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The determination of equipment repair and maintenance
Equipment maintenance can be divided into planned preventive maintenance, from the point of view of ensuring the safe operation of the equipment, it should be emphasized preventive maintenance. Planned maintenance is based on the law of wear and tear of equipment and equipment failure law, the development of equipment maintenance and repair methods. According to the role of maintenance, maintenance can be divided into maintenance, targeted repairs, planned repairs, project repairs, renovation and maintenance, etc., choose to determine the basis of maintenance is mainly based on the degree of wear and tear of equipment and its components, performance, precision deterioration and the possibility of failure. 1.three difficult maintenance system equipment maintenance work, according to the workload size and degree of difficulty, divided into routine maintenance, maintenance and secondary maintenance, the formation of the maintenance system is called "three maintenance system". (1) routine maintenance is the operator must be carried out every shift equipment maintenance work, the content includes: cleaning, refueling, adjustment, replacement of individual parts, check lubrication, noise, safety and damage. Daily maintenance is a kind of equipment maintenance that does not take up working hours alone, and is carried out together with daily inspection. (2) First-level maintenance is a form of indirect preventive maintenance based on regular inspection and supplemented by maintenance overhaul. Its main work is: check, clean, adjust the parts of the equipment; check the impeller of the sewage pump, seal, centrifugal pump impeller, seal, oiling; check the distribution cabinet lines, dust, fastening; found faults and abnormalities, to be excluded, and exclude leakage phenomenon, and so on. Equipment after the first level of maintenance is required to achieve: clean and bright appearance; no dust Inspection by time interval is divided into daily inspection and regular inspection. Daily inspection is carried out by the equipment operator, combined with daily maintenance, the purpose is to find abnormal technical conditions in a timely manner, to carry out the necessary maintenance work. Regular inspection is in accordance with the plan, in the operator to participate in
2. Equipment maintenance of the most basic requirements of what
The most basic requirements of equipment maintenance is to keep the equipment clean, neat, well-lubricated, safe operation, including timely fastening of loose fasteners, adjusting the gap of the movable parts.
In short, that is, "clean, lubricate, fasten, adjust, anti-corrosion" cross operation method. Practice has shown that the life of the equipment is largely determined by the maintenance of good and bad. Maintenance according to the size of the workload and the degree of difficulty is divided into routine maintenance, primary maintenance, secondary maintenance, tertiary maintenance.
Daily maintenance, also known as routine maintenance. Its main content is: cleaning, lubrication, fastening easy to loose parts, check the integrity of parts, components. This type of maintenance projects and parts are less, most of the external equipment.
First-level maintenance, the main content is: universal tightening, cleaning, lubrication, fastening, but also part of the adjustment. Routine maintenance and the first level of maintenance is generally undertaken by the operator.
Secondary maintenance. The main content includes internal cleaning, lubrication, local disassembly inspection and adjustment.
Tertiary maintenance. Mainly on the main part of the equipment disassembled to check and adjust the work, if necessary, to reach the limit of wear and tear of the parts to be replaced. In addition, the main parts of the wear and tear of the measurement, identification and record. Secondary maintenance, tertiary maintenance in the operation of workers to participate in, generally by full-time maintenance and repair workers.
Extended information
Maintenance items:
1) cleaning: not just the surface, to sweep the nooks and crannies, so that the equipment, tooling, wear and tear, noise, looseness, deformation, leakage and other defects are exposed, and timely exclusion;
2) lubrication: less oil, lack of grease caused by lubrication is poor, so that the equipment does not run properly, some parts of the excessive wear, temperature Excessive high hardness, wear resistance reduction, and even the formation of thermal fatigue and coarse grain damage. Should be timed, quantitative, qualitative, timely refueling, grease;
3) fastening: fasten the bolts, nuts, to avoid parts loosening, vibration, sliding, falling off and the resulting failure;
4) plugging: prevent, plug lubricating grease, compressed air, steam, water, cooling medium, cold air, heat leakage.
