What are the contents of the pre-service training for employees of the String Excitation Motor Motor Stator Press End Plate Machine?
Series excitation motor motor stator press end plate machine employee pre-service training content includes:
1、Equipment principle and structure
The working principle of series-excited motor: explain in detail the electromagnetic induction principle of series-excited motor, how the current passes through the stator and rotor windings, generating a rotating magnetic field to drive the motor, so that employees understand the basic operating mechanism of the motor and the characteristics of the series-excited motor (e.g., the speed of rotation varies greatly with the load, etc.), in order to lay the foundation for the subsequent understanding of the overall operation of the equipment and diagnosis of the faults.
Mechanical structure of end-plate press: introduce the overall structure of the end-plate press, including the position and role of the frame, press head, table, transmission system (such as screw drive, belt drive, etc.), guiding device and other components, so that employees have a clear understanding of the physical composition of the equipment, and clear how the various parts of how to work together to achieve the stator end-plate press fitting.
Equipment electrical system: explain the composition of the electrical system, such as power supply, motor controller, contactors, relays, sensors (pressure sensors, position sensors, etc.) and their connection and role, so that employees understand how the equipment through the electrical control to achieve automated operation and precise control of the press-fitting process.
2、Operation process and standardization
Preparation before starting the machine: teach the staff to check whether there is any damage to the appearance of the equipment, whether the connection of each part is firm, clean up the debris around the equipment and foreign objects on the working table; check whether the power connection of the electrical system is normal, whether the voltage is stable, and whether the various switches and buttons are in the initial position; make sure that the lubrication system is normal, and whether there is sufficient lubricant or grease in each lubrication point; check whether the cooling system (if there is any) is Check whether the cooling system (if any) is running normally, whether the water level of the water tank is in the normal range, and whether there is any leakage of the water pipe, etc., to ensure that the equipment can run stably after starting.
Equipment startup: start the equipment in the correct order, first turn on the main power supply, then turn on the control power supply, wait for the equipment self-test to be completed (if there is an indicator or display prompt), observe whether the meters and indicators are displayed normally, and confirm that there is no abnormal alarm information, then start the motor, pay attention to the sound and vibration of the motor startup, and if there is any abnormality, it should be shut down immediately to check it.
Pressing end plate operation: demonstrate how to place the stator correctly on the working table to ensure accurate positioning; according to the stator type and process requirements, set the appropriate pressure, speed and holding time and other parameters on the control panel; start the pressing procedure and observe the movement of the press head to ensure that the pressing process is smooth and without any abnormalities such as jamming and impact; after the completion of the pressing, check the quality of the end plate, including whether it is After the press fitting is completed, check the quality of end plate press fitting, including whether it is firm, flat, with or without offset, deformation, etc. If quality problems are found, the parameters of the equipment should be adjusted or the mold and other components should be checked in time.
Shutdown process: After completing the work, first stop the press fitting operation and lift the press head to a high position; turn off the motor and wait for the motor to stop running completely; turn off the control power supply and the general power supply in turn; clean up the residual materials and wastes on the working table of the equipment, and carry out a simple cleaning of the equipment, such as wiping the surfaces of the press head and the working table, etc.; check whether the various parts of the equipment are in a normal state of stopping, and make preparations for the next start-up.
3、Precautions
Electrical: Emphasize the electrical hazards of the equipment, such as the risk of electric shock, teach employees to strictly prohibit wet hands to operate the equipment, do not feel free to touch the electrical components and wires; in the electrical maintenance or inspection, the power supply must be cut off first, and hang the “someone working, prohibit the closing of the gate” warning signs; regular check of the grounding of the electrical equipment, to ensure that grounding good, to prevent leakage accidents; when an electrical fault occurs (such as smoke, fire, short-circuit tripping, etc.), the power supply should be cut off immediately and a dry powder fire extinguisher should be used to extinguish the fire, and it is strictly prohibited to use water or foam fire extinguishers.
