What is the content of the pre-service training for employees of motor motor rotor automatic receivers?
The following is a motor motor rotor automatic receivers employee pre-service training content:
I. Training objectives
To make new employees familiar with the basic operation of the motor motor rotor automatic rewinding machine, precautions, maintenance requirements and common trouble shooting methods, to be able to independently operate the equipment, to ensure that the production process is carried out smoothly.
Second, the training content
(A) equipment overview
Equipment use and function
Detailed introduction to the role of the reclaimer in the motor motor production process, that is, automatically collect and organize a rotor and placed in the tray, in order to achieve rapid material organization and subsequent processing links.
Explain the main functional modules of the equipment, such as the rotor transfer system, the gripping system, the pallet positioning and replacement system and other synergistic working principles.
Equipment structure and components
Combined with the actual equipment or detailed structural drawings, show employees the overall appearance and layout of the skimmer, including the location and function of various operating panels, indicator lights and buttons.
Analyze in-depth the key structural components inside the equipment, such as conveyor belts, rollers, gripping manipulators, pneumatic or electric actuators, pallet transfer chains, etc., and explain their working methods and the connection relationship between them.
(ii) Operation flow
Preparation before start-up
Check the environment around the equipment to ensure that there are no debris obstructing the operation of the equipment and that the ground is clean and dry to prevent slip and fall accidents.
Check whether the various parts of the equipment are in the initial position, such as whether the gripping robot is in the home position, whether the pallet is in the starting loading position, etc..
Check whether the power supply and gas source (if pneumatic equipment) are connected normally and stably, whether the power supply voltage meets the requirements of the equipment, and whether the pressure of the gas source reaches the specified value.
Confirm that the lubrication system of the equipment has been normally filled with lubricant, and that all moving parts such as guide rails, screws, hinges, etc. are well lubricated to minimize wear and running resistance.
Start and run operation
Turn on the power switch, start the sub-systems in accordance with the operating procedures, such as starting the conveyor system, observe whether the belt or chain running in the right direction, whether the speed is smooth; and then start the gripping system, check the opening and closing of the manipulator is flexible and accurate, and so on.
When the equipment enters the standby state, place the rotor to be collected in the designated position on the feeding conveyor belt, pay attention to the direction and number of rotors should be placed in accordance with the requirements of the equipment.
Press the button to start charging, and the equipment starts to run automatically. Employees need to closely observe the status of the rotors during the transfer process, whether there are any abnormalities such as stagnation, falling, etc.; at the same time, pay attention to whether the gripping action of the gripper robot is accurate and whether it can place the rotors to the correct position on the pallet smoothly.
Monitor the transfer and replacement process of the pallet to ensure that the pallet can be automatically switched to a new empty pallet when it is full of material, and that the positioning of the pallet is accurate to avoid rotor placement deviation.
Shutdown operation
When the feeding task is completed or the operation of the equipment needs to be suspended, first stop feeding and wait for the equipment to finish feeding all the rotors currently being processed.
Turn off the operation switches of each sub-system in turn, such as stopping the gripping system first, then turning off the conveyor system and so on.
Turn off the power supply and gas source of the equipment (if applicable), clean up the dust and sundries on the surface of the equipment and its surroundings, and keep the working area neat and tidy.
(iii) Safeguard Precautions
Electrical safeguard
It is strictly prohibited to carry out internal maintenance, cleaning or adjustment operations while the equipment is energized. If you need to carry out electrical maintenance, you must cut off the power supply first, and hang a “no-closing” warning sign at the power switch to prevent others from misoperation leading to electric shock accidents.
Regularly check the electrical wiring of the equipment for damage, aging, exposure, etc., and find problems for timely repair or replacement. Electrical wiring should be reasonably laid out to avoid friction with moving parts or being baked by high-temperature parts.