Baidu Encyclopedia - Equipment Maintenance
3. Overview of the main content of the maintenance of machinery and equipment
I. Maintenance of equipment By wiping, cleaning, lubrication, adjustment and other general methods of care of equipment to maintain and protect the performance of the equipment and the technical condition, known as equipment maintenance.
Equipment maintenance requirements are mainly four: (1) clean equipment inside and outside neat, the sliding surface, screw, rack, gear box, oil holes, etc., no oil, no oil leakage in various parts, no air leakage, equipment around the chips, debris, dirt to be cleaned up; (2) neat tools, accessories, workpieces (products) to be placed in a neatly organized, pipeline, line to be organized; (3) lubrication is good! (3) Good lubrication: refueling or oil change on time, no oil breakage, no dry friction phenomenon, normal oil pressure, bright oil mark, smooth oil circuit, oil quality in accordance with the requirements of the oil gun, oil cups, linoleum clean; (4) Safety: Observe the safety regulations, do not overload the use of equipment, the equipment's safety guards complete and reliable, and timely elimination of insecure factors. Equipment maintenance content generally includes routine maintenance, regular maintenance, regular inspection and accuracy checks, equipment lubrication and cooling system maintenance is also an important element of equipment maintenance.
The routine maintenance of equipment is the basic work of equipment maintenance, must be institutionalized and standardized. Regular maintenance of equipment to develop work quotas and material consumption quotas, and according to the quota assessment, regular maintenance of equipment should be included in the workshop contract responsibility system assessment.
Regular inspection of equipment is a planned preventive inspection, the means of inspection in addition to human senses, but also a certain inspection tools and instruments, according to the implementation of the regular inspection card, regular inspection of some people also known as regular inspection. Mechanical equipment should also be carried out precision checks to determine the actual accuracy of the equipment to the extent of the advantages and disadvantages.
Equipment maintenance should be carried out according to the maintenance program. Equipment maintenance program is the daily maintenance of equipment requirements and regulations, adhere to the implementation of equipment maintenance program, you can extend the service life of the equipment to ensure a safe and comfortable working environment.
Its main contents should include: (1) equipment to achieve neat, clean, strong, lubrication, corrosion, safety and other operational content, methods of operation, the use of tools and materials, to achieve the standards and precautions; (2) daily inspection and maintenance and regular inspection of parts, methods and standards; (3) check and evaluate the degree of operation of workers to maintain the equipment, such as the content and methods. Second, the three-tier maintenance system of equipment three-tier maintenance system is our country in the mid-1960s, summarizing the former Soviet Union plans to repair system in our practice on the basis of gradual improvement and development of a maintenance and repair system, which reflects the focus of our equipment maintenance management from repair to maintenance of the change, reflecting the progress of China's equipment maintenance management and maintenance management policy based on the main focus of prevention is more clear.
The three-level maintenance system includes: routine maintenance of equipment, maintenance and secondary maintenance. The three-tier maintenance system is based on the operator of the equipment for the main guarantee, warranty and the weight of the mandatory maintenance system.
The three-tier maintenance system is to rely on the masses, give full play to the enthusiasm of the masses, the implementation of group management group repair, specializing in the combination of groups, to improve the effective maintenance of equipment. (A) the daily maintenance of equipment maintenance of equipment, general maintenance and weekly maintenance, also known as daily and weekly routine insurance.
1. Day routine insurance day routine insurance by the equipment operators on the shift, seriously do four things before the class, five attention and four things after the class. (1) Four things before the shift Digest the drawing information, check the handover records.
Wipe the equipment, lubricate and refuel according to regulations. Check whether the handle position and manual operation parts are correct and flexible, and whether the safety device is reliable.
Low-speed operation to check whether the transmission is normal, lubrication, cooling is smooth. (2) five attention in the shift pay attention to the running sound, equipment temperature, pressure, liquid level, electrical, hydraulic, pneumatic system, instrumentation signal, safety insurance is normal.
(3) Four things after the shift Close the switch, all handles to zero. Remove iron filings, dirt, wipe the equipment rail surface and sliding surface of the oil, and refueling.
Clean the workplace, organize accessories and tools. Fill in the shift handover records and running time records, and handle the shift handover procedures.
