What are the contents of the pre-service training for employees of the semi-automatic spring brush machine for tandem motor motors?
The pre-service training of the employees of the semi-automatic spring brush machine of the tandem motor motor usually includes the following aspects:
First, the basic knowledge of the equipment
l Structure and principle: a detailed introduction to the overall structure of the brush machine, including the motor, drive system, brush part, control system and other components of the structure and layout, so that employees have an intuitive understanding of the equipment. In-depth explanation of the working principle of the series excitation motor, such as the application of electromagnetic induction principle in motor operation, and how the brush and commutator realize current commutation, to ensure that employees understand the basic working mechanism of the motor. At the same time, the workflow of the spring brush machine is explained, from the installation of the spring, the start-up of the brush machine, to the parameter control during operation, to the shutdown operation at the end of the work, so that the staff can clearly grasp the complete working process of the equipment.
l Model and Parameters: Train employees to recognize the model of the brush machine and understand the differences in functions, performance and applicable scenarios of different models of equipment, so that they can choose the right equipment for operation according to the actual production requirements. For the key parameters of the equipment, such as the power, speed and torque of the motor, the pressure and frequency of the brush machine, and the great working load of the equipment, etc., detailed explanations are given so that the employees can understand the influence of these parameters on the operation of the equipment and the production effect, as well as how to carry out reasonable adjustments and control according to the requirements of the parameters in the process of operation.
II. Operating Procedures
l Electrical protection: Emphasize the danger of the electrical system of the brush machine, train the employees how to identify the danger signs and warning signs on the electrical equipment, so that they can always keep alert during the operation. Teach employees the correct operation methods of electrical equipment, such as the electrical inspection steps before starting the machine, including checking whether the power lines are connected correctly, whether the grounding is good, and whether the electrical components in the control cabinet are normal, etc.; and the order and precautions for disconnecting the power after shutting down the machine, so as to prevent electrocution accidents due to misoperation. At the same time, employees are taught how to deal with electrical fires, short circuits and other emergencies, such as how to use fire extinguishers to extinguish fires, how to quickly cut off the power supply, etc., to ensure that employees are able to take the correct and effective measures to save themselves and each other in the event of electrical accidents.
l Mechanical protection: Explain the risks of mechanical injuries that may exist during the operation of the brush machine, such as the danger of entanglement of rotating parts (motor shafts, drive pulleys, brush rollers, etc.), the danger of ejection of spring loaded devices, and the collision injuries that may be caused by the vibration and displacement of the equipment during operation. Train employees how to conduct mechanical inspections before, during and after equipment operation, including checking whether the guards of rotating parts are firmly installed and intact, whether the bolts of each connecting part are tightened, and whether there is any abnormal jamming or loosening of the moving parts of the equipment. Teach employees the correct operation posture and standing position to avoid being close to the dangerous area when the equipment is running, such as forbidding to reach out and touch the rotating parts when the equipment is running, and not to stay close to the front or side of the equipment, etc., to ensure that the employees can effectively avoid mechanical injuries in the operation process.
l Fire protection: Popularize fire protection knowledge to employees, including fire prevention measures, such as keeping the workplace clean and avoiding the accumulation of flammable materials around the equipment; regularly check and maintain fire protection facilities, such as fire extinguishers and fire hydrants, to ensure that they are in normal working condition. Train employees on how to properly use fire fighting equipment, such as the correct way to hold a fire extinguisher, the spray angle and distance when extinguishing a fire, etc., as well as evacuation methods in case of fire, such as familiarizing themselves with the location of safe exits in the workplace, mastering the skills of escaping from the workplace by moving forward in a low position and using a wet towel to cover their mouths and noses, so as to improve the fire fighting awareness of the staff and their ability of escaping from emergencies.