Employees should avoid touching electrical equipment and buttons with wet hands when operating equipment to prevent the risk of electric shock. In case of electrical faults leading to emergencies such as smoke or fire in the equipment, dry powder fire extinguishers should be used immediately to extinguish the fire and report to the supervisor in time.
Mechanical protection
During the operation of the equipment, it is strictly prohibited to put your hands, head or other body parts into the range of the moving parts of the equipment, such as conveyor belts, gripping manipulators, pallet conveyor chains, etc., to prevent being pinched or bumped.
Before the equipment is turned on, be sure to check whether the guards are intact, such as belt guards, emergency brake buttons and so on. The guards should not be disassembled or damaged at will. If the guards are found missing or damaged, they should be stopped immediately and repaired before they can be used further.
When the equipment jamming, abnormal noise or vibration and other faults, you should first stop the equipment running, until the equipment is completely stopped before troubleshooting and processing. It is strictly prohibited to forcibly deal with the faults under the running state of the equipment, so as not to cause more serious mechanical damage or personal injury.
Other protective points
Train employees in the proper use of personal protective equipment, such as coveralls, work shoes, protective gloves, etc., which must be worn neatly when operating the equipment to minimize potential risks.
Inform employees to set up obvious warning signs around the equipment, such as “Dangerous Area”, “No Approach”, etc., to remind other personnel to pay attention and avoid unrelated personnel from entering the equipment operation area.
Emphasize that during the operation of the equipment, employees should not leave their posts without authorization, and should always pay attention to the operating status of the equipment and take timely measures in case of abnormalities.
(IV) Maintenance
Daily maintenance
At the end of each day's work, clean the surface of the equipment, remove dust, oil, iron filings and other impurities, and keep the appearance of the equipment neat and tidy.
Check whether the tension of the transmission belt and chain is appropriate, and adjust it in time if there is any slackness. At the same time, check whether the belt and chain are worn, broken, etc., and replace them in time when problems are found.
Check whether the gripping jaws of the gripping manipulator are worn, deformed or loose, if any abnormality needs to be repaired or replaced. Check whether the movement joints of the manipulator are flexible, if there is any jamming, appropriate amount of lubricant should be added for lubrication.
Check whether the pallet is damaged or deformed, and whether the pallet conveyor mechanism is running normally and whether there is any stagnation phenomenon. Clean up the debris on the pallet transfer track to ensure smooth pallet transfer.
Check the lubrication system of the equipment to ensure that there is enough lubricant in the lubricant tank, and check whether the lubrication points have normal oil, such as lubrication should be found in a timely manner to investigate the causes of poor lubrication and deal with.
Regular maintenance
Check the electrical system of the equipment once a week, including whether the electrical lines are firmly connected, whether the electrical components are working properly, and whether the grounding protection is reliable. Use compressed air or brush to clean the dust inside the electrical control cabinet to prevent electrical failure.
Inspect and maintain the equipment's pneumatic system (if applicable) every two weeks. Check whether the air source treatment triplex (filter, regulator, oil mist) is working properly, whether the filter needs to be drained or the cartridge replaced, and whether the lubricant in the oil mist is sufficient. Check whether there is leakage in the pneumatic pipeline, if there is leakage, it should be repaired in time. Clean and lubricate the pneumatic actuating elements such as cylinders, solenoid valves, etc., to ensure that their actions are sensitive and reliable.
Carry out in-depth maintenance on the mechanical transmission parts of the equipment once a month. Dismantle and clean the transmission rollers, bearings, screws and other components, check their wear and tear, for serious wear and tear of the components should be replaced in time. After reassembling, add appropriate amount of high-quality lubricant or grease, adjust the fit gap of each part to ensure the mechanical transmission precision and stability of the equipment.
Test and calibrate the precision of the equipment once a quarter, such as the positioning precision of the gripping manipulator and the positioning precision of the pallet. Use professional testing tools and methods to measure the precision indicators of the equipment, such as found that the precision deviation exceeds the permissible range, should be adjusted and calibrated in a timely manner, in order to ensure the quality of the receipt of materials.