2. Weekly routine maintenance Weekly routine maintenance is carried out by the equipment operators at the end of each week, the maintenance time is: general equipment 2h, fine, large and rare equipment 4h. (1) Appearance Wipe clean the equipment guide rail, the transmission parts and the exposed parts, clean the workplace.
To achieve internal and external cleanliness without dead ends, no rust and corrosion, the surrounding environment is clean. (2) Manipulate the transmission Check the technical condition of each part, tighten the loose parts, adjust the fit gap.
Check the interlock, insurance devices. To achieve normal transmission sound, safe and reliable.
(3) Hydraulic lubrication Clean the oil line, dust felt, oil filter, oil tank add oil or oil change. Check the hydraulic system to achieve clean oil, smooth oil circuit, no leakage, no research injury.
(4) Electrical system Wipe the surface of the motor, snake skin tube, check the insulation, grounding, complete, clean and reliable. (B) the first level of maintenance The first level of maintenance is based on the operation of the workers, maintenance workers to assist, according to the plan of the local disassembly and inspection of the equipment, cleaning of the prescribed parts, dredging of the oil circuit, piping, replacement or cleaning of the oil line, felt, oil filter, adjusting the gap between the various parts of the equipment, tightening of the various parts of the equipment.
The time used for the first level of maintenance is 4-8h, after the completion of the first guarantee should make a record and indicate the defects that have not yet been cleared, the workshop mechanic to organize acceptance. The scope of a guarantee should be all the equipment in use, the key equipment should be strictly enforced.
The main purpose of a guarantee is to reduce equipment wear and tear, eliminate hidden problems, extend the service life of the equipment, for the completion of the next guarantee period of production tasks in the equipment to provide protection. (C) the second level of maintenance The second level of maintenance is based on maintenance workers, operating workers to participate in the completion.
The second level of maintenance is included in the overhaul program of the equipment, part of the equipment dismantling inspection and repair, replacement or repair of worn parts, cleaning, oil change, inspection and repair of the electrical part of the technical condition of the equipment to achieve the full range of equipment to meet the requirements of the standard of integrity of the provisions of the equipment. The time used for secondary maintenance is about 7 days.
After the completion of the second maintenance, maintenance workers should fill out the maintenance records in detail, by the workshop mechanic and operator acceptance, acceptance sheet to the equipment power section archives. The main purpose of the second guarantee is to make the equipment to reach the standard of integrity, improve and consolidate the equipment integrity rate, and extend the overhaul cycle.
The implementation of the "three-tier maintenance system", must make the operator of the equipment to do "three good", "four will", "four requirements " and comply with the "five disciplines". Three-tier maintenance system highlights the maintenance of equipment management.
4. What are the contents of equipment maintenance
Equipment maintenance refers to the repair or replacement of worn parts, adjust the accuracy, troubleshooting, restore the original function of the equipment and technical activities, its main role is to restore the accuracy of the equipment, performance, improve efficiency, extend the service life, and maintain production capacity.
The basic content of equipment maintenance includes: equipment maintenance, equipment inspection and equipment repair. First, equipment maintenance equipment maintenance content is to keep equipment clean, neat, well lubricated, safe operation, including timely fastening of loose fasteners, adjusting the gap between the moving parts.
In short, that is, "clean, lubricate, fasten, adjust, anti-corrosion" cross operation method. Practice shows that the life of the equipment is largely determined by the maintenance of good and bad.
Maintenance according to the workload size and degree of difficulty is divided into routine maintenance, primary maintenance, secondary maintenance, tertiary maintenance. Daily maintenance, also known as routine maintenance.
Its main content is: cleaning, lubrication, fastening easy to loose parts, check the integrity of parts, components. This type of maintenance projects and parts less, most of the external equipment.
First-level maintenance, the main content is: general tightening, cleaning, lubrication, fastening, but also part of the adjustment. Routine maintenance and the first level of maintenance is generally undertaken by the operator.
Secondary maintenance. The main content includes internal cleaning, lubrication, local disassembly inspection and adjustment.
