Motor motor rotor automatic six-station double flying fork winding machine staff pre-service training content?
Motor motor rotor automatic six-station double flying fork winding machine staff pre-training content:
First, the basic theoretical knowledge of equipment
1, the working principle of the winding machine
l Detailed explanation of how the winding machine through the collaboration of six stations and the movement of the double flying fork to achieve the motor rotor winding process. Including the rotation and translation movement of the flying fork, rotor indexing and positioning in each station, as well as the delivery of the line, winding and other actions of the synergistic mechanism. For example, the use of animation demonstration or physical model display, so that employees intuitively understand the complete process of releasing the wire from the spool, guided by the wire device, and driven by the flying fork to wind the wire on the core of the rotor, as well as the precise time and space coordination relationship between the various links.
l Introduce the principle of the electrical control system of the winding machine, such as how the Programmable Logic Controller (PLC) receives the sensor signals and controls the motors, solenoid valves and other actuators according to the preset program to realize the automatic control of the winding process. Explain the impact of different control signals on the operating state of the equipment, and how to set and monitor the parameters through the human-machine interface (touch screen or operating panel).
2、Structural composition of equipment
l Lead employees to recognize the main mechanical components of the winding machine, such as the flying fork mechanism, fixture system, indexing mechanism, wire feeding mechanism, etc., and explain their functions and interconnections. For example, show the structure of the flying fork, including the fork head, rotating shaft, bearing and other parts, and explain its design features in high-speed rotation and precise position control; introduce how the fixture system realizes the firm clamping and fast loosening of different sizes of rotors by pneumatic or hydraulic devices, and the influence of the precision requirements of the fixture on the quality of the winding.
l Explain the components of the electrical system, including motors, drives, sensors, controllers, power supplies and so on. Explain the position, model and function of each electrical component, such as how the position sensor accurately detects the position of the flying fork and rotor, how the tension sensor monitors the wire tension during the winding process and feeds back to the control system for adjustment, and how the motor driver controls the speed and torque of the motor according to the instructions of the controller.
Second, equipment operation skills training
1、Operating panel and parameter setting
l Introduce to the staff the various function keys of the operation panel of the winding machine, the information displayed on the display and the operation method. Train employees how to enter the parameter setting interface, set the number of turns of winding, winding speed, flying fork speed, tension and other key parameters. For example, explain in detail the meaning of each parameter, the range of values, and the impact on the quality and efficiency of winding, and through practical demonstrations, let employees learn to correctly set the parameters according to different specifications of the motor rotor and the requirements of the winding process, as well as to save and recall the parameters.
l Teach the staff how to start, stop, pause and reset the equipment on the operation panel, and how to respond to various prompt messages and alarm signals during the operation of the equipment. For example, when there is a line break alarm, employees should know how to pause the equipment, find the location of the broken line and deal with it, and then resume the equipment operation; when the equipment overload alarm, employees should understand how to check the load and take appropriate measures, such as cleaning up the windings, adjusting the tension and so on.
2、Winding operation process
l In accordance with the standard operation flow, demonstrate step by step the whole operation process starting from installing the motor rotor on the fixture to completing the winding and removing the rotor. Including how to correctly place the rotor to ensure its concentricity with the fixture; how to thread and lead the wire, so that the wire can be smoothly wrapped around the rotor; how to monitor the wire tension during the winding process, the number of turns of the wire, and other parameters, to ensure that the quality of the winding meets the requirements. For example, in the process of threading, emphasize that the wire should pass through the correct position of the wire die to avoid problems such as jamming and skipping; in the process of winding, teach the employees how to observe the trajectory of the flying fork and the rotation of the rotor, so as to find out the abnormality in time and make adjustments.
l Let the staff practice actual operation, in the process of staff operation, the trainer conducts on-site guidance, corrects the wrong operation of the staff in time, to ensure that the staff can skillfully and accurately complete the winding operation process. At the same time, to cultivate the staff's sense of protection, such as strictly prohibited in the process of equipment operation reach out and touch the moving parts, must wear protective gloves and other personal protective equipment.
Third, equipment maintenance and maintenance knowledge
1, daily maintenance programs and methods
l Training staff every day in the use of equipment before and after the use of daily maintenance work content. Including cleaning the equipment body, flying fork, fixture, guide rail and other parts of the dust, oil and debris, check the transmission components (such as belts, chains, gears) of the tension and wear and tear, to see whether the electrical connection lines are loose, broken, as well as to check the lubrication of the lubrication points and add lubricant or grease in a timely manner. For example, demonstrate how to wipe the surface of the equipment with a clean soft cloth and a special cleaner, how to check and adjust the tension of the belt with a wrench, and how to judge the wear of the gears by observation and feel.
l Teach employees how to carry out daily inspection of the equipment, such as checking whether the running sound of the motor is normal and whether there is any abnormal heat phenomenon; checking whether the installation position of the sensors is correct and whether there is any looseness or damage; checking whether the pressure of the pneumatic or hydraulic system is normal, and whether there is any leakage in the pipeline. Employees are required to be able to find out the potential problems of the equipment in time, and record the daily operation status and maintenance of the equipment.
