As the core equipment of polyurethane filter, it requires daily maintenance and cleaning, including four modules PU mechanical structure, hydraulic system, electrical control and mold maintenance. This will ensure the steady operation of the equipment, prolong service life and ensure the quality of the filter core. Specific caveats are as follows:
I. Mechanical Structure maintenance
Lubrication Maintenance
KEY COMPONENTS: Special grease (such as lithium based grease) is regularly applied to moving parts such as guide rails, lead screws and bearings to reduce wear and tear.
Recommended cycle time: once per shift (8 hours), a full lubrication once a week to reduce the life cycle of high-load equipment.
For example, an automatic lubrication system controlled by PLC is used in the production of Jiediou filters to ensure smooth operation of the discharge head.
Fastener Inspection
Key points: check whether bolts on the motor, pump body and drive belt are loose and prevent vibration from causing parts to fall off.
Tool Requirements: Use torque wrench to tighten to the torque value specified in the equipment manual to avoid overtightening or overtightening.
Transmission System maintenance
Belt tension: Adjust the drive belt tension to an appropriate range (usually no more than 10mm sagging when pressing the middle of the belt by hand) to prevent sliding or cracking.
Chain Lubrication: Spray chain lubrication on chain drive to remove old oil stains and prevent blockage.
II. Hydraulic System Maintenance
Oil management
Oil level check: Check the hydraulic level daily before starting the engine to ensure that the hydraulic level is within the range indicated by the oil oil level gauge and to prevent the oil pump from sucking in air.
Oil quality monitoring: the oil viscosity, acid value and moisture content are sampled every 3 months. Change the oil if you exceed the standard.
Oil Change Interval: Hydraulic oil is Generally replaced every 12 months, which can be shortened to six months for high-load equipment.
Replace filters
Hydraulic Oil Filter: Replace the oil filters every 500 hours to prevent impurities from entering the system.
Air filter: Wash once a week and change once a month to prevent dust from contaminating the oil.
Systematic cleaning
Fuel tank cleaning: Wash the fuel tank thoroughly once a year to remove sediment and moisture from the bottom and wipe the inside with a clean cloth.
Pipeline inspection: Check for leakage, aging or bending of hydraulic lines and replace damaged lines in a timely manner.
III. Electrical Control and Maintenance
Cleaning and dust-proofing
3. Cleaning of cabinets: Clean the inside of cabinets with compressed air once a month, paying special attention to cleaning of cooling fans and wiring terminals.
Damp proof: In a humid environment, place a dryer in the cabinet and check the heater regularly to see if it is working properly.
Wiring Inspection
Loosen detection: Quarterly check that all wiring terminals are loose, especially largecurrent lines (such as motor wiring).
Insulation Testing: Test the insulation resistance of motor and cable annually with a megohmmeter to guarantee ≥ 1 omega.
Parameter Calibration
Temperature control: Regularly calibrate heating system (e.g. PU casting temperature) to ensure that the error does not exceed + -2°C.
Pressure Calibration: Check the accuracy of the system pressure gauges in the hydraulic system; if there is deviation, replace or send for inspection.
IV. INTRODUCTION Mold Maintenance
Cleaning and rust prevention
Slag removal: After each production run, clean mold cavity with special solvent (such as isopropyl alcohol), remove PU residue, prevent mold damage after curing.
Rust-proof: When the mold is not in use for a long period, apply rust oil to the surface of the mold and cover with dust cover cover.
Mold Closing Mechanism Inspection
Guide Guide Pillar Lubrication: Apply grease to the mold closing guide column weekly to reduce wear and tear.
Adjust clamping force: Adjust the clamping force according to the size of the filter core to avoid excessive force leading to mold deformation or insufficient force leading to flash.
Mold Life Management
Usage Records: set up mold usage file, record production batches and maintenance history, forecast mold life.
Periodic inspection: After every 5000 mold closing cycles, the die is thoroughly inspected and worn parts (such as ejector pins and sliders) are replaced.
V. Cleaning Operation Procedures
Safeguarding
Power outage operation: before cleaning, the device must be disconnected from power, and display ``do not lose power "warning sign.
Personal protection: Wear protective gloves, goggles and dust masks to prevent polyurethane residues from touching your skin or eyes.
Choice of cleaning tools
Non-metal tools: Clean mould with plastic or wooden scrapers to avoid scratching cavity surface.
Specialized Solvents: use polyurethane special cleaning agent, avoid the use of gasoline, alcohol and other corrosive solvents.
Waste Disposal
Sorted recycling: PU waste and hydraulic oil filters from cleaning process and hand them over to a professional agency for recycling.
Environmental Requirements: comply with local environmental laws and regulations, prohibit dumping of waste liquids and slag.
VI. INTRODUCTION Maintenance Records and Plans
Establishment of maintenance files
Record the time, contents, replacement parts and maintenance personnel of each repair to facilitate traceability of problems.
Example: Jiediou filters track the entire life cycle of a device through an ERP system system management maintenance records.
Develop Preventive Maintenance plans
Develop an annual maintenance plan with a clear maintenance cycle and standards for each component according to the equipment manual and production needs.
Recommended Tools: Create maintenance work orders automatically using (Computerized Maintenance Management System).