1.5 key point checking and main taining
How to use the limited number of maintenance personnel to ensure the maximum operation of the equipment is the subject of research by our equipment management personnel. Many large-scale equipment and production lines may have many faults, and it is very difficult for maintenance workers to want to cover everything during inspections. On the contrary, many maintenance workers are often left unattended and spend a lot of energy on some minor issues. In response to this situation, we have implemented a working method called “checking and repairing†to guide the daily inspection and maintenance of maintenance workers. This method is to list several of the most critical parts according to the different conditions of each equipment, and send them to the relevant maintenance workers in the form of graphs. It is required to carry out key inspections on these places every day, and find abnormal and timely maintenance. Good result. When setting up the checklist, you must pay attention to the following two points.
1) The key points must be properly and accurately determined. We have integrated the technical manual of the equipment, the opinions of experienced service technicians, and the previous equipment failures.
2) The key point should be “fineâ€. Generally, there are no more than 10 key points in a large equipment or 500 m2 production line, otherwise it is likely to flow in form.
1.6 defect retrofitted
In the long-term maintenance work, we found that some devices often have some repeated faults, and the randomness is very strong. After further analysis, we found and confirmed that the equipment is defective in the design and manufacturing process. It cannot be eradicated only by maintenance, and must be modified to eradicate hidden dangers. To give a typical example, a factory has a vacuum thermoforming machine for refrigerators imported from Italy. The heating control part uses a single-chip system to exchange data with a host computer. The fault that often occurs is that the communication between the single-chip microcomputer and the microcomputer is not smooth, but the power-on or the replacement of a single-chip motherboard may return to normal, and one of the faults will burn out the COM1 port of the microcomputer. Later, after looking up the information, we found that the communication method used in the design was unreasonable. The single-chip microcomputer and the microcomputer adopt the RS232C mode direct connection, there is no isolation, and the cable length exceeds 30 m. We know that the RS232C communication method has poor anti-interference and the communication distance is generally less than 15 m. To this end, we have modified the communication cable, and installed ADAM's 7520-RS485/RS232 optical-to-space converter on both ends, so that RS485 is used to transmit data in most distances, and no fault has ever occurred.
1.7 Real time monitoring
CNC machine tools often have some soft faults, which makes it difficult to diagnose. At this time, the key point signal can be collected and recorded in real time by using a data acquisition card, etc., so that comprehensive analysis can be performed at the time of diagnosis. The advent of "virtual instruments" offers the possibility of real-time monitoring. It should be noted that the monitoring system and the CNC are independent of each other, and the monitoring system is self-made by the end user.
2 Several options for CNC transformation 2.1 Using PLC to realize CNC transformation
In some occasions where the printing and packaging requirements are not too high, and some production line control occasions, the NC transformation task can be completed by PLC. At this time, a general-purpose PLC is used instead of a numerical control-specific type such as FANUCPMC.
At present, the general-purpose PLC function is very powerful, including positioning module, A/D, D/A, I/O mode, which can realize many industrial control functions.
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