不论是进口还是国产注塑机都具有以下特点：

不论是进口还是国产注塑机都具有以下特点： 不论是进口还是国产注塑机都具有以下特点: 1.注塑机固定资产投资大,生产规模大,消耗原料多,劳动生产率高,创产值大。是一种劳动效率较高的生产组织形式。 2.注塑机由机械、液压、电器、专用配套件等,按照注塑加工工艺技术的需要,有机地组合在一起,自动化程度高,相互之间关联紧密;注塑机可3班24h连续运转。若注塑机的某个元件发生故障,将导致停机。 3、注塑机上虽然操作简单,工人少,但注塑机管理和维修的技术含量高,工作量也大。 所以要保证注塑机经常处于完好状态,就必须加强注塑机管理工作,严格控制注塑机的故障发生。以达到降低故障率,减少维修费用,延长使用寿命的目的。 注塑机故障,一般是指注塑机或系统在使用中丧失或降低其规定功能的事件或现象。注塑机是企业为满足注塑制品生产工艺要求而配备的。注塑机的功能体现着它在注塑制品生产活动中存在的价值和对注塑生产的保证程度。在现代化注塑机生产中,由于注塑机结构复杂,自动化程度很高,液压、电控及机械的联系非常紧密,因而注塑机出现故障,那怕是局部的失灵,都会造成整个注塑机的停产。注塑机故障直接影响注塑产品的数量和质量。 一、注塑机故障的分类 注塑机故障是多种多样的,可以从不同角度对其进行分类。 1.按故障发生状态,可分为: (1:渐发性故障。是由于注塑机初始性能逐渐劣化而产生的,大部分注塑机的故障都属于这类故障。这类故障与电控、液压机械元配件的磨损、腐蚀、疲劳及蠕变等过程有密切的关系。 (2:突发性故障。是各种不利因素以及偶然的外界影响共同作用而产生的,这种作用超出了注塑机所a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the 能承受的限度。例如:因料筒进入铁物出现超负荷而引起螺杆折断;因高压串入而击穿注塑机电子板。此类故障往往是突然发生的,事先无任何征兆。 突发性故障多发生在注塑机使用阶段,往往是由于、制造、装配以及材质等缺陷,或者操作失误、违章作业而造成的。 2.按故障性质划分,可分为: (1:间断性故障。注塑机在短期内丧失其某些功能,稍加修理调试就能恢复,不需要更换零部件。 (2:永久性故障。注塑机某些零部件已损坏,需要更换或修理才能恢复使用。 3.按故障影响程度划分,可分为: (1:完全性故障。导致注塑机完全丧失功能。 (2:局部性故障。导致注塑机某些功能丧失。 4.按故障发生原因划分,可分为: (1:磨损性故障。由于注塑机正常磨损造成的故障。 (2:错用性故障。由于操作错误、维护不当造成的故障。 (3:固有的薄弱性故障。由于设计问,使注塑机出现薄弱环节,在正常使用时产生的故障。 5.按故障的危险性划分,可分为: (1:危险性故障。例如安全保护系统在需要动作时因故障失去保护作用,造成人身伤害和注塑机故障;液压电控系统失灵造成的故障等。 (2:安全性故障。例如安全保护系统在不需要动作时发生动作;注塑机不能启动时启动的故障。 6.按注塑机故障的发生、发展规律划分,可分为; a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the (1:随机故障。故障发生的时间是随机的。 (2:有规则故障。故障的发生有一定规律。 每一种故障都有其主要特征,即所谓故障模式,或故障状态。各种注塑机的故障状态是相当繁杂的,但可归纳出以下数种:异常振动、机械磨损、输入信号无法让电脑接受、电磁阀没有输出信号、机械液压元件破裂、、比例线性失调、液压压降、液压渗漏、油泵故障、液压噪音、电路老化、异常声响、油质劣化、电源压降、放大板无输出、温度失控及其它。不同类型注塑机的各种故障模式所占比例有所不同。 二、故障分析与故障排除程序 为确保故障分析与排除的快捷、有效,必须遵循一定的程序,这种程序大致如下。 第一步 保持现场的情况下进行症状分析 1.询问操作人员 :1:发生了什么故障,在什么情况下发生的,什么时候发生的, :2:注塑机巳经运行了多久, :3:故障发生前有无任何异常现象,有何声响或声光报警信号,有无烟气或异味,有无误操作:注意询问方式:, :4:控制系统操作是否正常,操作程序有无变动,在操作时是否有特殊困难或异常, 2.观察整机状况、各项运行参数 :1:有无明显的异常现象,零件有无卡阻或损伤,液压系统有否松动或泄漏,电线有无破裂、擦伤或烧毁, :2:注塑机运行参数有何变化,有无明显的干扰信号,有无明显的损坏信号, 3.检查监测指示装置 :1:检查所有读数值是否正常,包括压力表及其它仪表读数,油面高度情况。 a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the :2:检查过滤器、报警器及联锁装置、动作输出或显示器是否正常。 4.点动注塑机检查:在允许的条件下: 检查间歇情况、持久情况、快进或慢进时的情况,看在这些情况下是否影响输出,是否可能引起损坏或其它危险。 第二步 检查注塑机:包括零件、部件及线路: 1.利用感官检查:继续深入观察的过程: 1看:插头及插座有无异常,电机或泵的运转是否正常,控制调整位置是否正确,有无起弧或烧焦的痕迹,保险丝好坏,液体有无泄漏,润滑油路是否畅通等。 2摸:注塑机振动情况,元:组:件的热度,油管的温度,机械运动的状态。 