What are the contents of the pre-service training for employees of DC motor motor automatic worm gear assembly machine?
DC motor motor automatic worm gear assembly machine staff pre-training content covers a number of key areas, designed to allow new employees to quickly familiarize themselves with the equipment, master the operating skills, to protect the production and product quality, as follows:
1、Equipment knowledge explanation
l The overall structure and principles of the equipment: detailed description of the mechanical structure of the assembly machine, including the frame, table, transmission system (such as worm gear drive, belt chain drive and other components of the layout and connection), fixture devices and mechanical arms and other parts of how to work together to achieve the automation of the assembly process of the worm. In-depth explanation of the basic principles of DC motors, such as the application of the principle of electromagnetic induction in the operation of the motor, and how the motor provides power for the assembly machine, to help employees understand the theoretical basis of the operation of the equipment.
l Key parameters and specifications of the equipment: Introduce the range of DC motor models applicable to the assembling machine, the size specifications of the worm (such as modulus, number of teeth, helix angle and other parameters), the requirements for assembly accuracy (such as the tolerance of the worm and other components), productivity indicators (number of assemblies per hour or per minute), etc., so as to make the employees clear about the working boundaries and performance objectives of the equipment and ensure that the operation is in line with the standard.
2、Operating skills training
l Control panel operation: Teach employees to familiarize themselves with the layout of the control panel of the assembly machine, the function and use of various types of buttons (such as start, pause, stop, reset buttons), indicators (power indicator, fault indicator, etc.), display (showing the status of the equipment, parameter setting interface, etc.). Employees need to master how to adjust the parameters on the control panel, such as motor speed, assembly pressure, movement stroke and other parameters set, and how to view the real-time operation of the equipment through the display screen information, fault alarm prompts, and be able to make the correct response.
l Manual operation practice: In the state of equipment shutdown and ensure protection, guide employees to practice manual operation, including manual movement of the robot arm to the designated position, adjust the degree of fixture opening and closing and positioning accuracy, loading and unloading of the worm gear and related parts and so on. Through manual operation, employees are trained to feel the manipulation of various parts of the equipment and familiarize themselves with the logic of mechanical action of the equipment, laying the foundation for subsequent automated operation.
l Automation process operation: systematically train the staff to master the whole process of automation operation of the equipment, from raw material loading (to understand the operation of the loading device and the requirements of the material placement), the automatic grasping of the worm gear (the programming of the action of the robotic arm and the grasping strategy), positioning and assembling (according to the requirements of the equipment precision, to master how to ensure the accurate position of the worm gear in the assembling process) to finished product discharging (the unloading of finished products and the storage specifications). ). Let the staff clarify the sequence of each link, the key points of convergence and the built-in automatic detection and error correction mechanism of the equipment, to ensure that the staff can skillfully guide the equipment to accurately complete the assembly task.
3、Training on Attention Matters
l Mechanical protection knowledge: Emphasize the mechanical risks during the operation of the equipment, such as the risk of involvement of transmission parts (belts, chains, gears, etc.), the risk of fixture injuries, the risk of collision with the robot arm, and so on. Train employees to correctly wear personal protective equipment (PPE), such as protective gloves, overalls, etc., as well as how to work around the equipment, maintain a protective distance, and strictly follow the standardized procedures for starting and stopping the equipment, so as to prevent mechanical injuries caused by misuse.
l Knowledge of electrical protection: Explain the composition of the electrical system involved in the equipment, including the power supply method and voltage level of the DC motor, controller, sensor, driver and other electrical components. Teach employees electrical operating procedures, such as forbidding wet hand operation of electrical equipment, how to recognize electrical fault alarms (such as overload and short circuit alarms) and take emergency measures, and avoiding contact with electrically-charged parts, etc., so as to prevent electrocution accidents. Regularly organize electrical inspections to ensure the integrity of electrical lines and the reliability of grounding.
l Essentials of fire protection: Popularize the general knowledge of fire protection, such as the location of fire escapes around the equipment, the use of fire extinguishers (including the applicable scenarios of dry powder fire extinguishers and carbon dioxide fire extinguishers), and the process of fire alarms. Let the staff understand the factors that may cause fire in the operation of the equipment (such as electrical short circuit, mechanical friction overheating, flammable materials close to the heat source, etc.), improve the staff's awareness of fire prevention and emergency response capabilities, to ensure that they can take action quickly and effectively in case of emergency.
