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Repair and modification of imported equipment
Source: Bearing network time: 2013-01-23
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Our company introduced the Austrian Steyr diesel engine project in the 1980s; a large number of imported equipment were used for the production of the tightening process. In recent years; after the repair and absorption of imported equipment; in the repair of equipment; skill transformation and localization of imported equipment spare parts He has done a lot of homework; he has gained valuable experience; it is useful in the practice of production; and has achieved remarkable economic and social benefits.
First, the equipment repair in order to make the imported equipment repair work habits modernized company's demand; improve the repair quality of imported equipment; promote the company's product brand effect; we do three-place guidelines in the import equipment repair.
1. Analyze the problem in the past repair work; everyone is accustomed to finding faults and eliminating faults as the content of the repair operation; in fact, this is only a part of the repair work. In the repair of imported equipment; more importantly, Analyze the cause of the occurrence of the disease; avoid adopting countermeasures to prevent repeated episodes of similar problems. Because the drawings and random materials of imported equipment are lacking; the repairing experience of the repairing equipment is less; the more careful and careful analysis of the disease is required; The strike and repair of the equipment took time and ruin. For example; a K4960 double-axis hole boring machine introduced by Austria was put into operation, and the spindle hole was not cross-cut and cross-cut uneven; because it was unfamiliar with the machine tool; After dissecting the discussion, it was decided to dismantle the imported mast for alignment inspection and repair. After the mast was dismantled, it was found that the slider in the cross-cutting knife was severely corroded; the feed was uneven when the knife was raised; the bottom edge was not matched by the chip liquid. Reasonable and smooth sliders in the mast. If there is no deepening, there is alignment fault analysis; blind intention to dismantle Complement; only cause of the malfunction can not handle the machine base; and equipment problems to be dangerous; shorten life of the machine; reduced machining accuracy.
2, the adoption of the method in place is the so-called method is to completely eliminate the cause of the problem; so that similar problems no longer occur. The method is in place; refers to the selection method is useful and reliable. To apply sophisticated skills or layout guidelines according to existing conditions; do not present new ones Responsible links and the source of the attack. In the above, for example, the economically viable methods; which one is better? It is necessary to think about the problems in dealing with machine tools; it is also necessary to think about the cost; if the cost of using imported cuttings is higher than the cost of using domestic high-quality cutting fluid, it will be several times higher or even hundreds of times higher. According to the above reasons; The method is to select the domestically produced high-quality cutting liquid to make the ratio reasonable; to strengthen the mast seal and the mast slider smooth. After the selection of high-quality oil seal for the cutting liquid protection; after the selection of Mobil 3# smooth oil for the slider is smooth; after long time use The above problems are presented again.
3, the repair record should be in place.
Take this unit as an example; we will monitor these imported equipment as bottleneck equipment in the production process; establish equipment repair records, equipment repair notices and other imported equipment repair files. The equipment repair records include: 1) equipment title 2) fault location 3) Causes of faults 4) Types of faults 5) Treatment methods 6) Replacement of spare parts title, type 7) Remaining problems 8) Repair of personnel 9) Date and strike hours. Every repairer needs to fill in carefully and carefully; Repairing this equipment; it will be very convenient. Equipment repair notice; each shift equipment will be filled out after repair; in order to summarize. Others; the establishment of import critical equipment fault files in the middle of maintenance; network processing. Thorough equipment repair records; Quickly find faults; shorten the important guarantee of repair time.
4, strengthen equipment inspection; pre-inspection pre-repair; to achieve the equipment's predictive repair time capital is the heavy burden of machine tool repair costs; imported CNC machine tool stop loss is usually 100~500 yuan / hour; large machine tools or even thousands of yuan / Hours. In order to better save time capital; pre-screening pre-repair of imported equipment; to achieve predictable repair; to deal with faults in germination; is the general direction of equipment repair operations in the future.
Second, the transformation of equipment in the late 1980s; imported equipment in terms of processing accuracy and processing power; still the degree of initiative is attributed to the international and domestic first-class level. Imported equipment for our company with high quality and high output value products in the fierce market In the competition, it has gained a firm foothold; it has made a major contribution to the production base of the largest high-speed diesel engine in China.
However, with the passage of time and long time; some machine tools are significantly reduced in accuracy; the precision requirements required for the product are not met; and the loss of various organizational components is also very serious; the machine tool has many problems and shortcomings; The precision requirements of new products. After years of repairing the imported equipment; in order to better use imported equipment for production; we have achieved a very good experience in the transformation of imported equipment.
