Research on Cold Rolling Equipment Management and Maintenance (1)
Abstract:
Cold rolling equipment production involves transmission system, rolling oil cooling, heating system, thin oil lubrication system, air purging system, oil and gas lubrication system, carbon dioxide fire extinguishing system, thickness control system, plate control system, hydraulic auxiliary system, rolling oil smoke recovery system, rolling oil regeneration system, water circulation system, etc., the equipment is composed of many, complex process, interaction, The mutual influence increases the difficulty of judging, analyzing and solving problems, and puts forward higher and stricter requirements for equipment management and maintenance. And cold rolling equipment is in high speed, heavy load, 24h continuous operation environment, or key fire equipment, its stability and operation reliability is very important, the use of scientific and efficient equipment management and maintenance methods and principles, is to ensure its safe and reliable operation of the main means. According to the characteristics of cold rolling production process, the method and principle of cold rolling equipment management are analyzed from the selection, use, management and maintenance of cold rolling equipment. The measures and skills of equipment management and maintenance are discussed from the aspects of the law, phenomenon and characteristics of the cold rolling equipment failure, which has certain guidance and reference significance for the scientific management level and the reliability of the cold rolling equipment.
Key words: cold rolling equipment; Equipment management; Equipment maintenance
Cold rolling equipment is widely used, where hot rolling requirements continue to roll, and performance, organization, surface quality and dimensional precision requirements of the product, are cold rolling. Cold rolling equipment from the earliest two high cold rolling mill to four high, six high cold rolling mill, and then to the present cold tandem mill, the capacity of the equipment is constantly improving, the operation efficiency is constantly improving, the performance is constantly improving, the intelligent level of the equipment is getting higher and higher, the judgment of the problem, the analysis of the problem, the solution of the problem, the problem is becoming more and more difficult. The technical personnel of equipment management and maintenance are put forward higher requirements. The application of scientific equipment management and maintenance methods to ensure the stability and reliability of cold rolling equipment is an important task of equipment management, and also an important object of enterprise management. Our company Jiangsu Sual Aluminum Co., LTD., established in 1958, has been engaged in cold rolling production, in the cold rolling equipment management and maintenance of accumulated rich experience and lessons, in the inheritance of cold rolling equipment management and maintenance experience at the same time, learn lessons, improve the equipment management and maintenance of the loopholes, learn our company's equipment management methods and means, Referring to the management system of our company in equipment management, combined with the author's many years of experience in cold rolling equipment management and maintenance, this paper analyzes the reasons for the failure of cold rolling equipment, in view of the common problems existing in equipment management, and combined with the production characteristics of cold rolling equipment, put forward scientific management methods and means for cold rolling equipment.
1 Main reasons for the failure of cold rolling equipment
(1) Natural damage of parts. In the process of equipment use, parts will produce wear, fatigue and deformation and other natural damage, resulting in failure. Although the failure caused by such damage cannot be avoided, it can be mastered and eliminated through strict implementation of maintenance system and prior maintenance of equipment. For example, wear damage, cold rolling equipment up and down roll cleaner scraper, coiler belt, etc., because of long-term contact with the roll; The clearance of rotary joint, roll coupling shaft, etc. becomes larger because of relatively frequent movement. Fatigue damage, heavy duty and continuous operation of equipment prone to fatigue damage, cold rolling reel spring fatigue fracture, tie rod. Aging damage, elastic coupling elastic components, shock absorbers, nylon gear coupling and other use time is long, easy to aging.
(2) poor lubrication. Mechanical equipment rotation cannot do without bearings, cold rolling equipment involved in a large number of types and quantities, there are various types of bearings, bearing, copper sleeve, coupling, so lubrication management is very important, especially by rolling oil, high speed, heavy load, lubricating oil loss, aging. When there are design defects, unreasonable installation, continuous operation, rotating parts, not designed refueling holes or can not be refueling, it is easy to cause bearing damage, therefore, it is necessary to regularly check and add lubricating oil, eliminate equipment failure caused by poor lubrication.
(3) The operation condition of the machine is poor. Cold rolling equipment in the production run, due to load changes, pressure changes, tension changes, uneven cooling, rolling oil permeability, easy to break the belt, fire and other adverse conditions, will aggravate the damage of parts or bearings, equipment failure. The characteristics of cold rolling equipment production, large vibration, easy to cause equipment fastening screw loose, pipe clamp loose, weld welding, hydraulic hose wear, purging Angle dislocation, etc., resulting in equipment failure.
(4) The processing and assembly quality of manufactured parts is poor. Parts in the manufacturing and repair processing, do not strictly implement the process specification, did not meet the technical requirements of the design, make do with the use of parts, destroy the mechanical performance of the parts should be, the technical performance of the machine is poor, easy to make parts early damage, equipment failure.
(5) Human causes. The operator of the equipment is not familiar with the operation procedures, operation error, or carelessness, resulting in equipment failure. For example, the roll transport car off the roll, smash the car guide rail, drag chain, replace the roll, smash the rolling line adjustment cylinder, oil and gas lubrication hose, or in the roll change, lifting process damage equipment. Equipment maintenance personnel, technical ability is not enough, in the process of equipment maintenance, do not operate according to the standard, parts are not cleaned, poor lubrication, brutal operation, do not operate according to the process, so that the assembly quality is poor, or in the use of equipment in the process of maintenance is not timely, will also aggravate the damage of zero parts, failure.
2. Problems existing in cold rolling equipment management and maintenance
(1) The management system is not perfect, and the management organization is not sound enough. Production and operation units do not pay attention to equipment management and maintenance, or the degree of attention is not enough, do not set up special equipment management personnel, or equipment management personnel are not professional, set up management and maintenance work is just a formality, what is more, there is no basic management of equipment, not to mention a perfect equipment management and maintenance system, there is no sound equipment management and maintenance system. Equipment management and maintenance work without rules to follow, management chaos.
(2) The quality improvement training of equipment management personnel and maintenance personnel is not in place. Production and operation units do not pay attention to equipment management and maintenance personnel, do not have high requirements for equipment management and maintenance, pay attention to immediate interests and short-term interests, and are unwilling to spend money on training supporting facilities and operation and maintenance personnel, which directly leads to low management level and maintenance skills, so that the new equipment cannot reach the original equipment level in the maintenance process.
(3) Disconnection between equipment production and management and maintenance, and not full participation. Some companies adopt maintenance management outsourcing system, operators often have a "only responsible for use, not responsible for maintenance" mentality to work, indifferent to the operating conditions of equipment, work habits and operation mode subtly change, indirectly lead to equipment in a high load state, and even make the equipment work with illness. It accelerates the aging speed of cold rolling equipment, intensifies the wear of parts between the equipment and shortens the service life.
(4) The team of maintenance personnel is unstable and lack of skills, which reduces the level of equipment management and maintenance work. Equipment maintenance is a hard, dirty and tiring job. In addition, the company leaders only pay attention to production, but not maintenance, and the wages and benefits do not go up, so more and more people are reluctant to do maintenance. In order to meet the needs of the company's initial operation, the mode of recruiting equipment maintenance personnel is adopted. The skills of equipment management and maintenance personnel are not high, but also lack of professional maintenance skills, no concept and experience of equipment management, and the sense of responsibility is not strong, the overall and overall cognition of cold rolling equipment is not enough, ignoring the accuracy requirements of the internal parts and the combination of the situation, which leads to the secondary damage of the equipment after maintenance.
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