4、Quality control training
l Assembly quality standards: Define the quality standards of worm assembly, including the meshing precision of worm and supporting components (such as gap requirements, contact area ratio), the tolerance range of installation position, the firmness of the connection (such as the tightening torque standard of threaded connection), etc.. Through physical samples, drawings labeling or three-dimensional model demonstration, let employees intuitively understand the appearance of qualified products and internal quality characteristics, so that the quality standards in-depth.
l Quality Inspection Methods: Train employees to master commonly used quality inspection tools and methods, such as calipers, micrometers, protractors for measuring dimensional and angular accuracy, torque wrenches for detecting the torque of threaded connections, as well as the key points and techniques of visual inspection (e.g., checking the surface of the worm with or without scratches, cracks, whether the assembly is in place, etc.). Employees need to learn to carry out timely quality self-inspection in the assembly process and after the completion of assembly, and follow the principle of “not accepting substandard products, not manufacturing substandard products, not flowing substandard products” to ensure that the quality of products meets the standards.
l Quality Problem Handling Process: Teach employees how to identify common quality problems, such as crooked worm installation, poor engagement, poor fastening, etc., and master the corresponding corrective and preventive measures. Once quality problems are found, employees should stop the machine immediately, report according to the specified process (fill in the quality problem report form, describing in detail the problem phenomenon, discovery time, location and other information), processing (such as self-adjustment and repair or notify the professional maintenance personnel), to avoid unqualified products flowing into the next process, and at the same time, analyze the quality problems retrospectively, to prevent the problem from recurring.
5、Maintenance training
l Daily Maintenance Tasks: Introduce the daily maintenance tasks that employees need to undertake, such as cleaning the surface of the equipment (using the appropriate cleaning agents and cleaning tools to avoid damage to the surface of the equipment), lubrication of mechanical parts (based on the lubrication chart of the equipment, regularly add lubricant or grease to the bearings, guide rails, screws and other moving parts), the inspection of electrical wiring (to see if there is any damage, loosening, whether the joints are good) and so on. Routine maintenance to extend the service life of the equipment, to ensure the normal operation of the equipment.
l Regular maintenance project: explain the regular maintenance plan and project of the equipment, including the replacement cycle of transmission parts (such as belts, chains according to the wear and tear of regular replacement, gears according to the degree of wear and mesh precision changes in the appropriate time to change), the calibration cycle of the sensors (the use of standard calibration parts on the photoelectric sensors, encoders, etc., precision calibration), the calibration of the precision of the equipment (through a professional measuring instrument on the assembly machine table flatness, encoder, etc.) (calibration of the table flatness, guide rail straightness, positioning accuracy of the robotic arm, etc. by professional measuring instruments), and so on. Let employees know when they need to cooperate with maintenance personnel to carry out in-depth maintenance to ensure stable equipment performance.
l Failure to report the repair process: train employees how to identify the initial symptoms of equipment failure, such as abnormal noise (common mechanical failure), increased vibration (may arise from imbalance, loosening, etc.), odor (electrical short-circuit, mechanical overheating may occur), and master the process and specifications of failure to report repair. Employees need to know how to accurately describe fault phenomena (including time of occurrence, duration, frequency of occurrence, accompanying symptoms, etc.) to maintenance personnel in a timely manner after discovering a fault, so that maintenance personnel can quickly diagnose and repair the equipment and reduce downtime.
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