3听:有无异常声响。 4嗅:有无焦味、漏气味、其它异味。 5查:工件的形状与位置变化,注塑机性能参数的变化,线路异常检查。 2.评定检查结果 评定故障判断是否正确,故障线索是否找到,各项检查结果是否一致。 第三步 故障位置的确定 1.识别系统结构及确定测试方法 查阅注塑机说明书,识别注塑机是哪一种结构,用什么方法进行测试,需要什么测试手段,可能获得什么测试参数或性能参数,在什么操作条件下进行测试,必须遵守哪些安全措施,是否需要操作许可证。 2.系统检测 采用最适合于系统结构的技术检测。在合适的测试点,根据输入和反馈所得结果与正常值或性能标准进行比较,查出可疑位置。 a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the 第四步 修理或更换 1.修理 查找故障原因,针对注塑机故障进行修理并采取预防措施;检查相关零件,防止故障扩散。 2.更换 正确装配调试更换零件,并注意相关部件。换下的零件进行修理或报废。 第五步 进行性能测定 1.起动注塑机 零部件装配调试后起动注塑机,先手动:或点动:,然后进行空载和负载测定。 2.调节负载变化速度由低到高,负载由小到大,系统压力最高不能超过140kg/cm2,按规定标准测定性能。 3.扩大性能试验范围 根据需要,由局部到系统逐步扩大性能试验范围。注意非故障区系统运行状况。如性能满足要求则交付使用,如不满足要求则重新确定故障部位。 第六步 记录并反馈 1.收集有价值的资料及数据,如注塑机故障发生的时间、故障现象、停机时间、修理工时、修换零件、修理效果、待解决的问题、结算费用等,按规定的要求存入档案。 2.统计分析 定期分析注塑机使用记录,分析停机损失,修订备忘目录,寻找减少维修作业的重点措施,研究故障机理,提出改进措施。 3.按程序反馈有关故障上报主管部门,并反馈给注塑机制造单位。 三、故障管理的展开程序 a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the 要做好注塑机故障管理,必须掌握发生故障的原因,积累常发故障和典型故障的资料和数据,开展故障分析,重视故障规律和故障机理的研究,加强日常维护、检查和预修。故障管理的展开程序有以下8个方面。 1.做好教育工作,使操作工人和维修工人自觉地对注塑机故障进行认真的记录、统计、分析,提出合理化建议。 2.紧密结合注塑生产实际和注塑机状况特点,把在用注塑机分成A、B、C三类,以确定故障管理的重点。 3.采用监测仪器,对重点注塑机的重点部位进行有计划的监测,以及时发现故障的征兆和劣化的信息。 一般注塑机也要通过人的感官及一般检测工具进行日常点检、巡回检查、定期检查:包括精度检查:、完好状态检查等,着重掌握易出故障的部位、机构及零件的技术状态和异常现象的信息。同时要制订检查标准,确定注塑机正常、异常、故障的界限。 4.开展故障分析,培训注塑机维修工掌握故障分析方法。 5.故障记录是实现注塑机故障管理的基础资料,又是进行故障分析、处理的原始依据,记录必须完整正确。注塑机维修工人在现场进行检查和故障修理后,应按照“注塑机故障修理单”的内容认真填写,车间机械员按月统计分析并报送注塑机管理主管。 6.车间注塑机维修员除日常掌握故障情况外,应按月汇集“故障修理单”和维修记录。通过对故障数据的统计、整理、分析,计算出各类注塑机的故障频率、平均故障间隔期,分析单台注塑机的故障动态和重点故障原因,找出故障的发生规律,以便突出重点采取对策,将故障信息整理分析资料反馈到计划部门,以便安排预防修理或改善措施计划,还可以作为修改定期检查间隔期、检查内容和标准的依据。 根据统计整理的资料,可以绘出统计分析图表,如单台注塑机故障动态统计分析表是维修班组对故障及其它进行目视管理的有效方法,既便于管理人员和维修工人及时掌握各类型注塑机发生故障的情况,又能在确定维修对策时有明确目标。 7.通过维修工人的日常巡回检查和注塑机状态检查,取得的状态信息和故障征兆,以及有关记录、分析资料,由车间注塑机维修员或修理组长针对各类型注塑机的存在问题,及时安排日常维修,充分利用生产空隙时间或节假日,做到预防在前,以控制和减少故障发生。对某些故障征兆、隐患,日常维修无力承担的,则反馈给计划部门安排计划修理。 8.制订故障信息管理流程图。 a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the 四、注塑机故障规律 研究故障规律对制定维修对策,以至建立科学的维修体制都是十分有利的。注塑机在使用过程中,其性能或状态随着使用时间的推移而逐步下降。很多故障发生前会有一些预兆,这就是所谓潜在故障,其可识别的物理参数表明一种功能性故障即将发生,功能性故障表明注塑机丧失了规定的性能标准。 注塑机故障率随时间的变化规律,常被叫做浴盆曲线。注塑机的故障率随时间的变化大致分三个阶段:早期故障期、偶发故障期和耗损故障期。 1.早期故障期 注塑机处于早期故障期,开始故障率很高,但随时间的推移故障率迅速下降,早期故障期对于机械产品又称为磨合期。此段时间的长短,因产品、系统的设计与制造质量而异。此期间发生的故障,主要是由设计、制造上的缺陷所致,或是使用环境不当所造成。 2.