2、Points for regular maintenance and upkeep
l Introduce the regular maintenance cycle of the winding machine (e.g. weekly, monthly, quarterly, etc.) and the corresponding maintenance items. For example, it is necessary to deeply clean and lubricate the flying fork mechanism every week, check the accuracy of the flying fork and make adjustments; it is necessary to make all inspections of the electrical system every month, including cleaning the circuit boards, checking the performance of the electrical components, updating the control system software, etc.; it is necessary to make all inspections and adjustments of the mechanical structure of the equipment every quarter, such as checking the levelness of the machine body, the positioning accuracy of the various stations, etc., and make calibrations and repairs according to the needs. Calibrate and repair as needed.
l Train employees on how to carry out regular maintenance work, such as how to disassemble and install flying forks, clamps and other components for cleaning and maintenance, how to use professional tools (such as multimeters, oscilloscopes, etc.) for testing and repairing electrical components, and how to carry out precision calibration operations of the equipment. At the same time, emphasize the importance of regular maintenance work, only do a good job of regular maintenance, in order to ensure the long-term stable operation of the equipment, reduce equipment failure and downtime.
Fourth, the operating procedures and emergency measures
1、Operating procedures
l Explain in detail to employees the operating procedures of the winding machine, including the inspection of the equipment before starting, such as checking whether the protective device is intact, whether there are any obstacles around the equipment, etc.; the precautions to be taken during the operation of the equipment, such as forbidden to cross and touch the moving parts, and not to place irrelevant items on the equipment, etc.; equipment stopping the operation requirements, such as cutting off the power supply, cleaning up the workplace, etc.. For example, it is emphasized that the protective door must be closed in place before starting the equipment to prevent personnel from accidentally contacting the high-speed movement of the flying fork and rotor; during the operation of the equipment, employees are not allowed to leave their posts, and they should always keep an eye on the operating status of the equipment and stop immediately to deal with any abnormality found.
l Train employees to use personal protective equipment correctly, such as protective glasses, protective gloves, etc., and require employees to wear them strictly during work. For example, protective gloves must be worn to prevent the hands from being scratched by the wire during the winding operation; protective glasses may be needed to prevent dust, oil and other splashes into the eyes during the maintenance and repair of the equipment.
2、Emergency measures
l Teach employees how to deal with emergencies that may occur during the operation of the equipment, such as sudden power outages, abnormal movements due to equipment failure, fire, etc. For example, in case of sudden power failure, employees should know how to turn off the power switch of the equipment, so as to prevent the equipment from automatically starting up after the incoming call and causing danger; when the equipment has abnormal movement, such as the flying fork is out of control, the employees should immediately press the emergency stop button and stay away from the equipment, waiting for the professional maintenance personnel to deal with it; if a fire occurs, the employees should be familiar with the use of the fire extinguishers and the location of evacuation routes, and be able to take fire-fighting and evacuation measures quickly. If a fire occurs, employees should be familiar with the use of fire extinguishers and the location of evacuation routes, and be able to take fire extinguishing and evacuation measures quickly.
l Conduct emergency drills to simulate various emergencies and let employees practically operate the emergency treatment process, so as to improve their emergency response ability and self-protection awareness. At the same time, employees are required to remain calm when encountering emergencies and deal with them in an orderly manner in accordance with the trained emergency handling measures, and not to panic and act blindly.
V. Quality control and inspection standards
1、Winding quality standards
l Explain to employees the various standards and requirements of winding quality, including the accuracy of the number of winding turns, the alignment of the line neatness, the consistency of the line tension, the insulation properties of the winding, etc.. For example, it is stipulated that the error range of the number of winding turns shall not exceed ±1 turn, and the arrangement of the wire on the rotor core shall be close and even, with no cross, overlap or loose phenomenon; the wire tension shall be kept within a certain range, too large may lead to breakage of the wire or damage to the rotor core, while too small will make the winding not tight, affecting the performance of the motor; and the insulation resistance of the windings shall comply with the relevant standards to ensure the operation of the motor.
l Showing the comparison between qualified and unqualified samples of winding quality, so that the staff can visualize the difference in the quality of winding, and facilitate the staff to carry out quality control in the actual operation. At the same time, teach employees how to use simple tools (such as turns counter, tensiometer, insulation resistance meter, etc.) to detect and monitor the quality of winding, and require employees to carry out regular quality inspections during the winding process, and make timely adjustments when problems are found.
2、Quality problem analysis and solution
l Train employees how to analyze the quality problems in the winding process, such as inaccurate number of winding turns may be caused by counting sensor failure, parameter setting error or mechanical transmission parts slipping, etc.; line alignment may be due to the flying fork movement is not smooth, inaccurate positioning of the fixture or wire device problems, etc.; unstable line tension may be due to the failure of the tension regulating device, quality of the line or wire feeding mechanism jamming, etc.; line tension may be due to the failure of the tension regulating device, quality of the line The unstable wire tension may be caused by faulty tension adjusting device, quality problem of the wire, or jamming of wire feeding mechanism. By analyzing quality problems, employees can find the root causes of the problems and take appropriate measures to solve them.
l For example, when the number of winding turns is found to be inaccurate, the employees should first check the working status of the counting sensor to see whether the sensor is loose, damaged or covered, and also check whether the parameter settings are correct, and if there are no problems with any of them, then further check the connection of the mechanical transmission parts; when there is the problem of the wire not being arranged in a neat manner, the employees should check the operation of the flying fork, fixture and wire device respectively, and make adjustments or repairs to the Adjust or repair the problems found, such as adjusting the balance of the flying fork, calibrating the positioning accuracy of the fixture or cleaning up the sundries of the wire device.
Through all the above pre-job training content, it can make the new employees quickly familiar with the motor motor rotor automatic six-station double flying fork winding machine related knowledge and skills, improve the staff's level of operation and awareness of the protection, to ensure the normal operation of the equipment and the quality of the product is stable.