Tertiary maintenance. Mainly on the main part of the equipment disassembled to check and adjust the work, if necessary, to reach the prescribed wear limit of the parts to be replaced.
In addition, the main parts of the wear and tear of the measurement, identification and record. Secondary and tertiary maintenance is generally undertaken by full-time maintenance and repair workers with the participation of the operator.
In all types of maintenance, routine maintenance is the basis. Maintenance of the categories and content, to be specified for the characteristics of different equipment, not only to take into account the production process, structural complexity, scale and size of the equipment and other specific circumstances and features, while taking into account the long-term formation of maintenance habits within different industrial enterprises.
Second, equipment inspection Equipment inspection, refers to the operation of the equipment, working accuracy, wear and tear or corrosion degree of measurement and calibration. Through the inspection to fully grasp the technical status of machinery and equipment and wear and tear, timely identification and elimination of hidden equipment, purposefully do the preparatory work before the repair, in order to improve the quality of repair, shorten the repair time.
The inspection is divided into daily and periodic inspection according to the time interval. Daily inspection by the equipment operator, combined with routine maintenance, the purpose is to find abnormal technical conditions in a timely manner, to carry out the necessary maintenance work.
Regular inspection is in accordance with the plan, under the participation of the operator, regularly by full-time maintenance workers. The purpose is to check, comprehensively and accurately grasp the actual situation of wear and tear of parts in order to determine whether there is a need for repair.
Inspection according to technical function, can be divided into function check and precision check. Functional inspection refers to the function of the equipment to check and determine, such as whether the oil leakage, water leakage, air leakage, dustproof sealing how, parts of high temperature, high speed, high pressure performance.
Accuracy check refers to the actual processing accuracy of the equipment to check and determine the accuracy of the equipment in order to determine the degree of accuracy of the degree of excellence for the acceptance of the equipment, repair and update the basis. Third, equipment repair equipment repair, refers to repair due to routine or abnormal reasons caused by equipment damage and precision degradation.
Through the repair and replacement of wear and tear, aging, corrosion of parts and components, equipment performance can be restored. Repair and maintenance of equipment is a different aspect of equipment maintenance, the two due to the content of the work and the role of the difference is not interchangeable, the two should be done at the same time, in order to cooperate with each other, complement each other.
1, the type of equipment repair. According to the size of the repair scope, repair intervals, repair costs, equipment repair can be divided into small repair, repair and large repair three categories.
(1) small repairs. Small repairs usually only need to repair and replace part of the wear and tear faster and the use of the period equal to or less than the repair interval parts, adjust the local structure of the equipment to ensure that the equipment can operate normally to the planned repair time.
Small repairs are characterized by: the number of repairs, the workload is small, each time the repair time is short, the repair cost is included in the production costs. Small repairs are generally carried out at the production site by the workshop full-time maintenance workers.
(2) in the repair. Repair is part of the equipment disintegration, repair or replacement of some of the main parts and benchmark parts, or repair of the use of the period is equal to or less than the repair interval parts; at the same time to check the entire mechanical system, fasten all the parts, to eliminate the expansion of the gap, correct the equipment benchmarks to ensure that the machine and equipment can be restored to achieve the desired standards and technical requirements.
Repair is characterized by: repair more often, the workload is not very large, each time the repair time is shorter, the repair cost is included in the production costs. Most of the repair projects by the workshop full-time maintenance workers in the production workshop on-site, the individual requirements of the project can be undertaken by the machine shop, after the repair should be organized to check and acceptance and for repair and repair unit handover procedures.
(3) major repair. Major repair refers to the replacement, restoration of its major components, restore the original accuracy of the equipment, performance and productivity and comprehensive repair.
The characteristics of major repairs are: fewer repairs, heavy workload, each repair time is longer, repair costs paid by the major repair fund. Equipment overhaul, quality management and equipment management departments should be organized to use and repair units *** with the inspection and acceptance of qualified repair units and repair units for handover procedures.
