What is the content of the pre-service training for motor motor rotor automatic balancing machine employees?
The following are the details of the pre-service training for motor motor rotor automatic balancing machine employees:
First, the theoretical knowledge to explain
1, balancing machine working principle
In-depth explanation of the concept of dynamic balancing, that is, when the rotor is rotating, due to uneven mass distribution and centrifugal force, balancing machine how to detect this centrifugal force and its caused by vibration, displacement and other signals, the use of the relevant algorithms to calculate the size of the rotor's inequality and phase. For example, use the principle formula of mechanics to show employees the relationship between the amount of unevenness and parameters such as centrifugal force, rotational angular velocity, rotor radius, etc., to help them understand the theoretical basis of balancing machine measurement.
Introduce the main components of the balancing machine, such as the mechanical system (including the rotor support device, transmission mechanism, etc.), the measurement system (various types of sensors and their modes of operation), and the control system (control circuits, computer software, etc.) in realizing the synergistic operation mechanism in the process of balance measurement and calibration. Detailed explanation of the function of each part and the signal transmission path between each other, so that employees have a clear understanding of the overall structure of the balancing machine.
2、Equipment structure and function
Lead employees to observe the balancing machine in the field, and introduce in detail the appearance and structure of the equipment, including the position and function of each part of the body frame, protection device, operation panel, etc. For example, explain the buttons on the operation panel. For example, explain the function of each button, indicator and display on the operation panel, such as the start button, stop button, emergency brake button, speed display, unevenness display, etc., so that employees are familiar with how to carry out basic control and parameter setting of the equipment through the operation panel.
In-depth analysis of the internal structure, such as opening the equipment shell to show the structure of the mechanical transmission part, including the connection and transmission ratio of the pulley, coupling, drive shaft, etc.; explaining the installation position and installation method of the sensors in the measurement system, such as the displacement sensor is installed close to the rotor in order to accurately measure its vibration displacement, and the speed sensor is coordinated with the rotor's speed marker to obtain the rotational speed signal, etc.; introducing the The layout and function of the circuit board, chips, terminals, etc. in the control system, so that the employees have an intuitive understanding of the internal structure of the equipment, laying the foundation for the subsequent maintenance and troubleshooting.
3、Operating regulations
Emphasize the importance of protection, and explain the hidden dangers that may exist during the operation of the balancing machine, such as the personnel injury that may be caused by the high-speed rotor, the electric shock accident that may be triggered by the electrical part, and the pinch injury that may be caused by the movement of mechanical parts. Through actual case studies, employees are made to deeply realize the serious consequences of not complying with the regulations.
Detailed introduction of operating procedures, such as before the start of the equipment must check whether the rotor is correctly installed, firmly fixed, whether the protective device is intact; in the process of equipment operation, it is strictly prohibited to open the protective door, reach out and touch the rotating parts; in the maintenance and overhaul of the equipment, the power supply must be cut off first, and to take appropriate locking measures to prevent others from accidentally starting the equipment, and so on. At the same time, train employees to use personal protective equipment correctly, such as protective gloves, goggles, etc..
4、Quality control standards
Explain the quality control indexes of the balancing machine, such as the allowable tolerance range of the unbalance amount, the requirement of residual unbalance amount, etc.. According to different types of motor-motor rotors and their application scenarios, clarify the corresponding quality standards, so that employees understand what kind of balancing results are qualified, and what kind of further correction is required.
Introduce the methods and processes of quality control, such as how to analyze and judge the measurement data after the balancing measurement is completed, and determine whether the calibration operation is needed based on the quality standards; how to choose the appropriate calibration methods (such as weighting and de-weighting) and calibration amount during the calibration process, as well as how to verify whether the calibrated rotor meets the quality requirements. Through practical demonstrations and case studies, employees can master the basic skills of quality control.
Second, practical operation training
1、Basic operation of equipment
The trainer conducts practical operation demonstration beside the equipment, including how to turn on and off the balancing machine correctly, how to set the measurement parameters (e.g. rotor mass, diameter, rotational speed, etc.), how to start the measurement program, and how to read and record the measurement data. During the demonstration, the key points and precautions of each operation step are explained in detail, such as making sure that the input data are accurate when setting parameters, otherwise it may lead to wrong measurement results; checking the installation of the rotor and the status of the equipment again before starting the measurement program, and so on.
Let the staff practice the actual operation under the guidance of the trainer, starting from the simple opening and closing of the equipment, and gradually transitioning to the complete measurement operation process. Trainers in the process of staff operation, timely correction of their faulty operation, to answer their questions, to ensure that employees can master the basic operating skills of the equipment.
2、Rotor installation and disassembly
Demonstrate the correct installation method of the rotor, including how to use special tools to place the rotor smoothly on the supporting device of the balancing machine, how to adjust the position of the rotor so that it can be accurately docked with the transmission mechanism, and how to tighten the fixing bolts to ensure that the rotor is firmly installed and the coaxiality meets the requirements. At the same time, explain the details that need to be paid attention to in the installation process, such as avoiding the rotor to collide with the equipment components, preventing foreign objects from entering into the equipment and so on.