Third, operation skills training
l Equipment start and stop: Explain in detail the preparatory work before starting the brush machine, including checking the integrity of each part of the equipment, lubrication, the normalcy of the electrical system and the safety of the workplace. Train the staff to start the equipment according to the correct operation steps, such as closing the main switch of the power supply first, and then start the control switches of the motor, brush machine and other parts in turn, and at the same time, observe whether the starting process of the equipment is normal, and whether there is any abnormal sound, vibration or strange odor. In terms of equipment stopping operation, teach employees how to operate in accordance with normal stopping procedures, such as stopping the work of the brusher first, waiting for the equipment to run smoothly and gradually reduce the motor speed, and then turn off the power switch, and emphasize that it is strictly prohibited to cut off the power supply suddenly when the equipment is in high-speed operation, so as not to cause equipment damage and accidents.
l Parameter Setting and Adjustment: Train the staff how to set the parameters of the equipment according to different spring processing requirements, such as the speed of the motor, the pressure and frequency of the brusher. Explain the basis and method of parameter setting, so that employees understand how to determine the appropriate parameter values according to the material, specifications and processing technology of the spring, in order to ensure the processing quality and productivity of the spring. At the same time, teach employees how to adjust the parameters according to the actual situation during the operation of the equipment, such as how to increase the pressure of the brusher or adjust the rotational speed of the motor when it is found that the surface quality of the spring processing is not good, as well as how to accurately adjust the parameters through the equipment's control panel or the operator interface, to ensure that the employees are able to skillfully master the setup of the parameters of the equipment and the adjustment of the skills.
l Daily Maintenance and Repair: Train the staff on the daily maintenance and repair of the brush machine, including the cleaning methods of the equipment, such as what kind of cleaning tools and detergents are used to clean the surface of the equipment, internal parts, as well as the frequency and precautions for cleaning; identification of lubrication points and lubrication operations, such as the lubrication cycle of the motor bearings, the brush machine transmission parts, and the type of lubricating grease to use, and how to correctly carry out lubrication operations to ensure even lubrication and lubrication of the brush machine. Lubrication operation, to ensure uniform and appropriate amount of lubrication; inspection and replacement of wearing parts, such as brushes, springs, belts and other wearing parts of the wear judgment criteria and replacement steps, and how to ensure the correct operation of the equipment when replacing the wearing parts, so that employees can independently complete the daily maintenance of the equipment, to extend the service life of the equipment to ensure the normal and stable operation of the equipment.
Fourth, quality control and testing
l spring processing quality standards: to employees clear spring processing quality standards and requirements, including spring dimensional accuracy (such as outer diameter, inner diameter, length, pitch and other tolerance ranges), shape accuracy (such as perpendicularity, cylindricity and other permissible deviations), mechanical properties (such as elastic modulus, yield strength, fatigue life and other index requirements) and surface quality (such as surface roughness, depth of decarburization, surface defects) and other aspects of the limitation conditions. (e.g. surface roughness, depth of decarburization layer, surface defects, etc.) and other aspects of the standard. Through information such as physical samples, drawings and technical documents, employees can intuitively understand the differences between springs of different quality levels, so that they can clearly know what kind of springs are qualified products and what kind of springs are defective or waste products during the operation process, thus providing clear guidance for the production of springs that meet the quality standards.
l Quality inspection methods and tools: train employees to master the spring processing quality inspection methods and tools used, such as the use of calipers, micrometers, projectors and other measuring tools to test the dimensional accuracy of the spring and operating skills, including how to correctly measure the dimensions of each part of the spring, how to read and record the measurement data and how to determine whether the measurement results comply with the quality standards; the use of hardness tester, Tensile testing machine and other equipment to test the mechanical properties of the spring steps and precautions, such as how to select the appropriate test parameters, how to correctly clamp the spring for testing and how to analyze the test data to obtain the mechanical properties of the spring indexes; the use of surface roughness meter, metallurgical microscope and other tools on the surface quality of the spring testing methods and points, such as how to operate the surface roughness meter to measure the surface roughness value of the spring, how the surface of the spring through the metallurgical microscope, how to measure the roughness value of the surface of the spring Roughness value of the surface of the spring, how to observe the metallographic organization of the spring and surface defects through the metallographic microscope, etc., so that employees can skillfully use a variety of testing tools and methods to accurately detect and assess the processing quality of springs, and timely detection of quality problems and take appropriate measures to improve.
l Quality problem analysis and solution: Teach employees how to analyze the quality problems during spring processing, for example, when the spring has excessive dimensional deviation, insufficient elasticity, surface scratches or cracks and other quality problems, how to analyze the causes from the equipment parameter settings, operating methods, raw material quality, mold condition and other aspects, to find out the underlying factors that lead to quality problems. At the same time, training staff for different quality problems to take appropriate measures to solve the problem, such as through the adjustment of equipment parameters, improve the operating process, replacement of raw materials or maintenance of molds and other methods to solve the quality of springs, to improve the staff's ability to solve the quality of the actual problem, to ensure that the processing of springs of stable and reliable quality.
