What are the contents of the pre-service training for employees of motor motor rotor automatic duplex fine-turning machine?
Motor motor rotor automatic duplex fine-turning machine employee pre-training content:
First, the basic knowledge of equipment training
l equipment structure and principle of explanation
Detailed introduction of the overall mechanical structure of the fine turning machine, including the bed, spindle box, tool holder, table, feed system and other major components of the structure and function. Through three-dimensional models, physical disassembly diagrams or on-site demonstrations, employees can intuitively understand the connection between the components and the way of movement.
Explain in depth the working principle of the equipment, such as how the spindle drives the rotor to rotate, how the tool holder realizes the feeding movement of the tool, and how the duplex station works together to complete the machining process. Explain the interrelationship between parameters such as cutting force, rotational speed and feed, and their influence on machining quality and efficiency.
l Introduction of electrical control system
Explain the electrical control system architecture of the fine-turning machine, including the roles and interconnections of the programmable logic controller (PLC), industrial control machine, drives, sensors, motors and other electrical components. Introduce how to input processing parameters through the operation panel or software interface, how these parameters are transmitted to the electrical control system and transformed into the action of the execution of the components of the command.
Explain the common electrical control circuits, such as the start-stop control of spindle motor, tool changer control of tool holder, and feed control of worktable. Let the staff understand the working principle and troubleshooting method of relays, contactors, switches and other components in the circuit, as well as how to analyze the circuit and troubleshooting through the electrical schematic diagram.
Second, equipment operation skills training
l Familiarize with the operation panel and software interface
The operation panel of the fine turning machine is fully introduced, including the function and operation method of each button, knob and indicator. For example, start button, stop button, emergency stop button, spindle speed adjusting knob, feed speed adjusting knob, tool changer button and so on. Employees will be able to master the use of the operation panel through actual operation practice and be able to accurately and correctly carry out the basic operation of the equipment, such as starting, stopping, and parameter adjustment.
Train employees to use the software interface (if any) that comes with the fine-turning machine. Introduce the software's login method, main menu functions, parameter setting page, and processing status monitoring page. Let employees learn how to enter machining task information in the software, such as rotor model, size, machining process parameters, etc., as well as how to view real-time data in the machining process, such as spindle speed, feed, tool position, and other information. Through the simulation of machining tasks, employees can familiarize themselves with the operation process of the software and the use of various functions.
l Machining operation process standardization
According to the standard machining operation flow, it demonstrates in detail the whole process from loading and clamping the rotor blank to completing the machining and discharging. Including how to correctly mount the rotor on the fixture to ensure accurate positioning and solid clamping; how to select the appropriate tool according to the processing requirements and correctly mount the tool on the tool holder; how to set the processing parameters, such as spindle speed, feed rate, depth of cut, etc., to ensure the quality and efficiency of machining.
During the demonstration, emphasize the precautions during operation, such as prohibiting touching the moving parts when the equipment is running and preventing chips from splashing and hurting people. Allow employees to practice actual operation, in the process of employee operation, the trainer to carry out on-site guidance, timely correction of employee errors in operation, to ensure that employees can skillfully, standardized to complete the machining operation process.
Third, equipment maintenance and maintenance knowledge training
l Daily maintenance points to explain
Introduce the daily maintenance of fine turning machine, including equipment cleaning, lubrication, fastening and other aspects. Teach the staff to check the appearance of the equipment for damage, clean the debris and chips on the worktable, and check whether the tools and fixtures are firmly installed before each shift. During the working process, pay attention to observe the running status of the equipment, such as whether there is abnormal noise, vibration, heat and other phenomena, if any abnormality should be stopped in time for inspection.