1. The correct plan is to change half of the work.
After a reform project was put forward, the investigation and discussion on the transformation target was fully deepened. Our 4RPL and 5RPL Japanese grinding machines were introduced in the 1980s; they are mainly responsible for the finishing mission of the main shaft and connecting rod neck of the diesel engine crankshaft; Due to long-term work wear; active grinding wheel trimming organization; the roughness of the workpiece after grinding of the finished wheel can not meet the process requirements of the product, and the rounded corners of R4 and R5 can not meet the drawing requirements of the original machine tool. , the demonstration of the craftsman and the repairing staff; the screening of multiple sets of renovation plans. 17 17. 惶 惶 è‰½é” è‰½é” è‰½é” è‰½é” ãž ãž ãž ãž çžŽ 瞎 瞎 瞎 瞎 瞎 å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’± å’±Wear parts are de novo drawn and improved; the original diamond grinding pen is changed to a new wheeled multi-point granular diamond grinding wheel; improved finishing precision and R5, R4 forming precision. In the aspect of model change; Scientific accounting and certification. The accuracy and shape of the mold directly affect the dressing track of the grinding wheel and the precision of the workpiece; it is the key part of the trimming organization; its conclusion Success; ensure the machining accuracy of the machine.
2. Reasonable implementation and verification.
Determined the transformation plan of the machine tool; the equipment, commissioning and verification in practice must be reasonable; there is no trace of omission; this is the key to the success of the technical transformation. Take the above-mentioned transformation plan as an example; drawings of various cheap spare parts are made to the parts. The processing must be specially staffed; the purchased standard parts must also be of quality first; conform to the national standards. After all the preparations are completed, it is the critical device and debugging period; it must be caught during the installation and debugging process. Two criteria of safety and reliability; special transformation of imported equipment; the reliability of machine tools is the first. If you do not think hard about protection and security organization interlocking; it will become a disaster. A successful Reconstruction; the demand is verified in practice. The results of the modified machine tool after commissioning and trial cutting are consistent with the theoretical analysis; the arrival and even better than the original organization; the equipment is completely satisfied with the process requirements.
3. Revision of equipment materials and equipment modification Because of changes in functions and layouts, it is necessary to revise the random materials and skill drawings of the original machine tools; in fact, it reflects the technical transformation of the equipment. However, some machine tool equipment transformations were found in practice. There are some minor changes; no corresponding revisions and clarifications have been made on the associated skills documents; the constituent documents are inconsistent with the practice; the repair of imported equipment is severely restricted. Therefore, the revision of the equipment materials after the transformation; the renovation and repair operations Perfection.
Third, the research and application of localization of imported equipment spare parts.
The composition of the imported equipment, subordinate spare parts and fixtures are highly accurate. Because the computer skills, information skills, and active skills are widely used in the manufacturing industry; combined with the use of new materials and new processes; the spare parts of imported equipment are highly accurate. Its equipment and according to systemization, standardization, generalization depiction; also has greater flexibility and specificity; in the processing accuracy and process has a significant skill advantage.
With the passage of time; the problems of imported equipment are becoming more and more frequent; the factors affecting the quality of repairing and repairing speed have the following aspects: 1) less random materials; unable to accurately grasp the principle of equipment control; 2) damaged parts are difficult to buy in China To, 3) spare parts accuracy can not meet the demand, etc. The most important thing is the spare parts; if the spare parts work is done; other aspects are easy to escape.
In spite of the problem of aligning spare parts, we have adopted corresponding measures; such as establishing a special imported spare parts warehouse; setting up a special person to handle; maintaining contact with imported equipment agents; but the spare parts problem still faces three problems: First, our existing spare parts Basically, they are purchased together with the equipment; the quantity is limited; in the repair of several years; some common spare parts are no-inventory; second, some spare parts are often used for their particularity and specificity; The replacement of spare parts; the high investment of repair costs will affect the cost of the product, and the third is to follow the rapid development of science and technology; many spare parts are replaced by newer ones; the procurement method is not smooth; it will affect the organization of production.
In view of the above situation, the localization of the components of imported equipment is an urgent task that we face; it has far-reaching meaning and great prospects for development. It is often replaced by rational scientific selection; it can not only improve the operating power; it also saves A lot of money; going to significant economic benefits.
Take our factory as an example; Austria K4950 machine tool; the spindle hole and camshaft hole of the workpiece are required to have higher azimuth requirements and coaxiality requirements; it is a high-precision device; respectively, the azimuth is ±0. 02mm; Axiality of 0. 02mm. Accuracy is mainly based on the front, middle and rear of the three 镗 formwork of the fourteenth German bearing NA4890A/P5 (2 pay); B71930CTP4SDBL (2 pay); B71915CTP4SDBL (8 pay); B71924CTP4S%26# 8226; VT (2 pay) to ensure that. In the purchase of equipment and the use of more than 800,000 yuan to purchase a number of this bearing as a spare parts inventory. Because of the processing mission and machine aging; under normal circumstances; at least monthly Two replacements are carried out; and the standard parts of imported equipment are expensive and the procurement period is long; directly affecting the output and cost of the products. Therefore, it is necessary to localize the imported equipment spare parts. Let us try to replace them with domestic high-precision bearings; The precision, azimuth and coaxiality of the workpiece in the machining process have reached the process requirements. After the standardization of the localization; useful to reduce the cost of repair.
After years of repairing imported equipment; our repair personnel from learning, exploratory repair to grasp the imported equipment, technical transformation; cultivated a large number of high-quality, high-skilled repair staff. Scientific skills are constantly developing; Let us work together; to improve the level of imported equipment repair; to fight for the cultivation of a high-quality imported equipment to repair troops.
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