2, equipment repair methods Commonly used equipment repair methods are mainly the following: (1) standard repair method, also known as the mandatory repair method, refers to the service life of the equipment parts, the preparation of a specific repair plan in advance, specify the date of repair of the equipment, the category and content. Equipment operation to the specified period, regardless of its technical condition, whether good or bad, the task is light or heavy, must be in accordance with the provisions of the scope of operations and requirements for repair.
This method is conducive to the repair of the preparatory work, effectively ensure the normal operation of the equipment, but sometimes cause excessive repair, increased repair costs. (2) regular repair method, refers to the service life of the parts, production type, workpiece conditions and the relevant quota information, set out in advance a fixed sequence of various types of planned repairs, planned repair intervals and their repair workload.
Before the repair is usually based on the state of the equipment to determine the content of the repair. This method is conducive to good preparations for repair, is conducive to the use of first.
5. Ask for advice: equipment maintenance
Regional maintenance of equipment is also known as the maintenance worker package mechanism.
Maintenance workers to undertake a certain production area of equipment maintenance work, and production operations workers *** with the daily maintenance, inspection tours, regular maintenance, scheduled repairs and troubleshooting, and is responsible for the completion of the tube area of the equipment intact rate, failure downtime rate and other assessment indicators. Regional maintenance responsibility system is to strengthen the maintenance of equipment for production services, mobilize the enthusiasm of maintenance workers and production workers to take the initiative to care about equipment maintenance and repair work in a good form.
The main organizational form of professional equipment maintenance is the regional maintenance group. Regional maintenance group is fully responsible for the production of regional equipment maintenance and emergency repair work, its work tasks are: (1) responsible for the maintenance and repair of equipment in the region to ensure the completion of the equipment integrity rate, failure downtime rate and other indicators; (2) the implementation of the equipment regular inspection and regional inspection system, guidance and supervision of operators to do a good job of routine maintenance and regular maintenance work; (3) in the workshop under the guidance of the mechanics to participate in the equipment condition survey, accuracy and precision of the system. (3) Under the guidance of the shop mechanic, participate in equipment condition survey, precision inspection, adjustment, leakage control, fault analysis and condition monitoring.
Regional maintenance group of this form of equipment maintenance organization has the advantage of: a high degree of mobility in the completion of emergency repairs, so that the shortest possible downtime for equipment repair, and duty clampers in the absence of a call, you can complete the preventive operations and participate in the planned repairs. Equipment maintenance area should take into account the distribution of production equipment, equipment condition, technical complexity, production needs and repair of the technical level of the clampers and other factors.
According to the above factors, the workshop equipment can be divided into a number of regions, but also according to the type of equipment divided into regional maintenance group. Flow production line equipment should be divided into maintenance areas by line.
The regional maintenance group should prepare a regular inspection and accuracy inspection program, and set out the time for routine inspection of equipment on each shift. In order to make these tasks do not affect the production, the planned inspection of equipment to be arranged in the plant on non-working days, and each shift of routine inspection should be arranged in the production workers' lunch break.
6. How to carry out maintenance and maintenance of machinery and equipment
Four requirements for equipment maintenance
(1) neat: tools, workpieces, accessories placed neatly; complete safety guards; line piping integrity.
(2) clean: equipment inside and outside clean; the sliding surface and screw, gear, rack, etc., no oil, no bruises; all parts of the oil leakage, water leakage, gas leakage, electricity leakage; chips and garbage clean sweep.
(3) lubrication: refueling and oil change on time, the oil quality meets the requirements; oil pots, oil guns, oil cups, linoleum, oil line is clean and complete, the oil label is bright, the oil circuit is smooth.
(4) safety: the implementation of scheduled machine and shift handover system; familiar with the structure of the equipment and comply with the operating procedures, the rational use of equipment, careful maintenance of equipment, to prevent accidents.
Site equipment maintenance management content
Equipment maintenance work, according to the time can be divided into daily maintenance and regular maintenance; according to the maintenance mode can be divided into general maintenance, regional maintenance and key equipment maintenance. Maintenance work content broadly includes; view, inspection, adjustment, lubrication, dismantling and repair and replacement of the site management maintenance work.
