What are the contents of the pre-service training for the employees of the serial motor motor automatic terminal press?
Serial motor motor automatic crimping machine staff pre-training content usually covers the following aspects:
1, the basic knowledge of equipment
l equipment structure and principle: a detailed introduction to the overall structure of the automatic crimping machine, including the serial motor, drive system, crimping mechanism, feeding device, control system and other parts of the composition and layout, so that employees have an intuitive understanding of the equipment. In-depth explanation of the working principle of the series excitation motor, such as electromagnetic induction principle of how to drive the motor operation, as well as the motor speed, torque characteristics. At the same time, elaborate the workflow of the terminal press, from the feeding and positioning of terminals and wires, to the execution of crimping action, and then to the discharge of the finished product, so that employees can clearly understand the complete work process of the equipment, and understand the synergistic relationship between the various components.
l Equipment models and parameters: Train employees to recognize the model of the crimping machine, and understand the differences between different models of equipment in terms of function, performance and application scenarios, for example, some models may be suitable for specific specifications of the terminals or wires, or have a higher crimping accuracy and speed. For the key parameters of the equipment, such as motor power, speed, crimping pressure, feed length and speed, terminal crimping size, etc., to explain in detail, so that employees understand the impact of these parameters on the quality of terminal crimping and productivity, as well as how to make reasonable parameter adjustments and settings according to the actual production needs.
2、Protection operating procedures
l Electrical Protection: Emphasize the dangers of the electrical system of the equipment, train employees how to identify the danger signs and warning signs on the electrical equipment, so that they are always vigilant in the operation process. Teach employees the correct operation methods of electrical equipment, such as the electrical inspection steps before starting the machine, including checking whether the power lines are connected correctly, whether the grounding is good, and whether the electrical components in the control cabinet are normal, etc.; and the order and precautions for disconnecting the power after shutting down the machine, so as to prevent electrocution accidents due to misoperation. At the same time, employees are taught to deal with electrical fires, short circuits and other emergencies, such as how to use fire extinguishers to extinguish fires, how to quickly cut off the power supply, etc., to ensure that employees can take the correct and effective measures to save themselves and each other in the event of electrical accidents.
l Mechanical protection: Explain the risks of mechanical injury that may exist during the operation of the terminal press, such as the pressure injury of the stamping mechanism, the danger of entanglement of the transmission parts, the pinch injury of the feeding device, and the collision injury that may be caused by the vibration and displacement of the equipment during operation. Train employees on how to conduct mechanical inspections before, during and after equipment operation, including checking whether stamping dies are securely mounted, whether guards for drive belts and chains are intact, and whether feeding rails are smooth and free of foreign objects. Teach employees the correct operation posture and standing position to avoid being close to the dangerous area when the equipment is running, such as forbidding reaching or placing objects under the stamping die, not crossing or leaning on the equipment when it is running, etc., to ensure that the employees can effectively avoid mechanical injuries during the operation process.
l Fire protection: Popularize fire protection knowledge to employees, including fire prevention measures, such as keeping the workplace clean and avoiding the accumulation of flammable materials around the equipment; regularly check and maintain fire protection facilities, such as fire extinguishers and fire hydrants, to ensure that they are in normal working condition. Train employees on how to properly use fire fighting equipment, such as the correct way to hold fire extinguishers, the spray angle and distance when extinguishing fires, as well as evacuation methods in case of fire, such as familiarizing themselves with the location of the exits in the workplace, mastering the skills of escaping from the workplace such as moving forward in a low position and covering their mouths and noses with a wet towel, so as to improve the fire fighting awareness of the staff and their ability of escaping from emergencies.
