The high-speed chenille machine is a key equipment used in the textile industry to produce chenille yarn. It has high operating speed, complex structure, and strict maintenance requirements. Scientific maintenance methods can not only extend equipment lifespan and reduce failure rates, but also ensure stable yarn quality. The following are detailed maintenance methods for high-speed Schunier machines, covering daily inspections, regular maintenance, key component maintenance, and fault prevention:
1. Daily maintenance: the foundation of fault prevention
Cleaning and dust removal: the surface of the machine body: wipe the machine body with a dry cloth every day to remove flying flowers, dust, and oil stains, and avoid dust accumulation affecting heat dissipation or entering transmission components.
Key areas: Focus on cleaning the fiber accumulation around cutting blades, rollers, spindles, and other components to prevent entanglement from causing jamming or wear.
.Electrical cabinet: Clean the inside of the electrical cabinet with a vacuum cleaner every week to avoid dust causing short circuits or poor contact.
. Lubrication and maintenance: Lubrication point inspection: Check the oil level or nozzle of each lubrication point (such as bearings, gears, chains) before starting up daily to ensure sufficient lubricating oil. Automatic lubrication system: If the equipment is equipped with an automatic lubrication device, it is necessary to regularly check whether the oil circuit is unobstructed and whether the oil pump pressure is normal (usually 0.2~0.5MPa).Lubricating oil selection: Choose the appropriate oil according to the equipment manual (such as low viscosity lubricating oil for high-speed bearings and industrial gear oil for gears) to avoid mixing and causing performance degradation.
.Running status monitoring: Abnormal noise inspection: Listen for the running sound of the equipment after starting up. Abnormal noise (such as friction sound, impact sound) may indicate bearing damage or component looseness.
.Temperature monitoring: Touch the motor, bearings, and other parts with your hands. If the temperature is too high (over 70 ℃), it may be due to insufficient lubrication or excessive load.
.Yarn quality: Real time observation of the twist and plush uniformity of the chenille yarn. If there are any abnormalities, immediately stop the machine and check the status of the cutter or roller.
.2. Regular Maintenance: The Key to Extending Equipment Life
Monthly Maintenance Item: Transmission Component Inspection: Check the tension of belts and chains. Improper tension can cause slipping or breakage.
. The tension of the belt should comply with the requirements of the equipment manual (such as the tension of the walking belt, which is usually 50-100N).Check the gear meshing condition, and replace if the tooth surface wear exceeds 0.5mm.
. Electrical system testing: Use a multimeter to check whether the voltage and current of electrical components such as motors and sensors are stable, and whether the wiring terminals are loose. Clean the motor cooling fan, ensure good ventilation, and avoid overheating.Knife maintenance: Check the sharpness of the cutting edge, and after passivation, use an oilstone or a specialized sharpening machine to polish it (the cutting edge angle is usually 30 °~45 °).
.Adjust the gap between the cutter and the roller (usually 0.1~0.3mm). If the gap is too large, it will cause uneven yarn plush, and if it is too small, it will easily wear down the parts.
. Quarterly maintenance items: Bearing replacement: High speed bearings (such as spindle bearings) need to be replaced after running for 500-1000 hours to avoid fatigue damage. When replacing, pay attention to the installation direction and preload force (such as adjusting the axial clearance of angular contact bearings with special tools).Surface treatment of roller: Check the smoothness of the roller surface. If it is worn or scratched, it needs to be chrome plated or polished again to ensure even friction on the yarn.
. Pneumatic system maintenance: Check the sealing of the cylinder and solenoid valve, and replace the sealing ring if there is a leak. Clean the air filter, drain and prevent rust, and ensure stable compressed air pressure (usually 0.5~0.7MPa). Annual overhaul: Complete machine disassembly inspection: Disassemble the equipment, clean all components, and check whether the frame, wall panels, and other structural components are deformed or cracked. Replace aging seals, hoses, and other vulnerable parts.Accuracy adjustment: Adjust the parallelism and coaxiality of each roller and cutter (error ≤ 0.05mm) to ensure uniform yarn twist.
. Calibrate the zero point and range of sensors (such as tension sensors and speed sensors) to ensure data accuracy.III. Special maintenance of key components
Cutting blade system: Blade protection: Cover the cutting blade with a special protective sheath during shutdown to avoid collision damage.
. Cooling and lubrication: During high-speed cutting, it is necessary to spray coolant (such as emulsion) to reduce edge heating and wear.Dynamic balance: When the cutting blade rotates at high speed (usually 5000-10000rpm), a dynamic balance test is required, with an imbalance of ≤ 0.5g · cm.
Roller components: Surface cleaning: Wipe the surface of the roller with alcohol to avoid oil stains causing yarn slippage.
.Bearing lubrication: Roller bearings need to be lubricated with grease (such as lithium based grease) every shift, and the amount of grease added should be based on the overflow of old grease.
.Tension control: Regularly calibrate the roller tension sensor to ensure stable yarn tension (error ≤± 5%).
Spindle and yarn tube: Spindle runout inspection: Use a dial gauge to detect the radial runout of the spindle (allowable value ≤ 0.03mm). If it exceeds the tolerance, replace the bearing or spindle rod.
.Yarn tube positioning: Check the clearance between the yarn tube and the spindle. If the clearance is too large, the yarn may shake, and the yarn tube needs to be replaced or the spindle needs to be adjusted.
.IV. Fault Prevention and Emergency Handling
Common faults and causes: yarn breakage: may be caused by blunting of the cutting blade, uneven tension of the roller, or blockage of the yarn channel, which needs to be investigated one by one.
.Equipment vibration: Often caused by damaged bearings, loose belts, or loose frames, it is necessary to tighten bolts or replace components.
.Electrical faults: such as sensor failure or PLC program errors, spare sensors need to be replaced for testing or the system needs to be restarted.
.Emergency response process: Shutdown safety: If a fault is found, immediately press the emergency stop button, cut off the power, and then operate.
. Fault record: Detailed record of fault symptoms, occurrence time, and handling process for subsequent analysis. Spare parts management: Reserve commonly used spare parts (such as bearings, cutters, belts) to shorten downtime.V. Suggestions for Maintenance Management Optimization
Establish maintenance files: record the time, content, replaced parts, and equipment operation data of each maintenance, providing a basis for equipment life assessment.
. Personnel training: Regularly provide maintenance skills training to operators to master equipment structure, lubrication points, and fault phenomena.Intelligent upgrade: Install online monitoring devices such as vibration sensors and temperature sensors to provide real-time feedback on equipment status and achieve predictive maintenance.
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