The flange facing machine is a special equipment for processing flange end faces, which is widely used in the petroleum, chemical, electric power and other industries. However, due to long-term use or improper operation, the flange facing machine will also have some common faults. This article will introduce some common flange facing machine faults and provide some solutions.
The spindle system is one of the core parts of the flange facing machine, which directly affects the processing accuracy and stability. The failure of the spindle system usually manifests itself in the following forms:
Spindle overheating: Spindle overheating is usually caused by insufficient lubrication or abnormal operation of the cooling system. Long-term high-temperature operation will cause the spindle to deform, which in turn affects the processing accuracy. The solution is to regularly check the quality and quantity of the lubricating oil, ensure the normal operation of the cooling system, and replace the high-efficiency cooling device when necessary.
Excessive spindle vibration: Excessive spindle vibration may be caused by spindle bearing wear, imbalance or loose connection parts. This situation will not only affect the processing quality, but may also cause damage to the bearings or other components. Solutions include replacing worn bearings, re-balancing and tightening all connection parts.
Spindle cannot start: The spindle cannot start usually due to power failure, control system failure or transmission system failure. First, check the power line and control system to ensure that all signals are normal. If the problem is in the transmission system, it is necessary to check the status of transmission components such as chains and belts, and replace damaged components in time.
The guide rail system plays a guiding and supporting role in the flange end face machine, and its failure will directly affect the accuracy and stability of the machine tool. Common guide rail system failures include:
Guide rail wear: The guide rail will wear during long-term use, resulting in reduced processing accuracy. The solution is to regularly check the wear of the guide rail, and once severe wear is found, it should be repaired or replaced in time. At the same time, a guide rail protection device can be installed to reduce the damage to the guide rail by external factors.
Loose guide rail: Loose guide rails will cause the machine tool to shake during processing, affecting the processing quality. The solution is to regularly check and tighten the fixing screws of the guide rail to ensure that it is in a firm state. In addition, the stability of the guide rail can be improved by adjusting the guide rail gap.
The tool holder system is an important part responsible for tool installation and movement, and its failure will directly affect processing efficiency and quality. Common tool holder system failures include:
The tool holder is not locked firmly: The tool holder is not locked firmly, which will cause the tool to shift during processing and affect the processing accuracy. The solution is to check the working status of the tool holder locking device, replace the worn parts in time, and ensure that the tool holder can be stably locked.
The tool holder is not moving smoothly: The tool holder may be caused by wear of the guide rail, poor lubrication or failure of the transmission components. The solution is to lubricate and clean the guide rail regularly to ensure its smooth operation. For the failure of the transmission components, it is necessary to adjust or replace them in time.
The hydraulic system is often used to provide power and control actions in flange facing machines. Its failure will cause the machine tool to fail to work properly. Common hydraulic system failures include:
Hydraulic oil contamination: Hydraulic oil contamination will cause increased wear and even failure of hydraulic components. The solution is to replace the hydraulic oil regularly and use a high-quality oil filter to prevent contaminants from entering the hydraulic system.
Hydraulic system oil leakage: Hydraulic system oil leakage will cause insufficient pressure and affect the normal operation of the machine tool. The solution is to check the hydraulic pipelines and joints, replace damaged seals in time, and ensure the sealing of the hydraulic system.
The electrical system is the control system of the flange end machine. Its failure will cause the machine tool to fail to start or malfunction. Common electrical system failures include:
Control system failure: Control system failure may be caused by aging of electrical components, poor line contact or programming errors. The solution is to regularly check the electrical components and lines, replace aging components in time, and ensure that the lines are firmly connected. For programming errors, it is necessary to check and correct the program.
Sensor failure: Sensor failure will cause the machine tool to be unable to accurately detect the position and status, affecting the processing accuracy. The solution is to regularly calibrate and check the sensor to ensure that it works properly. For damaged sensors, they need to be replaced in time.
In order to reduce the failure rate of the flange end machine, daily maintenance and care are essential. The following points are the key to maintenance and care:
Regular inspection: Regularly check the various systems of the machine tool to detect and deal with potential problems in time. For example, check the lubrication of the spindle system once a month, check the wear of the guide system once a quarter, etc.
Correct operation: Operators should use machine tools in strict accordance with the operating procedures to avoid failures caused by improper operation. At the same time, operators should receive professional training and be familiar with the structure and maintenance methods of machine tools.
Environmental control: Keep the workshop environment clean and constant temperature to avoid environmental factors such as dust and humidity affecting the performance of machine tools. Clean up chips and debris around the machine tools regularly and maintain good ventilation conditions.
Record management: Establish detailed maintenance and maintenance records to record the situation of each inspection and maintenance. This helps to analyze the cause of the failure, formulate preventive measures, and improve the reliability and service life of the equipment.
In summary, flange facing machines may encounter a variety of failures in actual applications. Understanding these common failures and their solutions can help companies better maintain and manage equipment and improve production efficiency and product quality. At the same time, through daily maintenance and maintenance, the service life of the equipment can be effectively extended, the failure rate can be reduced, and the smooth progress of production can be guaranteed.
As a flange facing machine manufacturer, we are well aware of the importance of equipment stability and reliability to corporate production efficiency and product quality. Therefore, we are always committed to providing high-quality flange facing machine products and providing customers with comprehensive technical support and services.
Mr. Jeff Huang
15251441199
Miss Doria Zhu
15102105304
Miss Jina Wang
18261592800
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Nov 01,2023