V. Troubleshooting and diagnosis
l Common failure phenomenon identification: through pictures, videos and actual cases and other information, show employees brush machine in the operation process may appear in a variety of common failure phenomena, such as motor does not rotate, speed abnormalities, brush spark is too large, brush machine vibration is intense, the processing of the spring quality is not qualified and other failure characteristics, so that employees can quickly and accurately identify these failure phenomena, for the subsequent diagnosis of the problem and troubleshooting work to lay the foundation. Lay the foundation for subsequent fault diagnosis and troubleshooting work.
l Failure cause analysis method: train employees to master the basic methods and ideas of failure cause analysis, such as from the electrical system, mechanical transmission system, control system, working environment and operating methods and other aspects of the start, the failure phenomenon step by step investigation and analysis. For example, when the motor does not rotate, employees should know whether to first check the power supply is normal, whether the motor winding is disconnected or short-circuited, whether the contactor and relay and other control components are damaged, whether the drive belt is broken or slippery and other reasons that may lead to the failure, and find out the real cause of the failure through the exhaustion and analysis of these factors one by one.
l Troubleshooting steps and skills: for various common failures, teach employees the corresponding troubleshooting steps and operating skills, such as in troubleshooting motor speed abnormalities, employees should learn how to use a multimeter, tachometer and other tools to measure and analyze the motor's power supply voltage, current, speed and other parameters, and based on the results of the measurements to determine the fault is in the motor itself, the controller or other related components, and then According to the principle of first easy then difficult, first external then internal, gradually take measures such as replacing fuses, adjusting controller parameters, checking motor brushes and commutator, repairing or replacing motors, etc., to carry out troubleshooting and ensure that the staff can quickly and efficiently take the correct methods to deal with the faults, reduce the downtime of the equipment, and improve the production efficiency.
Sixth, emergency measures
l Emergency treatment of sudden equipment failure: Train the staff to take emergency treatment measures when they encounter sudden failure during the operation of the equipment, such as when the motor suddenly smokes, catches fire or emits an abnormal loud noise, the staff should immediately press the emergency stop button, cut off the power supply of the equipment and quickly use the fire extinguishers to extinguish the fire (if it is an electrical fire, carbon dioxide fire extinguishers or dry powder fire extinguishers should be used), and at the same time promptly report to the At the same time, report to the supervisor and maintenance personnel in time to ensure that the equipment failure is dealt with in time to avoid further expansion of the accident.
l Personal Accidental Injury Emergency Treatment: Teach the staff the emergency treatment method when personal accidental injury occurs in the process of work, for example, when the staff is accidentally involved by the equipment or injured by the mechanical impact, the surrounding colleagues should immediately stop the equipment, quickly call the first aid phone (e.g., 120), and wait for the arrival of the first aid personnel before the injured person to carry out simple first aid treatment, such as stopping the wound bleeding bandage (if there is bleeding), fix the fracture part (if there is fracture), transfer the injured to a ventilated place, etc., to ensure that the injured can get timely and effective treatment and greatly reduce the degree of injury.
l Emergency response to natural disasters such as fires and earthquakes: Conduct training on emergency response to natural disasters such as fires and earthquakes, so that employees can understand how to respond to fires or earthquakes in the workplace. For example, in case of fire, employees should familiarize themselves with the location of evacuation channels and exits in the workplace, and quickly evacuate the site according to the predetermined evacuation routes, cover their mouths and noses with wet towels, and walk in a low position to avoid inhaling smoke; in case of earthquakes, employees should immediately take refuge under tables and other solid furniture, and then evacuate the building in an orderly manner according to the command after the earthquake stops, so as to ensure that employees can protect their lives and minimize casualties in the event of natural disasters. When an earthquake occurs, employees should immediately take cover under tables and other sturdy furniture, and evacuate the building in an orderly manner according to the instructions.
※ If you need any help, please contact the technical specialist of Xinhui Electrical and Mechanical Equipment Co.