Explain the lubrication requirements of the equipment, such as which parts need to be lubricated, what kind of lubricant to use, and what is the lubrication cycle. Let employees learn how to add lubricant and grease correctly, and how to check whether the lubrication system is working properly. At the same time, teach employees to regularly check whether the fasteners of the equipment are loose, such as screws, nuts, bolts, etc., and tighten them in time if they are loose.
l Regular maintenance program and method training
Introduce the regular maintenance items and cycles of the fine-turning machine, such as weekly, monthly and quarterly maintenance work. For example, weekly need to clean and lubricate the tool holder, check the tool wear; monthly need to check the spindle box, including spindle radial runout, axial runout, bearing lubrication, etc.; quarterly need to calibrate the accuracy of the equipment, such as the flatness and perpendicularity of the worktable, the coaxiality of the spindle and the worktable, and so on.
Detailed explanation of the specific operation method of each regular maintenance project, such as how to use the gauge for precision measurement, how to adjust the geometric accuracy of the equipment, how to replace the wearing parts (such as belts, filters, etc.) and so on. Through the practical demonstration, the staff can master the skills of regular maintenance to ensure that the equipment can run stably for a long time.
Fourth, quality control and inspection standards training
l Processing quality standard introduction
Explain to the staff the processing quality standards of motor motor rotor, including the requirements of dimensional accuracy, shape accuracy, surface roughness and so on. For example, the allowable range of rotor diameter tolerance, cylindricity, coaxiality, and the numerical requirements of surface roughness. Through physical samples, drawings or data tables, etc., let employees intuitively understand the processing quality standards, and make clear the boundaries between qualified products and unqualified products.
Introduce the factors affecting machining quality, such as the selection and use of tools, the setting of machining parameters, the precision and stability of equipment, and the skill level of operators. Let employees understand how to control these factors in the machining process to improve the machining quality. For example, how to choose the appropriate tool material and geometric parameters according to the material and machining requirements of the rotor; how to reduce the machining error by optimizing the machining parameters; how to ensure the precision and stability of the equipment by regular maintenance of the equipment.
l Quality inspection methods and tools training
Train employees to master the use of common quality inspection methods and tools, such as calipers, micrometers, percentile tables, roughness meters and so on. Let employees learn how to use these gauges correctly for rotor size measurement, shape error measurement and surface roughness measurement. Through practical exercises, employees will master the use of gauges, be able to accurately read the measurement data, and judge whether the product is qualified according to the measurement results.
Introduce the process of quality inspection and record requirements, such as how to carry out the first piece inspection, process inspection and final piece inspection in the processing process, and how to fill in the quality inspection record form. Let employees understand the importance of quality inspection, develop good quality inspection habits, to ensure that each processed rotor meets the quality standards.
V. Standardized operation and emergency measures training
l Emphasize the standard operation
Detailed explanation of the operating procedures of the precision turning machine, including the inspection before the start of the equipment, such as checking whether the guard is intact, whether there are obstacles around the equipment, whether the electrical system is normal, etc.; the precautions to be taken during the operation of the equipment, such as prohibiting the touching of the moving parts, not to cross the rotating spindle, to prevent chips from hurting the people, etc.; the operating requirements after the equipment stops, such as stopping the spindle rotation, then turn off the power supply of the equipment, clean up the work area, etc.. Clean up the working area, etc.
Emphasize the proper use of personal protective equipment, such as protective glasses and gloves. Require employees to wear PPE before entering the work area and keep it on at all times during the work process. Through case studies or accident videos, let employees deeply realize the dangers of not complying with operating procedures, and improve their awareness of protection.
l Emergency Response Training
Train employees to master the emergency handling measures for emergencies that may occur during the operation of the equipment, such as sudden power outage, abnormal movement due to equipment failure, fire, etc. For example, in the event of a sudden power failure, employees should immediately turn off the power switch of the equipment to prevent the equipment from automatically starting up after an incoming call and causing danger; when the equipment shows abnormal movements, employees should immediately press the emergency stop button and stay away from the equipment, waiting for maintenance personnel to deal with the situation; in the event of a fire, employees should immediately use the fire extinguisher to extinguish the fire, and quickly evacuate the scene according to the predetermined evacuation routes.
Emergency drills are conducted through simulated emergencies to allow employees to actually operate the emergency handling process and improve their emergency response ability and self-protection awareness. Ensure that employees can calmly, quickly and effectively take countermeasures when encountering emergencies, and greatly reduce accident losses.
