8, motor motor rotor double station spot welding machine staff pre-service training content?
Motor motor rotor duplex spot welding machine employee pre-training content:
First, the basic theoretical knowledge of equipment
1, the working principle of the explanation
Detailed introduction to the welding principle of the duplex spot welding machine, that is, through the electrode to apply pressure and energized, the use of electric current flowing through the workpiece contact surface generated by the resistance of the heat so that the metal material melted and connected together. For example, use schematics or animations to demonstrate how current flows through the electrodes, motor rotor, and joining parts, and how the resistive heat causes the metal to reach the melting point and form a welded joint.
Explain the working principle of the electrical control system of the welding machine, including how the programmable logic controller (PLC) controls parameters such as welding current, welding time, electrode pressure, etc., as well as how it receives and handles feedback signals from sensors (e.g., pressure sensors, temperature sensors, etc.) in order to realize accurate automatic control of the welding process.
2、Equipment structure composition
Lead the trainees to recognize the main mechanical components of the welding machine, such as electrode mechanism, pressurization mechanism, fixture system, body frame, etc., and explain their functions and interconnections. For example, show the structure of the electrode mechanism, including the electrode head, electrode holder, electrode clamp and other parts, explain how it realizes the electrode replacement, adjustment and conductive function; introduce the type of pressurizing mechanism (e.g. pneumatic, hydraulic or mechanical pressurization) and its working principle, as well as how to regulate the size of the pressure; explain how the clamping system can locate and clamp the rotor of the motor, to ensure the accuracy of the weld position.
Explain the components of the electrical system, such as transformers, rectifiers, controllers, sensors, relays, and contactors. Explain the position, model and role of each electrical component, such as how the transformer converts the input voltage to a suitable voltage for welding, how the rectifier converts AC to DC, and how the controller coordinates the work of each electrical component through the control circuit.
Second, equipment operation skills training
1、Operating panel and parameter setting
Introduce to the students of the welding machine operating panel of the various functions of the keys, the display of the information shown on the screen and the method of operation. Trainees are trained how to enter the parameter setting interface, set the welding current, welding time, electrode pressure, pre-pressure time, holding time and other key parameters. For example, explain in detail the meaning of each parameter, the range of values, and the impact on welding quality and efficiency. Through practical demonstration, trainees can learn to set the parameters correctly according to different motor rotor materials, thicknesses, and welding process requirements, and save and recall the parameters.
Teach trainees how to start, stop, pause and reset the equipment on the operation panel, and how to respond to various prompt messages and alarm signals during the operation of the equipment. For example, when there is a current overload alarm, the trainee should know how to pause the equipment, check the welding circuit whether there is a short circuit or poor contact and other issues, and then resume equipment operation; when the equipment appears to be insufficient pressure alarm, the trainee should understand how to check the pressurizing mechanism and the gas pipe (or oil pipe) whether it is normal, as well as how to adjust the pressure parameters.
2、Welding operation process
In accordance with the standard operating procedures, step-by-step demonstration of the entire operation process starting from the installation of the motor rotor on the fixture to the completion of welding and removal of the rotor. This includes how to place the rotor correctly to ensure good contact with the fixture and positioning accuracy; how to adjust the electrode spacing and pressure to meet the welding requirements; how to start the welding program and monitor the parameters of the welding process, such as current, time and pressure, to ensure that the quality of the weld is in line with the standard. For example, when placing the rotor, it is emphasized that it should be held gently to avoid collision with the fixture and electrode; before starting the welding procedure, it is necessary to check again whether the parameter settings are correct.
Let the trainees carry out actual operation practice. During the trainees' operation, the trainer provides on-site guidance and corrects the trainees' wrong operation in time to ensure that the trainees can complete the welding operation process skillfully and accurately. At the same time, cultivate the trainee's sense of operational protection, such as strictly prohibited in the process of equipment operation reach out and touch the electrode and fixture, must wear protective gloves, goggles and other personal protective equipment.
Third, equipment maintenance and maintenance knowledge
1, daily maintenance programs and methods
Training students every day before the use of equipment and the use of daily maintenance work content. Including cleaning the equipment body, electrodes, fixtures, rails and other parts of the dust, oil and welding spatter, check the lubrication of the transmission components (such as screws, rails, gears, etc.) and add lubricant or grease in a timely manner to see whether the electrical connection lines are loose, broken, and check the pneumatic or hydraulic components (such as air cylinders, air tubes, solenoid valves, etc.) whether they work properly. For example, demonstrate how to wipe the surface of the equipment with a clean soft cloth and special cleaner, how to check and adjust the tightness of the screws with a wrench, and how to judge the lubrication of the gears by observation and hand feeling.
Teach trainees how to carry out daily inspection of equipment, such as checking the wear of electrodes, using calipers or micrometers to measure the diameter or length of the electrode head, which should be replaced in time when the wear exceeds the specified value; checking whether the clamping force of the fixture is sufficient and whether there is any loosening phenomenon; checking whether there is any abnormal heat, noise or odor in electrical components such as transformers, relays, contactors, etc., and reporting to the maintenance personnel in time if there are any problems. Trainees are required to be able to find potential problems with the equipment in time, and record the daily operating conditions and maintenance of the equipment.
