How to maintain the motor motor rotor duplex spot welder?
Motor motor rotor duplex spot welder maintenance guide:
I. Daily maintenance
Cleaning
Body cleaning: After each use, the body of the welder should be wiped with a clean soft cloth to remove dust, oil and welding spatter on the surface. Particular attention should be paid to cleaning impurities around the electrode, fixture and on the surface of the control unit, as dirt in these places may affect welding quality and equipment performance. For example, spatter around the electrode may cause poor contact between the electrode and the workpiece, thus affecting the conduction of the welding current.
Internal cleaning (periodic): At regular intervals (e.g. weekly or bi-weekly), open the welder housing and use a compressed air canister or a small vacuum cleaner to clean the interior. Focus on cleaning the dust on circuit boards, transformers, relays and other electrical components to prevent excessive accumulation of dust causing short circuits or poor heat dissipation.
Electrode Maintenance
Electrode cleaning: During the welding process, the surface of the electrode is easily stained with residues and oxides of the welding material. After each welding, use a special electrode cleaning tool (e.g. electrode brush or sandpaper) to gently clean the electrode surface and keep the electrode head clean and flat. For serious cases of adhesion, appropriate chemical cleaners can be used for treatment, but care should be taken to avoid corrosion of the electrode material by the cleaner.
Electrode wear check: Check the wear of the electrode regularly, generally the wear can be judged by measuring the diameter or length of the electrode head. When the electrode wear exceeds the specified range (determined according to the instruction manual of the welder), the electrode should be replaced in time. When replacing the electrode, make sure that the new electrode is installed in the correct position and has the same specifications as the old one.
Fixture Inspection and Maintenance
Fixture Cleaning: Like the machine body cleaning, the fixture also needs to be cleaned regularly. Use brushes and cleaners to wipe off oil, iron filings and other impurities from the surface of the fixture to ensure that the fixture's collets and locating pins can work properly. For pneumatic or hydraulic fixtures, but also to check the air or oil pipe interface leakage, such as leakage should be promptly repaired or replaced seals.
Fixture accuracy check: regularly check the accuracy of the fixture, including the clamping force of the collet, positioning pin positioning accuracy. Gauges (such as calipers, micrometers) can be used to check the dimensional accuracy of the fixture. If the accuracy of the fixture is found to have decreased, it should be adjusted or the damaged parts should be replaced in time. For example, if the positioning pin is worn out resulting in reduced positioning accuracy, the pin should be replaced with a new one.
II. Regular maintenance (monthly or quarterly)
Mechanical components maintenance
Maintenance of pressurizing mechanism: For welders using pneumatic or hydraulic pressurization, check the working condition of the cylinder or hydraulic cylinder. Check whether there is wear and tear of piston and piston rod, if there is wear and tear, it should be replaced in time; check whether there is aging and rupture of gas pipe or oil pipe, and replace seals and lubricating oil regularly. For the mechanical pressurizing mechanism, check whether the elasticity of the spring is normal or not, whether the connecting rod, cam and other transmission parts are loose or worn, if there is any problem, it should be tightened or replaced.
Inspection of working table and machine body: check whether the surface of working table is flat, if there is deformation, it should be repaired or replaced. Check whether the connecting parts of the machine body are loose, such as whether the screws are tightened and whether there are cracks in the welding parts. At the same time, check whether the ground bolts of the welding machine are loose, and make sure the welding machine is placed smoothly.
Electrical system maintenance
Inspection of electrical components: Regularly check the working status of electrical components such as transformers, relays, contactors, fuses, and so on. Use a multimeter to measure the winding resistance and insulation resistance of the transformer, check whether the contacts of the relay and contactor are ablated and whether the fuse is blown. For electrical components with problems, they should be replaced or repaired in time.
Connection line check: check the connection lines inside and outside the welder, including power lines, signal lines, welding cables, etc.. Check whether the lines are broken, aging, loose, etc. If there is any problem, it should be repaired or replaced in time. At the same time, check whether the connection of the line is firm, whether the plug and socket are in good contact, to avoid electrical failure caused by wiring problems.
Sensor calibration: Calibrate the pressure sensor, temperature sensor and displacement sensor on the welding machine. In accordance with the requirements of the equipment manual, the use of standard calibration equipment (such as pressure calibrator, temperature calibrator, etc.) to calibrate the sensor to ensure that the sensor's measurement accuracy. During the calibration process, the calibration data of the sensors should be recorded for subsequent comparison and tracking of changes in the performance of the sensors.
Software system maintenance
Parameter backup and check: Regularly backup the parameter settings in the welder software, including welding parameters, control parameters, etc.. At the same time, check whether the parameter settings are reasonable and whether there are parameters that do not meet the requirements of the welding process. If the parameter setting is found to be wrong, it should be adjusted in time.
Software update check: check whether the welder software has an available updated version. Software updates can repair known software vulnerabilities, add new features or improve the stability of the software. Follow the operating instructions for software updates to update the operation, and make sure to back up important data and parameters before updating.
III. Long-term maintenance (every year or every two years)
Mechanical components all overhaul
Dismantling and checking of mechanical parts: Dismantle and check the main mechanical parts of the welding machine, such as electrode mechanism, pressurizing mechanism and clamps. Check the wear and tear of each part, and replace the parts with serious wear and tear, such as electrode holders, fixture holders, transmission gears and so on. At the same time, check the internal lubrication of mechanical parts, clean up the old grease and reapply the appropriate amount of new grease.
Mechanical precision recovery: After a long time of use, the mechanical precision of the welder may decline. Use professional measuring tools (e.g. CMM) to measure the key dimensions and accuracy of the welding machine, such as the positional accuracy of the electrode, the positioning accuracy of the fixture and so on. According to the measurement results, adjust and restore the precision of the welding machine to ensure that the welding machine can meet the welding quality requirements.
Electrical System Upgrade and Remodeling
Upgrading of electrical components: With the development of technology, some old electrical components may decline in performance or face elimination. Consider upgrading the welding machine's electrical components, such as replacing better performance transformers, more advanced controllers (such as programmable logic controller PLC) or more accurate sensors. When upgrading the electrical components, pay attention to the compatibility of the components to ensure that the new components work properly with the rest of the welder.
Optimization of the electrical system: According to the actual welding needs and technological development, the welding machine's electrical system should be optimized and modified. For example, add energy-saving devices to improve the energy utilization efficiency of the welding machine; or modify the control system of the welding machine to achieve a higher degree of automation of the welding process, such as integration with automated production lines.
Equipment performance evaluation and calibration
Welding performance evaluation: Through actual welding tests, the welding performance of the welding machine is evaluated in all aspects. Use standard welding specimens, weld according to the specified welding process, and then test the quality of the welded joints, including the strength of the welded joints, the appearance of the metallurgical organization. Based on the evaluation results, the parameters and working condition of the welding machine are adjusted to ensure that the welding performance of the welding machine reaches an excellent state.
Equipment calibration and certification: The welder is regularly sent to a professional metrology institute or a repair center designated by the equipment manufacturer for calibration and certification. Calibration ensures that the parameters of the welder (e.g. welding current, voltage, time, etc.) are accurate, while certification proves that the welder complies with the relevant industry standards and protection codes. A calibrated and certified welder can provide more reliable welding quality, and also help companies to meet the requirements of quality control and production.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialists of Xinhui Mechanical & Electrical Equipment Co.