3、Operating skills training
l Equipment start and stop: Explain in detail the preparatory work before the start of the terminal press, including checking the integrity of all parts of the equipment, lubrication, and the normalcy of the electrical system. Train the staff to start the equipment according to the correct operation steps, such as closing the main switch of the power supply first, and then start the control switches of the motor, control system, feeding device and other parts in turn, while observing whether the starting process of the equipment is normal or not, and whether there is any abnormal sound, vibration or odor and so on. In terms of equipment stopping operation, teach employees how to operate in accordance with normal stopping procedures, such as stopping feeding and crimping action first, gradually reduce the motor speed after the equipment runs smoothly, and then turn off the power switch, and emphasize that it is strictly prohibited to cut off the power supply suddenly when the equipment is running at high speed, so as not to cause equipment damage and accidents.
l parameter setting and adjustment: train employees how to set the parameters of the equipment according to different terminal and wire specifications, such as crimping pressure, feeding length and speed, crimping time. Explain the basis and method of parameter setting, so that employees understand how to determine the appropriate parameter values according to the material, size, shape of the terminals, as well as the thickness and hardness of the wire and other factors, in order to ensure the quality and reliability of terminal crimping, while taking into account the production efficiency. At the same time, teach employees how to adjust the parameters according to the actual situation during the operation of the equipment, such as when the crimping of terminals is found to be not firm, how to increase the crimping pressure appropriately; when there is inaccurate feeding, how to adjust the feeding speed and length parameters, etc., as well as how to accurately adjust the parameters through the equipment's control panel or operator interface, to ensure that the staff is able to skillfully master the setup of the parameters of the equipment and the adjustment of skills. l Daily Maintenance and Repair: Train the staff on daily maintenance and repair.
l Daily Maintenance and Repair: Train the staff on the daily maintenance and repair of the terminal press machine, including the cleaning methods of the equipment, such as what kind of cleaning tools and detergents to clean the surface of the equipment, the internal parts, as well as the frequency of cleaning and precautions; the identification of lubrication points and lubrication operations, such as the lubrication cycle of the stamping mechanism, transmission components, feeding devices, and other lubricating grease types, and how to correctly carry out lubrication operations to ensure that the lubrication of the lubricant is not damaged. Correct lubrication operation, to ensure uniform and appropriate amount of lubrication; inspection and replacement of wearing parts, such as molds, tools, belts, bearings and other wearing parts of the wear and tear of the judgment criteria and replacement steps, and how to ensure the correct operation of the equipment when replacing wearing parts, so that employees can independently complete the daily maintenance of the equipment, to extend the service life of the equipment, to ensure that the equipment operates normally and stably.
4、Quality control and testing
l Terminal crimping quality standards: make clear to the staff the quality standards and requirements for terminal crimping, including specific indicators and tolerance ranges for terminal crimping height, width, depth, tensile strength, appearance quality (such as no burrs, cracks, deformation, etc.). Through physical samples, drawings and technical documents and other information, let employees intuitively understand the differences between different quality levels of terminal crimping, so that they can clearly know what kind of terminal crimping is a qualified product in the process of operation, and what kind of terminal crimping is a substandard or scrap, so as to provide clear guidance for the production of terminal crimping in line with quality standards.
l quality testing methods and tools: training staff to master the terminal crimping quality testing methods and tools, such as the use of calipers, micrometers, projectors and other measuring tools to test the dimensional accuracy of the terminal and operating skills, including how to correctly measure the size of the various parts of the terminal, how to read and record the measurement data and how to determine whether the measurement results comply with the quality standards; the use of tension tester The use of tensile strength testing machine to detect the steps and precautions, such as how to select the appropriate test parameters, how to correctly clamp the terminal test and how to analyze the test data to derive the tensile strength indicators of the terminal; the use of appearance inspection tools (such as magnifying glasses, microscopes, etc.) on the appearance of the terminals to detect the quality of the method and key points, such as how to observe the defects on the surface of the terminals, and how to determine the severity of the defects The staff can skillfully use a variety of testing tools and methods to accurately detect and assess the quality of terminal crimping, timely detection of quality problems and take appropriate improvement measures.
l Quality problem analysis and solution: teach employees how to analyze the quality problems in the process of terminal crimping, such as when the terminal crimping is not secure, the size deviation is too large, the appearance of defects and other quality problems, how to analyze the reasons from the equipment parameter settings, mold status, wire quality, operating methods and other aspects, to find out the underlying factors that lead to quality problems. At the same time, training staff for different quality problems to take appropriate measures to solve the problem, such as through the adjustment of equipment parameters, replacement of molds, replacement of wire, improve the operating process to solve the quality of terminals, improve the ability of employees to solve the actual quality problems, to ensure that the quality of terminal crimping is stable and reliable.
