shoved into a blasting machine and blasted to create a compressive stress layer on the surface. Don't underestimate the process.Direct fatigue life increase of 20-50%! Costs only a few thousand dollars, triple the cost of new springs! -
"Electrocardiographs" for conveyor lines.
Stick vibration sensors at key nodes and watch real-time fluctuations on your mobile phone.The frequency of anomalies is found to be overhauled quickly, which can kill the fault in the cradle.. A power plant has been installed for six months, and sudden failures have reduced 70% -
Modular conversion like Lego
Old style all-in-one takes half a day to remove a part? The new style accumulation and release line with quick release joints + limit ring, change the model is like changing the mobile phone case. After a factory in Guangdong changed, the time of changing production was reduced from 45 minutes to 10 minutes, and the production capacity was directly doubled!
If you ask me, maintaining a conveyor line is like keeping a car-Usually diligent maintenance, key components are willing to repair, occasional upgrades are not out of dateThe line teacher Lao Zhang said rightly: "You fool the equipment, the equipment will fool you! The assembly line teacher Lao Zhang said right: "You fool the equipment, the equipment will fool you!" Save the maintenance fee is real money, more open production line is a rolling source of wealth. Finally nagging sentence: explosive environment must do explosion-proof certification (GB 12476 standard), safety red line can not be touched!