偶发故障期 注塑机进人偶发故障期,故障率大致处于稳定状态,趋于定值。在此期间,故障发生是随机的。在偶发故障期内,注塑机的故障率最低,而且稳定。.因而可以说,这是注塑机的最佳状态期或称正常工作期。这个区段称为有效寿命。 偶发故障期的故障,多起因于设计、使用不当及维修不力。故通过提高设计质量、改进使用管理、加强监视诊断与维护保养等工作,可使故障率降低到最低水平。 3.耗损故障期 在注塑机使用的后期,故障率开始上升。这是由于注塑机零部件的磨损、疲劳、老化、腐蚀等造成的。如果在拐点即耗损故障期开始时进行大修,可经济而有效地降低故障率。 注塑机故障率曲线变化的三个阶段,真实地反映出注塑机从磨合、调试、正常工作到大修或报废故障率变化的规律,加强注塑机的日常管理与维护保养,可以延长偶发故障期。准确地找出拐点,可避免过剩修理或修理范围扩大,以获得最佳的投资效益。 a special tool to measure half a point the rotor shaft runout and simultaneous measurement of two coupling flutter testing, it should meet the requirements. Install the coupling housings to ensure embedded rotor coupling within a concave shoulder, and rotor clearance meets the design requirements. 6.4, 6, wearing construction technology of generator rotors demonstration 6.4.6.1 construction preparation and conditions through the stator before loading check and confirm to confirm air tightness test of the stator and stator mechanical, electrical, instrumentation and control and other related work had been completed. Internal cleaning of stator, high power vacuum the surface of the stator. Stator and rotor magnetic Center drainage is complete. In conjunction with the quality, mechanical, electrical and other relevant persons to finally cleaning check the stator, which is clean and free of any debris. Worn rotors check and confirm confirm before loading the rotor air tightness test, electrical test work has been completed. In conjunction with the quality, mechanical, electrical and other relevant persons to finally clean the rotors checked, its interior is clean and free of any debris. By quality, mechanical, electrical and other professionals to conduct an examination of the rotor, confirm the wear condition of the rotor. Special equipment inspection and rotor through the preparation tool before loading inventory, check to confirm that it appears intact, complete tool, tools required for use of wire rope that has a factory certificate and test report; wire rope should select the safety factor ? 6; hoist testing qualified; road have been equipment authorized Visa temporary support ties should be a hardwood. Ends bearing end cover with connection of the stator plate or gourds by exclusive lug on the end face of a temporary low-hanging on the