Machinery: Inform employees that during the operation of the equipment, it is strictly prohibited for any part of the body to touch the parts that are running, such as indenter, transmission parts, rotating motor shafts, etc., to prevent the occurrence of mechanical injuries such as pinching, involvement, collision and other mechanical injuries; when installing, dismantling molds or making adjustments to the equipment, it is necessary to stop the machine and use the appropriate tools, and it is strictly prohibited to carry out these operations while the equipment is running; the equipment should be equipped with the necessary protective devices, such as Protective doors, light curtains, emergency stop buttons, etc. Employees should understand the location and use of these devices to ensure that the equipment can be quickly stopped in case of emergency; regularly check the effectiveness of the protective devices, such as the closure of the protective doors is normal, whether the light curtains are sensitive, etc., and if there are any problems, they should be repaired or replaced in a timely manner.
Other matters: remind employees to wear personal protective equipment in the workplace, such as overalls, protective shoes, gloves, etc., to prevent material splashing, smashing and other accidents; clean up and properly store flammable and explosive materials around the equipment to prevent fire and explosion accidents; in the process of equipment maintenance, use tools and equipment that meet the requirements, and comply with the operating procedures to avoid accidents caused by improper operation. Accident.
4、Daily maintenance knowledge
Cleaning and maintenance: teach employees to clean the equipment every day, including wiping the dust and oil on the surface of the body, cleaning up the material residues and debris on the workbench, to keep the equipment neat and clean; regularly clean up the dust inside the equipment, such as the motor heat sinks, electrical control cabinets, and other parts, you can use compressed air or a small vacuum cleaner to clean up, but pay attention to avoid damage to the electrical components; clean the equipment guide rails, screws and other Moving parts of the equipment, remove dirt and impurities, and apply the appropriate amount of lubricant to ensure smooth movement and reduce wear and tear.
Lubrication and maintenance: introduce the parts of the equipment that need to be lubricated, such as bearings, guide rail slider, screw nut, transmission chain, etc., and explain the type and specification of the lubricant or grease used in each lubrication point; formulate lubrication plan, specify the lubrication cycle, and teach the staff how to use the lubrication tools (such as grease injector, grease gun, etc.) for lubrication operation correctly, so as to ensure that the parts are adequately lubricated to prolong the service life of the equipment; Regularly check the working condition of the lubrication system, such as whether the oil level of the lubricant is normal, whether the oil pipe is blocked or leaking, etc., and replenish or replace the lubricant in time.
Mechanical parts inspection: train employees how to check whether the mechanical parts of the equipment is normal, such as observing whether the pressure head is worn, deformation, whether the connection parts are loose; check the transmission parts of the belt, chain whether the tension is appropriate, there is no wear and tear, breakage phenomenon, gear mesh is good; check whether the guide rail is parallel, straightness is in line with the requirements of the slider movement is flexible, etc.; regular fastening inspection of mechanical components The fasteners such as loose bolts, nuts, etc. are tightened to prevent equipment failure due to loose parts.
Maintenance of electrical system: Teach the staff to regularly check whether the wiring of the electrical system is firm, whether there is any loosening, oxidation, burning and other phenomena, if any problem to repair or replace in time; check the electrical components (such as contactors, relays, switches, buttons, etc.) is in normal working order, whether there is any abnormal heat, noise or malfunction of the action, and so on, and replace the faulty components in time; use the multimeter and other tools to test the winding resistance, insulation resistance of the motor on a regular basis. The winding resistance, insulation resistance and other parameters of the motor to ensure the normal operation of the motor; backup of the electrical control system to prevent program loss, and regularly check the operation of the control system, update the software version in time to improve the stability and performance of the equipment.
5、Quality control points
Press-fitting quality standards: clearly inform the staff of the quality standards of stator end plate press-fitting, such as the fit of the end plate and stator should meet the requirements (the gap shall not exceed a certain value), the end plate after press-fitting should be kept flat, there shall be no obvious warping, deformation, etc.; explain how to observe, measure and other methods to determine the quality of the press-fitting qualified, such as the use of a plug ruler to measure the gap between the end plate and the stator, the use of caliper or micrometer to measure the flatness of the end plate.
