Failure procedure of injection molding machine and development procedure of fault management
Studying the law of failure is very beneficial for the development of maintenance measures and the establishment of a scientific maintenance system. During the use of the injection molding machine, its performance or state gradually decreases with the passage of time. There are some signs before a fault occurs. This is called a potential fault. The identifiable physical parameters indicate that a functional fault is about to occur. The functional fault indicates that the injection molding machine has lost the specified performance standards.
The change rate of injection molding machine failure rate with time is often called the bathtub curve. The failure rate of the injection molding machine changes with time in roughly three phases: early failure period, accidental failure period and wear failure period.
Early failure period
The injection molding machine is in an early failure period, and the failure rate is high, but the failure rate decreases rapidly with time. The early failure period is also called the running-in period for mechanical products. The length of this period varies depending on the design and manufacturing quality of the product and system. The failures that occurred during this period were mainly caused by defects in design and manufacturing, or caused by improper use of the environment.
2. Incidental failure period
When the injection molding machine enters an accidental failure period, the failure rate is roughly in a stable state and tends to be fixed. During this time, the failure occurred randomly. During the accidental failure period, the injection machine has the lowest failure rate and is stable. Therefore, it can be said that this is the best state of the injection molding machine or the normal working period. This section is called the effective lifetime.
The failure of the accidental failure period is caused by improper design, improper use and poor maintenance. Therefore, the failure rate can be reduced to a minimum by improving design quality, improving usage management, and strengthening monitoring, diagnosis, and maintenance.
3. Loss failure period
At the end of the use of the injection molding machine, the failure rate began to rise. This is caused by wear, fatigue, aging, corrosion, etc. of the parts of the injection molding machine. If the inflection point is overhauled at the beginning of the wearout period, the failure rate can be reduced economically and effectively.
The three stages of the failure rate curve of the injection molding machine truly reflect the regularity of the injection molding machine from running-in, commissioning, normal operation to overhaul or scrap failure rate, and strengthen the daily management and maintenance of the injection molding machine, which can prolong the accidental failure period. Accurately identify the inflection point to avoid excessive repair or repair coverage to achieve the best investment benefits.
Fault management expansion procedure
The fault management deployment procedure has the following eight aspects.
1. Do a good job in propaganda and education, so that the operators and maintenance workers consciously record, count, and analyze the failure of the injection molding machine, and put forward reasonable suggestions.
2. Closely combined with the actual production of injection molding and the characteristics of the injection molding machine, the injection molding machine is divided into three categories A, B, and C to determine the focus of fault management.
3. Using monitoring instruments, carry out planned monitoring of key parts of key injection molding machines, and timely detect signs of failure and deterioration.
General injection molding machines also carry out daily inspections, patrol inspections, periodic inspections (including precision inspections), and good condition inspections through human sensory and general inspection tools, focusing on the technical state and abnormalities of parts, mechanisms and parts that are prone to failure. Information about the phenomenon. At the same time, it is necessary to formulate inspection standards to determine the limits of normal, abnormal and faulty injection molding machines.
4. Carry out fault analysis and train the maintenance personnel of the injection molding machine to master the fault analysis method.
5. Fault record is the basic data to realize the fault management of injection molding machine, and it is the original basis for fault analysis and processing. The record must be complete and correct. After the inspection and fault repair of the injection molding machine maintenance workers, they should be carefully filled in according to the contents of the “Injection Machine Trouble Repair Orderâ€. The workshop mechanics will analyze and report to the injection molding machine management supervisor on a monthly basis.
6. Workshop injection molding machine maintenance personnel should collect “fault repair orders†and maintenance records on a monthly basis in addition to daily fault conditions. Through the statistics, collation and analysis of fault data, the fault frequency and average fault interval of various injection molding machines are calculated. The fault dynamics and key fault causes of a single injection molding machine are analyzed, and the occurrence law of faults is found out so as to highlight the key points. Countermeasure, feedback the fault information and analysis data to the planning department, in order to arrange the preventive repair or improvement measures plan, and also as the basis for modifying the periodic inspection interval, inspection content and standards.
According to the statistical data, statistical analysis charts can be drawn. For example, the failure dynamic statistical analysis table of a single injection molding machine is an effective method for the maintenance team to visually manage faults and other. It is convenient for managers and maintenance workers to master all types of injection molding in time. In the event of a machine failure, there is a clear goal in determining the maintenance strategy.
7. Through the daily inspection of the maintenance workers and the state inspection of the injection molding machine, the status information and the symptoms of the failure, as well as the relevant records and analysis data, the presence of the injection molding machine maintenance personnel or the repair team leader of the workshop for each type of injection molding machine, timely Arrange daily maintenance, make full use of production gap time or holidays, and prevent it from happening to control and reduce the occurrence of faults. For some fault signs, hidden dangers, and routine maintenance can not afford, then feedback to the planning department to arrange planned repairs.
8. Develop a flow chart for fault information management.
To do fault management of injection molding machines, it is necessary to grasp the causes of failures, accumulate data and data of frequent faults and typical faults, carry out fault analysis, pay attention to the study of fault rules and fault mechanisms, and strengthen routine maintenance, inspection and pre-repair.
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