Demonstrate the steps of rotor dismantling, emphasize the need to pay attention to protection in the dismantling process, to prevent the rotor from slipping and hurting people. Allow employees to carry out the actual rotor installation and dismantling exercises, the trainer on the side of the supervision and guidance to ensure that employees can skillfully complete this operation.
3、Balance correction operation
Explain the principles and methods of balancing correction, such as the application and operation steps of weighting correction and de-weighting correction. For weighting correction, introduce how to determine the position and weight of weighting according to the measurement data, and how to add counterweights using welding, sticking and other methods; for de-weighting correction, explain how to use drilling, milling and other methods to remove the amount of unevenness and how to control the amount of de-weighting and positional accuracy.
The trainer conducts a practical demonstration of balance calibration, including how to select the appropriate calibration tools and materials according to the measurement results, how to carry out precise weighting or de-weighting operations on the rotor, and how to take measurements again after completing the calibration in order to verify the calibration effect. Allow employees to practice the actual operation of balance calibration under the guidance of the trainer, through repeated practice, so that employees can master the balance calibration skills of different types of rotors.
4、Routine maintenance
Explain the daily maintenance of the balancing machine, including the cleaning of the equipment, such as regularly wiping the body, cleaning the rotor support device and transmission components on the dust, oil, etc.; lubrication and maintenance of mechanical parts, such as how to add grease or lubricant to the bearings, guide rails and other parts of the lubrication, as well as lubrication cycle and dosage; check the equipment to see if the connecting parts are loose, such as bolts, nuts, terminals, etc., and tighten them in a timely manner; check the sensor to see if it's loose or not; check the sensor to see if it's loose or not. Tighten in time; check whether the sensor is working properly, such as cleaning the sensor surface, check whether the sensor wiring is good.
Demonstrate the practical steps of daily maintenance, such as how to use the correct cleaning tools and lubrication tools, how to check the various performance indicators of the equipment (such as the use of a multimeter to check the electrical line on and off, the use of vibration meter to check the vibration of the equipment, etc.). Let the staff under the guidance of the trainer to carry out the daily maintenance of the actual operation of the practice, so that employees develop a good habit of regular maintenance of equipment to extend the service life of the equipment to ensure the normal operation of the equipment.
Troubleshooting and emergency response training
1、Common fault identification
Introduce the common fault phenomena that may occur during the operation of the balancing machine, such as the equipment can not be started, abnormal measurement data, unstable rotor rotation, poor calibration results. Through pictures, videos or actual failure cases, let employees have a visual understanding of these failure phenomena.
Explain the possible causes of each failure phenomenon, e.g. the equipment can not start may be due to power supply failure, control circuit failure, motor failure, etc.; abnormal measurement data may be due to sensor failure, signal processing circuit failure, parameter setting error, etc.. Help employees to establish the initial connection between the fault phenomenon and the cause of the fault, and improve their ability to recognize the fault.
2、Troubleshooting methods
Train employees to master the basic troubleshooting methods, such as from simple to complex, from external to internal troubleshooting order. First check whether the external connection of the equipment is normal, such as whether the power plug is plugged in, whether the data line is firmly connected, etc.; then check whether the operating parameters of the equipment are correctly set; if the external and parameters are not a problem, and then gradually go deeper into the interior of the equipment to check whether there are signs of damage to the electrical components (e.g., circuit boards, sensors, motors, etc.), whether there is any jamming of the mechanical components (e.g., transmission mechanisms, support devices, etc.), wear and tear, etc. and wear and tear.
Introduce the use of some commonly used troubleshooting tools, such as multimeter for checking circuit breakage and electrical parameters, oscilloscope for observing the signal waveform of the sensor output, vibration meter for detecting the vibration of the equipment and so on. Let the staff learn to use these tools for troubleshooting to improve the accuracy and efficiency of troubleshooting.
3、Emergency measures
Explain the emergency measures to be taken in the event of equipment failure, such as when the equipment appears abnormal vibration or noise, should immediately stop the equipment operation, to avoid further expansion of the fault; when an electrical failure caused by smoke, fire and other emergencies, should quickly cut off the power supply, and the use of fire extinguishers to extinguish the fire (and at the same time to train the staff to correctly use the fire extinguisher); when the equipment fails to work properly and When the equipment failure can not work normally and can not be repaired in a short time, it should be reported to the superior in time, and take corresponding measures to adjust the production plan to reduce the impact of equipment failure on production.
Conduct simulation drills of emergency treatment, set up some common failure scenarios, and let the employees operate the emergency treatment under the guidance of the trainer, so as to improve the ability of the employees to deal with the unexpected failures in the actual work.
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