Process quality control: teach the staff how to carry out quality control in the process of press-fitting, such as checking whether the mold is clean and intact and whether the positioning is accurate before each press-fitting; pay attention to observing whether the operating parameters of the equipment (e.g., pressure, speed, etc.) are stable in the process of press-fitting and stop the machine in time for checking if there is any abnormal fluctuation; emphasize that after each completion of a certain number of press-fitting, we should carry out sampling inspection of the quality of press-fitting, so that quality problems can be detected and solved in time to avoid batch defects and avoid the problem of batch failure. Solve quality problems in time to avoid the emergence of batch unqualified products; Record the quality data in the process of press-fitting, such as press-fitting pressure, holding time, product number, etc., in order to trace back and analyze the causes of quality problems.
Abnormalities: Train employees how to investigate and deal with abnormalities in press-fitting quality when they occur. For example, if it is found that the end plate is not firmly pressed, the possible reasons include insufficient pressure, mold wear, stator surface oil, etc. Employees should be able to check and eliminate these possible reasons step by step, and take appropriate measures to adjust or repair, such as increasing the pressure of the press-fit, replacing the molds, cleaning the surface of the stator, etc., to ensure that product quality meets the requirements.
6、Troubleshooting and troubleshooting basis
Identification of common fault phenomena: introduce the common fault phenomena of the equipment to the employees, such as motor does not start, indenter does not move, abnormal pressure, inaccurate position control, etc., through pictures, videos or actual cases to show, so that employees can quickly and accurately identify these fault phenomena for the subsequent troubleshooting and diagnosis of faults to provide the prerequisites.
Troubleshooting methods: Teach employees basic troubleshooting methods, such as according to the fault phenomenon, first start from the simple aspects of the inspection, such as whether the power supply is normal, whether the wiring is loose, whether the fuse is blown, etc.; for electrical faults, you can use a multimeter and other tools to measure parameters such as voltage, resistance, current, etc., to determine whether the electrical components are damaged; for mechanical failure, you can observe the appearance of the components, For mechanical failures, you can observe the appearance of the components, the movement, listen to the sound, feel the vibration and other ways to determine the cause of the failure; gradually narrow down the scope of the failure to determine the specific part of the failure and the cause.
Simple troubleshooting: Train employees to troubleshoot some simple faults, such as replacing blown fuses, tightening loose terminals, cleaning up blocked air or oil pipes, etc.; for some faults that require replacement of parts, such as worn motor brushes, sensor failures, etc., teach employees how to correctly dismantle and replace these parts, and emphasize that the replacement of parts should be carried out after the corresponding debugging and testing to ensure that the device Restore normal operation; let employees understand that when encountering complex faults that can not be eliminated on their own, they should report to the supervisor or professional maintenance personnel in a timely manner, and should not carry out unauthorized maintenance operations, so as not to cause greater damage to the equipment.
7、Teamwork and communication
Collaboration in the workflow: explain the roles and responsibilities of employees in the entire production process, as well as the collaborative relationship with upstream and downstream positions. For example, collaborate with material supply personnel to ensure the timely supply of stator and end plate, collaborate with quality inspection personnel to ensure that product quality meets the standards, and equipment maintenance personnel to collaborate on equipment maintenance and troubleshooting, etc.; Emphasize the importance of teamwork to improve production efficiency and product quality, and encourage employees to actively cooperate with the work of other positions to jointly complete the production task.
Information Communication and Feedback: Teach employees how to communicate effectively in the work, including reporting to supervisors on work progress, equipment operation, quality problems, etc.; exchanging operating experience, technical insights, troubleshooting methods, etc. with coworkers; transmitting product quality information and equipment status information to downstream positions; establishing a good information feedback mechanism to ensure that problems can be resolved in a timely manner to avoid production delays or quality problems due to poor information. To establish a good information feedback mechanism to ensure that problems can be solved in a timely manner, to avoid production delays or quality problems due to poor information; to encourage employees to put forward suggestions and ideas to improve workflow, productivity and product quality, and to promote the overall level of the team.
※ If you need any help, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