Regional maintenance of equipment
Regional maintenance of equipment is in accordance with the production area of the company's equipment or equipment type into a number of areas, maintenance workers have a clear division of labor and close cooperation with the operators, responsible for supervising and guiding the operators of the equipment under the jurisdiction of the region of the proper operation of the equipment, the rational use of carefully maintained equipment; inspection tours to grasp the situation of the equipment operation, and assume a certain degree of equipment maintenance work; responsible for the area of the equipment operator correctly operated, reasonable use of well maintained equipment; inspection tours to grasp the situation of equipment operation, and undertake Certain equipment maintenance work; responsible for the district city equipment completion rate, failure downtime rate and other assessment indicators to implement. Regional maintenance is to strengthen the equipment maintenance management for production services, mobilize the enthusiasm of maintenance workers a job responsibility system.
Regional maintenance work is:
A, the daily duty maintenance workers responsible for the equipment in the district city to take the initiative to patrol the whole installation level and accuracy, and make a detailed record, archive for inspection.
C, the environment has special requirements (constant temperature, humidity, vibration, dust) of the precision equipment, companies should take appropriate measures to ensure that the accuracy of the equipment, performance is not affected.
D, precision, rare, critical equipment in the routine maintenance generally do not dismantle parts, especially optical components. Must be disassembled, should be carried out by specialized repair workers. Equipment in operation if found abnormal phenomena, to stop immediately, not allowed to operate with disease.
E. Strictly in accordance with the instructions for the use of the equipment specified in the scope of the processing operation, do not allow over-specification, overweight, overload, overpressure use of equipment. Precision equipment is allowed only by direct use for finishing, processing allowance should be reasonable, processing castings, blank surface should be pre-blasted or painted.
F, equipment, lubricants, wiping materials and cleaning agents should be used in strict accordance with the provisions of the manual, not just substitute. Lubricating oil material must be tested and qualified, and must be filtered before adding to the tank.
R, precision, rare equipment in non-working time to add a protective cover. If a long time to stop, to be regularly wiped, lubrication and idling.
W, equipment accessories and special tools should have a special cabinet shelf amount, to keep clean, to prevent corrosion and bruising, shall not be lent or for other purposes.
Equipment lubrication is an important part of the use and maintenance of machinery and equipment. Correct and reasonable lubrication equipment can reduce friction and wear and tear of equipment parts, extend the service life of the equipment, give full play to the effectiveness of the equipment, reduce functional loss, prevent equipment corrosion and heat deformation. On the contrary, ignoring equipment lubrication work, improper lubrication of equipment will accelerate the wear and tear of equipment, resulting in frequent equipment failures and accidents, accelerate the deterioration of the technical state of the equipment, so that product quality and yield affected. Therefore, equipment management, the use of staff and maintenance personnel should pay attention to the lubrication of equipment.
On-site production equipment oil leakage management standards
(1) oil seepage: oil stains are not obvious, in the oil stains are wiped clean within five minutes after the oil stains do not appear for oil seepage.
(2) oil leakage: oil traces are obvious, some of the formation of oil droplets, in the oil traces or oil droplets are wiped clean within five minutes after the oil traces or oil droplets for oil leakage.
(3) oil leakage point: there is an obvious oil trace or an oil droplet, for an oil leakage point.
(4) non-leakage equipment: static bonding surface does not seep oil, dynamic bonding surface does not leak oil, for non-leakage equipment. 80% of the bonding surface does not leak oil, and the leakage of oil leakage parts of the oil leakage of no more than one drop in three minutes for the basic non-leakage equipment.
(5) serious oil leakage equipment: equipment with one of the following conditions, or an oil leakage point a minute more than three drops of oil, for serious oil leakage equipment.
(6) general oil leakage equipment: where the phenomenon of oil leakage, but not enough to the extent of the above serious oil leakage, general oil leakage equipment.
(7) governance qualified: static bonding surface without oil seepage, dynamic bonding surface (in addition to hand lubrication of the guide rail, screw, light bar, etc. at all moving parts) without oil leakage.