(E) common fault handling
Transmission system failure
Failure phenomenon: the rotor transfer speed is not stable, sometimes fast and sometimes slow.
Possible causes: loose conveyor belt, drive motor failure, inconsistent wear and tear of conveyor rollers.
Treatment: adjust the conveyor belt tensioning device; check the motor power connection, if normal, then further check the brush wear or winding short circuit and deal with it accordingly; check the degree of wear and tear of the rollers, slight wear and tear can be adjusted position, serious wear and tear need to be replaced.
Failure phenomenon: conveyor belt deflection.
Possible causes: incorrect installation of the conveyor belt, roller position deviation, uneven distribution of materials.
Treatment: Re-calibrate the installation position of the conveyor belt; adjust the position of the rollers to keep them horizontal and parallel; place the rotor evenly to avoid material bias.
Gripping system failure
Failure phenomenon: the gripper can not accurately grasp the rotor, gripping position deviation or can not grasp.
Possible causes: deformation of the mechanical structure of the gripper, air circuit (pneumatic gripper) or circuit (electric gripper) failure.
Treatment: Calibrate or repair the mechanical structure of the gripper, check the installation position; for pneumatic grippers, check the pressure of the air source, air leakage, cylinder seals, etc., and repair or replace them accordingly; for electric grippers, check the circuit connection, motor driver, sensors, etc., and repair or replace the faulty parts.
Fault phenomenon: gripper gripping force is insufficient.
Possible causes: insufficient air pressure (pneumatic gripper), motor torque set improperly (electric gripper).
Treatment: adjust the air pressure adjustment valve to increase air pressure (pneumatic gripper); adjust the motor driver parameters to increase torque (electric gripper).
Pallet system failure
Failure phenomenon: the pallet can not be accurately positioned.
Possible causes: pallet conveyor precision degradation, positioning sensor failure, pallet size deviation.
Treatment: check the transmission chain or belt and tensioning or replacement, check the drive motor; check the sensor installation position and output signal, repair or replacement of faulty sensors; check the size of the pallet, replace the pallet does not meet the requirements.
Fault phenomenon: pallet lifting mechanism failure.
Possible causes: insufficient hydraulic oil or leakage, oil pump failure (hydraulic lifting mechanism); motor, screw, guide rail failure (electric lifting mechanism).
Treatment: add hydraulic oil, repair leakage, repair or replacement of the oil pump (hydraulic lifting mechanism); check the motor supply voltage, sensor signals, repair or replacement of faulty motors, screws, rails and other components (electric lifting mechanism).
Training and Assessment
Theory assessment
Organize a closed-book examination for new employees, covering the structure of the equipment, operating procedures, precautions, maintenance points and common fault handling methods and other training knowledge. Question types can include multiple choice, fill in the blanks, short answer and expository questions to test the staff's mastery of the training content.
Practical assessment
In the actual equipment operation site, employees are required to follow the standard operating procedures for equipment start-up, operation, shutdown operations, and simulate some common failure scenarios, allowing employees to carry out troubleshooting and processing. The assessor observes the employees' performance in terms of operation proficiency, accuracy and protection awareness, and gives corresponding evaluation and guidance.
Evaluation of assessment results
The training effect of the staff is assessed according to the results of the theoretical and practical assessment. The assessment results are divided into four grades: excellent, good, qualified and unqualified. For the assessment of qualified and above grade employees, the training certificate will be issued to allow them to formally operate the equipment; for the assessment of unqualified employees, arrange for remedial examination or re-training, until the assessment is qualified.
Through all of the above systematic pre-employment training content, can make the new staff quickly familiar with the motor motor rotor automatic rewinding machine related knowledge and skills, for the production and operation of the enterprise to provide strong manpower support guarantee. In the actual training process, according to the specific characteristics of the equipment and the actual needs of the enterprise, the training content can be appropriately adjusted and supplemented. ※ If you need help, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