2、Points for regular maintenance and upkeep
Introduce the regular maintenance cycle of the welder (e.g., weekly, monthly, quarterly, etc.) and the corresponding maintenance program. For example, it is necessary to deeply clean and lubricate the electrode mechanism every week, check whether the connection between the electrode holder and electrode clamp is firm, and whether the surface flatness of the electrode head meets the requirements; it is necessary to carry out all the inspections of the electrical system every month, including cleaning the circuit boards, checking the performance of the electrical components, and updating the control system software, etc.; it is necessary to carry out all the inspections and adjustments of the equipment's mechanical structure every quarter, for example, to check the machine body's levelness, positioning accuracy of each station, pressure accuracy of pressurizing mechanism, etc., and carry out calibration and repair as needed.
Trainees are trained on how to carry out regular maintenance work, such as how to dismantle and install electrodes, fixtures and other components for cleaning and maintenance, how to use professional tools (such as multimeters, oscilloscopes, etc.) to test and repair electrical components, and how to carry out precision calibration operations of the equipment. At the same time, emphasize the importance of regular maintenance work, only do a good job of regular maintenance to ensure the long-term stable operation of the equipment, reduce equipment failure and downtime.
Fourth, the operating norms and emergency measures
1、Operation specification
Detailed explanation of the standard operation of the welder to the students, including the inspection of the equipment before starting, such as checking whether the protective device is intact, the equipment around any obstacles, power lines and gas pipes (or oil pipes) are connected correctly, etc.; equipment during operation, such as forbidden to cross the moving parts, touching the moving parts, shall not be placed on the equipment of extraneous items, the welding process to keep the hands dry, to avoid electrocution, etc.; equipment Operation requirements after stopping the equipment, such as cutting off the power supply, gas source (or hydraulic source), clean up the work site. For example, it is emphasized that the protective door must be closed in place before starting the equipment to prevent people from accidentally contacting the electrode and welding area; during the operation of the equipment, the trainees are not allowed to leave their posts, and they should always keep an eye on the operation status of the equipment and stop immediately to deal with any abnormalities found.
Trainees are trained to use personal protective equipment correctly, such as protective glasses and gloves, and are required to wear them strictly during work. For example, protective gloves must be worn during welding operations to prevent the hands from being burned or electrocuted; protective glasses may be required when cleaning up the equipment to prevent dust, spatters, etc. from splashing into the eyes.
2、Emergency measures
Trainees are taught how to deal with emergencies that may occur during the operation of the equipment, such as sudden power outages, abnormal movements due to equipment failure, fires, etc. For example, in case of sudden power failure, trainees should know how to turn off the power switch of the equipment and the switch of the gas source (or hydraulic source) to prevent the equipment from starting automatically after the incoming call, which may cause danger; when there is abnormal movement of the equipment, such as the electrode is out of control, the trainees should press the emergency stop button immediately and stay away from the equipment and wait for the professional maintenance personnel to deal with the problem; if a fire occurs, the trainees should familiarize themselves with the use of the fire extinguishers and the location of evacuation channels to be able to take quick action to extinguish the fire and evacuate. In case of fire, trainees should be familiar with the use of fire extinguishers and the location of evacuation routes, and be able to take fire-fighting and evacuation measures quickly.
Conduct emergency drills to simulate various emergencies and let the trainees practically operate the emergency handling process, so as to improve the trainees' emergency response ability and self-protection awareness. At the same time, trainees are required to remain calm when encountering emergencies and deal with them in an orderly manner in accordance with the emergency handling measures of the training, and shall not panic or act blindly.
V. Quality control and inspection standards
1、Welding quality standards
Explain to the trainees the various standards and requirements for welding quality, including the appearance of the welded joint quality (such as size, shape, surface flatness, color, etc.), welding strength, electrical conductivity, etc.. For example, it is stipulated that the diameter of the welded joints should be within a certain range, the surface should be smooth and free of air holes, cracks and false welds, the welding strength should meet the requirements for the use of the motor rotor, and the resistance value should comply with the relevant standards. l Show the comparison of qualified and unqualified samples of welding quality, so that the trainees can visualize the difference of welding quality, and facilitate the trainees to carry out quality control in actual operation.
Teach trainees how to use simple tools (such as magnifying glass, calipers, tensile testing machine, etc.) to detect and monitor the quality of welding, and require trainees to carry out regular quality checks during the welding process and make timely adjustments when problems are found. For example, the use of a magnifying glass to check the surface of the welded joints whether there are defects, the use of calipers to measure the diameter of the welded joints, the use of tensile testing machine to detect the welding strength, and so on.
2、Quality problem analysis and solution
Trainees how to analyze the welding process quality problems, such as welding joints too large or too small may be due to welding current, time or electrode pressure set improperly; welded joints have pores on the surface of the weld may be due to the welding material surface oil, moisture or impurities, or the welding environment, such as high humidity causes; welding strength is insufficient may be due to the welding parameters are not reasonable, the electrode wear and tear is serious, or welding material itself Quality problems, etc. By analyzing the quality problems, the trainees are able to find out the root causes of the problems and take appropriate measures to solve them.
For example, when it is found that the weld joint is too large, the trainees should first check whether the welding current and time parameters are set too high, and then check whether the electrode pressure is appropriate, and if the parameters are set correctly, then further check whether the diameter of the electrode head is worn out too much; when there is the problem of air holes on the surface of the weld joint, the trainees have to check the cleanliness of the surface of the weld material, and improve the welding environment such as increasing the ventilation equipment or using a desiccant to reduce the Humidity, etc.; When the welding strength is insufficient, the trainee should consider the welding parameters, electrode state and material quality, etc., and make adjustments or replacements accordingly.
※ If you have any other help, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