5、Troubleshooting and diagnosis
l common fault phenomenon identification: through pictures, videos and actual cases and other information, to show employees in the operation of the terminal press machine may appear in a variety of common fault phenomena, such as motor does not rotate, speed abnormalities, crimping pressure is not enough, inaccurate feeding, equipment vibration, control system failures and other failure characteristics, so that employees can quickly and accurately identify these fault phenomena, for the subsequent diagnosis of the problem and lay the foundation for troubleshooting. Lay the foundation for subsequent fault diagnosis and troubleshooting work.
l Failure cause analysis method: Train the staff to master the basic methods and ideas of failure cause analysis, such as from the electrical system, mechanical transmission system, control system, working environment and operating methods and other aspects of the failure phenomenon to start, step by step investigation and analysis. For example, when the motor does not rotate, employees should know whether to first check the power supply is normal, whether the motor winding is disconnected or short-circuited, whether the contactor and relay and other control components are damaged, whether the drive belt is broken or slippery and other reasons that may lead to the failure, and find out the real cause of the failure through the exhaustion and analysis of these factors one by one.
l Troubleshooting steps and skills: for various common failures, teach employees the corresponding troubleshooting steps and operating skills, such as in troubleshooting motor speed abnormalities, employees should learn how to use a multimeter, tachometer and other tools to measure and analyze the motor's power supply voltage, current, speed and other parameters, and based on the results of the measurements to determine the fault is in the motor itself, the controller or other related components, and then According to the principle of first easy then difficult, first external then internal, gradually take measures such as replacing fuses, adjusting controller parameters, checking motor brushes and commutator, repairing or replacing motors, etc., to carry out troubleshooting and ensure that the staff can quickly and efficiently take the correct methods to deal with the faults, reduce the downtime of the equipment, and improve the production efficiency.
6、Emergency measures
l Emergency treatment of sudden equipment failure: Train the staff to take emergency treatment measures when encountering sudden failure during equipment operation, such as when the motor suddenly smokes, catches fire or emits abnormal loud noise, the staff should immediately press the emergency stop button, cut off the power supply of the equipment and quickly use the fire extinguisher to extinguish the fire (if it is an electrical fire, carbon dioxide fire extinguisher or dry powder fire extinguisher should be used), and at the same time promptly report to the higher management and maintenance personnel to ensure that the equipment can be quickly and effectively dealt with. At the same time, report to the supervisor and maintenance personnel in time to ensure that the equipment failure is dealt with in time to avoid further expansion of the accident.
l Personal Accidental Injury Emergency Treatment: Teach the staff the emergency treatment method when personal accidental injury occurs in the process of work, for example, when the staff is accidentally involved by the equipment or injured by the mechanical impact, the surrounding colleagues should immediately stop the equipment, quickly call the first aid phone (e.g., 120), and wait for the arrival of the first aid personnel before the injured person to carry out simple first aid treatment, such as stopping the wound bleeding bandage (if there is bleeding), fix the fracture part (if there is fracture), transfer the injured to a ventilated place, etc., to ensure that the injured can get timely and effective treatment and greatly reduce the degree of injury.
l Emergency response to natural disasters such as fires and earthquakes: Conduct training on emergency response to natural disasters such as fires and earthquakes, so that employees can understand how to respond to fires or earthquakes in the workplace. For example, in case of fire, employees should familiarize themselves with the location of evacuation channels and exits in the workplace, and quickly evacuate the site according to the predetermined evacuation routes, cover their mouths and noses with wet towels, and walk in a low position to avoid inhaling smoke; in case of earthquakes, employees should immediately take refuge under tables and other solid furniture, and then evacuate the building in an orderly manner according to the command after the earthquake stops, so as to ensure that employees can protect their lives and minimize casualties in the event of natural disasters. When an earthquake occurs, employees should immediately take cover under tables and other sturdy furniture, and evacuate the building in an orderly manner according to the instructions.
※ If you need any help, please contact the technical specialist of Xinhui Electrical and Mechanical Equipment Co.
