The basic contents of equipment maintenance include: equipment maintenance, equipment inspection and equipment repair.
I. Equipment maintenance
The content of equipment maintenance is to keep the equipment clean, tidy, well lubricated and safe, including fastening loose fasteners in time and adjusting the clearance of moving parts. In short, it is the cross operation method of "cleaning, lubricating, fastening, adjusting and anticorrosion". Practice has proved that the service life of equipment largely depends on the maintenance quality. According to the workload and difficulty, maintenance is divided into daily maintenance, primary maintenance, secondary maintenance and tertiary maintenance.
Daily maintenance, also known as routine maintenance. Its main contents are: cleaning, lubricating, fastening loose parts and checking the integrity of parts. There are few maintenance items and parts, most of which are outside the equipment.
The first-class maintenance mainly includes: general fastening, cleaning, lubrication, fastening and local adjustment. Daily maintenance and primary maintenance are generally undertaken by operators.
Secondary maintenance. The main contents include internal cleaning, lubrication, partial disintegration inspection and adjustment.
Three-level maintenance. It is mainly to disassemble, inspect and adjust the main parts of the equipment, and replace the parts that reach the specified wear limit when necessary. In addition, it is necessary to measure, identify and record the wear of major components. Secondary maintenance and tertiary maintenance are generally carried out by full-time maintenance personnel with the participation of operators.
In all kinds of maintenance, daily maintenance is the foundation. According to the characteristics of different equipment, the categories and contents of maintenance should be specified, and the specific conditions and characteristics of equipment such as production technology, structural complexity and scale should be considered, as well as the long-term maintenance habits of different industrial enterprises.
Second, the equipment inspection
Equipment inspection refers to measuring and verifying the operation, working accuracy, wear or corrosion degree of equipment. Through inspection, we can fully grasp the technical status and wear of mechanical equipment, find and eliminate hidden dangers of equipment in time, make preparations before repair purposefully, improve repair quality and shorten repair time.
Inspection is divided into daily inspection and regular inspection according to time interval. The daily inspection is carried out by equipment operators, combined with daily maintenance, with the purpose of finding abnormal technical conditions in time and carrying out necessary maintenance work. With the participation of operators, full-time maintenance personnel will conduct regular inspections according to the plan. The purpose is to comprehensively and accurately grasp the actual situation of parts wear through inspection, so as to determine whether it is necessary to repair.
According to technical functions, inspection can be divided into functional inspection and accuracy inspection. Functional inspection refers to the inspection and determination of various functions of equipment, such as oil leakage, water leakage, air leakage, dust sealing, high temperature resistance, high speed and high pressure of parts, etc. Accuracy inspection refers to the inspection and determination of the actual machining accuracy of equipment, so as to determine the quality of equipment accuracy and provide basis for equipment acceptance, repair and update.
Third, equipment repair.
Equipment repair refers to the repair of equipment damage and accuracy deterioration caused by routine or abnormal reasons. By repairing and replacing worn, aged and corroded parts, the equipment performance can be restored. Equipment repair and maintenance are different aspects of equipment maintenance. Because the work content and function are different, they can't replace each other. They should be done at the same time, so as to cooperate with each other and complement each other.
1. Type of equipment maintenance. According to the repair scope, repair interval and repair cost, equipment repair can be divided into three categories: minor repair, medium repair and major repair.
(1) minor repairs. Minor repairs usually only need to repair and replace some parts with fast wear and service life equal to or less than the repair interval, adjust the local structure of the equipment, and ensure the normal operation of the equipment until the scheduled repair time. Minor repairs are characterized by frequent repairs, small workload and short repair time, and repair costs are included in production costs. Minor repairs are generally carried out by full-time maintenance workers in the workshop at the production site.
(2) medium repair. Repair refers to the partial disassembly of equipment, repair or replacement of some main parts and benchmark parts, or repair of parts with service life equal to or less than the repair interval of 2. At the same time, it is necessary to inspect the whole mechanical system, tighten all parts, eliminate the enlarged gap, and calibrate the equipment benchmark to ensure that the mechanical equipment can be restored and meet the due standards and technical requirements. The characteristics of repair are: more repair times, less workload, short repair time each time, and repair costs are included in the production cost 2. Most of the repair projects are carried out by full-time maintenance workers in the production workshop, and some demanding projects can be undertaken by the mechanic workshop. After the repair, it is necessary to organize the acceptance inspection, and handle the handover procedures of the repair sending and repairing unit 2.
(3) major repairs. Overhaul refers to a comprehensive repair to restore the original accuracy, performance and production efficiency of the equipment by replacing and restoring its main components. Major repairs are characterized by a small number of repairs, a large workload and a long time for each repair, and the repair costs are paid by the major repair fund. After the overhaul of equipment, the quality management department and the equipment management department shall organize the relevant personnel of the user and the contractor to carry out the acceptance, and send them to the repair unit and the contractor for handover procedures after passing the acceptance.
2. Equipment maintenance method [1]
Commonly used equipment repair methods mainly include the following:
(1) The standard repair method, also known as the forced repair method, refers to the preparation of a specific repair plan in advance according to the service life of equipment parts, and clearly stipulates the repair date, category and content of equipment. When the equipment runs to the specified time limit, it must be repaired according to the specified scope and requirements, regardless of its technical status and tasks. This method is conducive to the preparation before maintenance and effectively ensures the normal operation of the equipment, but sometimes it will cause excessive maintenance and increase the maintenance cost.
(2) Regular repair method refers to the fixed order, planned repair interval and repair workload of various planned repairs in advance according to the service life of parts, production type, workpiece condition and relevant quota data. Before maintenance, the maintenance content is usually determined according to the state of the equipment. This method is conducive to the preparation before repair, and the advanced repair technology is adopted to reduce the repair cost.
(3) Repair after inspection means that only the number and time of inspection are specified in advance according to the wear data of equipment parts, and the specific cycle, category and content of each repair are determined by the results after inspection. This method is simple and easy to operate, but due to poor repair plan and subjective judgment error of equipment condition during inspection, it may cause excessive wear or failure of parts.
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