What are the contents of the pre-service training for employees of DC motor motor automatic bearing press fitting machine?
1, the basic principle and structure of the equipment
Equipment overview:
Introduce the use of DC motor motor automatic bearing press fitting machine to the employees, mainly used to accurately press fit the bearing into a specific shaft or seat hole, is the key equipment in machinery manufacturing and other industries.
Show the appearance of the equipment, including the main machine, control cabinet, operation panel and other main parts, so that employees have an overall understanding of the equipment.
Working principle explanation:
Explain in detail the driving role of the DC motor in the equipment, such as how the motor transmits the power to the press-fitting parts through the transmission mechanism (such as belts, chains, gears, etc.).
Explain the principles of the press-fitting process, including the generation of pressure (e.g. hydraulic, pneumatic or mechanical lever principles), the control of displacement (through sensors and control systems) and how to ensure press-fitting accuracy.
Introduction to equipment structure:
The mechanical structure of the equipment is broken down and introduced, such as the function of the body frame, press-fitting head, table, guides and other parts and how they are connected to each other.
Introduces the electrical system, including the location and basic functions of electrical components such as motors, sensors, controllers (e.g., PLCs), relays, contactors, etc., so that employees can understand how the equipment realizes automated control.
For equipment containing hydraulic or pneumatic systems, explain the working principles and functions of hydraulic stations (or gas source devices), hydraulic cylinders (or cylinders), and various hydraulic valves (or pneumatic valves).
2, the operation process and standardization
Operation process demonstration:
Preparation before starting the machine: Teach the staff to check whether the environment around the equipment is reliable, and whether the connection of each part of the equipment is normal, such as power supply, gas source (if any), hydraulic source (if any), and so on. Check the lubrication of the equipment and make sure there is enough lubricant or grease in each lubrication point.
Start-up operation: Detailed description of the start-up steps, including turning on the power switch, starting the motor, waiting for the equipment self-test (if any), starting the control system and other operations, as well as the matters to be noted in each step, such as observing the start-up sound of the equipment, the status of the indicator lamps and so on.
Bearing press-fitting operation: according to the actual production process, demonstrate how to place the bearings and workpieces, how to set the press-fitting parameters (such as press-fitting force, displacement, speed, etc.) on the operation panel, how to start the press-fitting program, and how to observe the status of the equipment and the progress of the press-fitting in the press-fitting process.
Operation after press-fitting: Demonstrate how to take out the workpiece after press-fitting is completed, how to clean up the working area of the equipment, and how to shut down the equipment correctly, including shutting down the control system, motor and power supply.
Operation specification emphasis:
Operation specification: Emphasize that it is strictly prohibited to put hands or other parts of the body into the press-fitting area during the operation of the equipment, and must wait for the equipment to stop completely before cleaning or adjusting the work. At the same time, care must be taken to prevent hair, clothing, etc. from being caught in the moving parts of the equipment.
Precision operation specification: Teach employees to set press-fitting parameters in strict accordance with process requirements and not to change the parameters at will. When placing bearings and workpieces, make sure the position is accurate to avoid quality problems of press-fitting due to improper placement.
Record operation specification: Employees are required to make a good record of equipment operation during the operation process, including information such as start-up time, type and quantity of bearings pressed and loaded, pressing and loading parameters, abnormal conditions of the equipment, etc., so as to facilitate the traceability and quality control.
3、Precautions
Machinery protection:
Explain the dangerous areas of the equipment, such as under the press-fitting head, around the transmission parts, etc., which may cause injuries to the human body such as pinching and squeezing during the operation of the equipment.
Introduce the location and use of guards on the equipment, such as guard rails, light curtains (if any), and emergency stop buttons. Require employees not to remove or damage guards at will.
Electrical guarding:
Train employees to recognize electrical hazards such as electric shock, short circuits, overloads, etc. Inform employees not to touch electrically charged wires and electrical components, and to stop operation and report immediately if they find broken wires or smoking appliances.
Explain equipment grounding protection measures, emphasize the importance of grounding, and ensure that equipment is well grounded to prevent electric shock accidents.
Hydraulic and Pneumatic Protection (if any):
For equipment containing hydraulic systems, describe the dangers that can be posed by the pressure of the hydraulic fluid, such as a ruptured hose resulting in a spray of hydraulic fluid that can injure someone. Teach employees how to check hydraulic systems for proper pressure and how to avoid hydraulic fluid leaks.
For pneumatic systems, explain the potential dangers of compressed air, such as the injuries that can be caused by high velocity jets of gas. At the same time, pay attention to the noise control of the pneumatic system to avoid long-term exposure to high decibel noise environment.
4, maintenance knowledge
Daily maintenance content:
Equipment cleaning: teach employees how to clean up oil, dust and debris on the surface of the equipment at the end of each day's work, including the use of appropriate cleaning tools (e.g., rags, brooms, vacuum cleaners, etc.) and cleaning agents.
Simple inspection: train employees how to perform simple equipment inspections, such as checking for loose bolts, proper electrical connections, and lubrication points that need to be replenished with lubricant.
Introduction to regular maintenance content:
Regular maintenance program: explain to employees the regular maintenance program of the equipment, including weekly, monthly, quarterly and yearly maintenance items that need to be carried out, such as changing lubricating oil, checking the accuracy of sensors, calibrating the equipment and so on.
Maintenance operation demonstration: For some regular maintenance operations that employees can participate in, such as replacing filter elements, cleaning guide rails, etc., conduct a live demonstration so that employees can understand the methods and steps of maintenance.
Maintenance responsibility division of labor:
Clarify the responsibilities of employees in equipment maintenance, such as operators need to be responsible for daily maintenance and simple failure reports, maintenance personnel are responsible for complex repairs and regular in-depth maintenance.
5、Quality control points
Press-fitting quality standards:
Introduce the quality standard of bearing press-fitting to the staff in detail, including the requirements of parameters such as the fit accuracy (e.g., overload, clearance, etc.) of the bearing and the shaft or seat hole after press-fitting, and the positional accuracy (e.g., axial and radial runout) of the bearing.
Samples of qualified and unqualified press-fit products are displayed so that employees can visually identify quality differences.
Quality control methods:
Teach employees how to ensure quality during operation, such as setting and adjusting press-fitting parameters correctly, and observing whether the pressure - displacement curve (if the equipment has this function) is normal during press-fitting.
Introduces quality inspection tools and methods, such as the use of calipers, micrometers, plug gauges and other tools, and how to perform simple quality inspection operations.
Quality problem handling:
Train employees how to deal with quality problems if they find them, such as stopping production immediately, marking and isolating unqualified products, and reporting quality problems in time. At the same time, employees should be made aware of the traceability process of quality problems in order to find out the causes of the problems.
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