On 2018-08-08 14:48:54
heat treatment equipment maintenance status and optimization measures
Generally speaking, the technical requirements for the failure maintenance of heat treatment equipment are relatively high, especially in China where the failure rate of heat treatment equipment increases, so it is more urgent to do a good job in the maintenance of heat treatment equipment, so as to fundamentally improve the quality of heat treatment equipment.
I. Current situation of failure maintenance of heat treatment equipment in China
At present, there are many defects in the use of heat treatment equipment in China, which have a great impact on the reliability of heat treatment equipment itself. For example, due to the long-term continuous use of heat treatment equipment, there are many damaged areas on the surface, but these damaged areas are ignored, which makes the heat treatment equipment appear more serious faults in the later use process. For example, the service life of different heat treatment equipment is different, and some maintenance personnel change some heat treatment equipment in advance for convenience, which seriously reduces the use value of heat treatment equipment. In addition, according to the actual investigation, many enterprises due to the lack of attention to heat treatment equipment, heat treatment equipment due to maintenance in a timely manner affect the production of the phenomenon. Of course, it is not surprising that heat treatment equipment will eventually develop more faults due to local faults. On the one hand, business leaders did not pay attention to the above problems and did not provide enough maintenance costs. On the other hand, the technical level of heat treatment maintenance technicians is not high, which increases the probability of heat treatment equipment failure. Therefore, to improve the maintenance condition of heat treatment equipment and improve the maintenance efficiency of heat treatment equipment is an urgent problem for machinery manufacturers.
The fault repair of heat treatment equipment is easy to be neglected
On the one hand, enterprises often have a one-sided understanding of the maintenance of heat treatment equipment in the process, leading to a big difference in the maintenance work and actual situation of heat treatment equipment, which further increases the maintenance cost of heat treatment equipment in enterprises and brings huge economic losses to enterprises. In the maintenance process of heat treatment equipment, enterprises should consider how to optimize the economic maintenance, in the fault detection process of heat treatment equipment, it is more necessary to carry out a comprehensive inspection of equipment, to avoid inaccurate positioning. According to relevant statistics, the risk of failure of heat treatment equipment is more than 80%, and most of the heat treatment equipment failure is related to improper maintenance. Attention should be paid to the safety maintenance and inspection of heat treatment equipment, as well as the maintenance related technical work of heat treatment equipment, and attention should be paid to reducing the risk of heat treatment equipment failure.
Quick maintenance of heat treatment equipment
(1) Quick maintenance method for electric furnace wire breakage
Wire breakage is common in heat treatment workshops. Under normal circumstances, because the temperature of the furnace is very high, we need to wait 2-3 days. After the temperature in the furnace cools down, we can enter the furnace and weld the resistance wire, which has a great impact on the production. It takes a lot of labor time to remove and install the resistance wire. Now take a section of the same as the original electric furnace wire helical old wire, with long pliers or iron fork plug into the broken wire, the two ends of the broken wire connected, can be electrified heating. This method is quick and simple, does not affect the production, the working efficiency is increased ten times, saves the raw material. To reduce wire breakage in the furnace bottom, the furnace bottom firebricks reverse the shape of the mountain, at each furnace bottom combined in one layer, and then cover the bottom of the furnace to prevent oxide coating from falling, resulting in electric furnace line combustion.
(2) Quick maintenance of salt bath resistance furnace
The salt bath furnace chamber built with firebrick has formed a thick hard layer together with the insulation material inside the ladle cement because the molten salt bath penetrates outside the furnace from the brick joint during long-term use. It takes a lot of effort to knock the stove out when repairing it. The simple solution is to take a spoon out and soak it overnight in water to dissolve the cemented salt. The next day, turn over the ladle, hammer a few times, firebricks all fall down, and then save time and effort, but also simple and practical.
(3) Optimization measures for fault maintenance of heat treatment equipment
(I) Apply LCC theory to the advanced prevention stage of heat treatment equipment failure
Enterprises should organize maintenance personnel in the process of selection of heat treatment equipment, heat treatment equipment in advance prevention, use of LCC theory in the process of selection, maintainability and operability of heat treatment equipment selection and grasp the key, and heat treatment equipment automation, regular maintenance, part of the common, rational and complete structure, rational, technical data, to perfect the content of many aspects, such as comprehensive study, improve the effect of heat treatment equipment overall failure problem prevention. At the same time, in the process of choosing heat treatment equipment, it is also necessary to timely understand the relevant information of heat treatment equipment, and accurate consultation with the manufacturer, so as to provide a reasonable reference for future fault maintenance.
(ii) Applying TMP theory to the fault problem in the maintenance stage of heat treatment equipment
Applying TPM theory to the fault problem of heat treatment equipment in the maintenance stage can fully improve the overall quality of the fault treatment of heat treatment equipment. First of all, equipment maintenance personnel should ensure the internal and external cleaning of heat treatment equipment, in the troubleshooting process should be in the oil hole, gear box, rack and other parts of the necessary oil cleaning work. At the same time, maintenance personnel should also be the friction parts and key structures of heat treatment equipment lubrication treatment, reduce the probability of component wear failure.
(3) Apply RCM theory to the maintenance stage after the failure of heat treatment equipment
RCM theory specifically refers to the analysis and study of problems and consequences of failures in the management process, so as to improve the accuracy and scientific nature of fault maintenance. In practical work, the maintenance inspector should first determine the normal use of heat treatment equipment, combined with the performance index and functional characteristics of heat treatment equipment in normal use, to further improve the overall quality of heat treatment equipment fault maintenance. Equipment maintenance personnel fault conditions of the heat treatment equipment and analysis of the cause of the problem, but also to deal with the equipment to study the expected performance, explore the failure of the heat treatment equipment factors, to ensure that the heat treatment equipment fault maintenance work can fully reduce the risk of heat treatment equipment failure hidden dangers, to ensure the production of enterprises.
In a word, the fault repair of heat treatment equipment is of great significance to the actual production of enterprises. At the present stage, some enterprises in China should pay attention to the maintenance of heat treatment equipment faults, carry out targeted improvement and optimization of common fault maintenance of heat treatment equipment, and improve the internal production and operation environment.