辊轴手册 .pdf

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1、2-修复流程2.1 清洗,检验和定期检修General maintenance instructions维修简介设备维修作业应符合本手册所列指示Equipment maintenance operations shall be carried out in compliance with the instructions set out in this manual.加强对设备操作的专业知识可以更好防止故障和事故的发生，减少维修成本，从而提高效率和生产力。A comprehensive knowledge of equipment construction and operation will

2、 provide better prevention against malfunctions and accidents and a longer life of equipment and will reduce maintenance work and costs,thereby improving efficiency and productivity.操作说明本手册仅注重基本方面。在相关领域的设备全部掌握将被收购的一步一步的基础上在整个操作和维修业务。Operations described in this manual focus only on essential aspects

3、.Full mastery of equipment in the relevant domain will be acquired on a step-by-step basis throughout the operating and maintenance operations.Only the maintenance operations related to the equipment supplied by mechanical engineering constructor are dealt with in this manual.General maintenance con

4、ditionsa)Storage and arrangement of equipment Mobile equipment(skips,tools)shall be kept stored at locations provided for this purpose and shall be clearly identified.After removal/disassembly of the components the tools used by maintenance personnel must not be stored in production areas.b)Cleanlin

5、ess All the products required for operation and maintenance(banding strip,wood,rags,papers.)shall not be left behind.Complete cleaning shall be carried out at the end of each operation.Some items of equipment are more likely to be exposed to dirt accumulation and need to be cleaned at each maintenan

6、ce operation using adequate means(air,water,detergents,rags,brushes.).名师资料总结-精品资料欢迎下载-名师精心整理-第 1 页，共 36 页 -Types of equipment concerned:Slide ways guiding rods-runways Photocells-footlights Electric auxiliary devices Belts-chains-cables Roll barrel and roll coatings c)Safety system安全系统Safety devices

7、 shall be kept in proper place and perfectly operational.安全设备将需要在在正确的地方和完善的操作d)Ground condition 地面条件Keep the ground free from slippery elements(oil,grease).Any leaks shall be cleaned off with absorbent materials(sawdust.).地面远离光滑的东西（如：油脂）任何泄露将被用吸附材料清除（如：锯木屑）e)Pipe condition Defective pipes(leaks,vibr

8、ations)shall immediately be repaired.漏油管需立即修理Possible causes:faulty flange assembly,faulty seals,faulty pipe supports,faulty assembly of union joints.可能导致因素：错误的法兰装配，错误的密封，错误的油管供应，错误的连接装配Do not forget to paint pipes after repair work.在修理工作后勿忘装涂油管f)Equipment vibrations 设备振动A first visual and/or tactil

9、e inspection may be carried out.开始首次视觉和触觉的检验Vibrations may originate from wrong/inadequate fastening of equipment and/or piping.振动可能来自错误/紧固设备不足和/或管道g)Electric wiring on machine 机械电线Visual inspection of cable quality:cables should be kept protected,packing boxes in good condition,terminal devices and

10、 boxes closed,conductors identified.目测检查电缆的质量：电缆应尽量保护，包装完好，终端设备和纸盒封闭，导体确定。h)Pumps Important recommendations Pumps shall be installed on a stand-by redundancy basis,ie the same pump must be used as long as it is operating smoothly,while the other pump is used as a stand-by pump.泵应安装在一个独立的冗余基础相同，即必须使用

11、泵，只要它运作良好，而其他泵作为备用泵。In the event of anomalies such as noise or abnormal behaviour of the pump in operation start-up the stand-by pump and carry out a thorough inspection of the defaulting pump.After inspection,re-install and restart the pump,carefully rinse the pump and shut the outlet pipe off.在如噪音

12、或启动运作的发现泵异常行为的异常活动，由泵，进行了彻底检查问题泵。检查后，重新安装并重新启动泵，仔细冲洗泵和关闭的排气管了。Systematic alternate use of pumps is prohibited as the two pumps of the same circuit would 名师资料总结-精品资料欢迎下载-名师精心整理-第 2 页，共 36 页 -accumulate the same operating time and,in case of malfunction of one of the pumps,there is a too high likeline

13、ss that the second pump would also break down.系统地泵交替使用，禁止作为同一赛道的两个水泵将累积相同的操作时间，在对其中的泵故障的情况下，有一个过高likeliness，第二水泵也将打破。Every month,when the pumps are equipped with a rinse system,it is recommended that the stand-by pump be switched on and run a few minutes.When using products likely to crystallize,rin

14、se carefully and drain the pump body.Shut the drain pipe after dripping.Beware:!After each operation on the electric part of a pump,it is absolutely necessary to disconnect the pump motor and to check the rotational direction of the motor before restarting the pump.i)Lubrication Equipment lubricatio

15、n operations shall be carried out according to the specified periodicity,using the recommended types of lubricants.Grease nipples must be properly wiped before receiving the grease pump.Excess grease must be wiped.Use clean and not plushy rags.For some equipment the pressure of grease pump should no

16、t exceed a certain value.Use equipment fit for the task to be carried out.For some pumps and fans included in VAI CLECIM?s scope of supply,bearings are lubricated by oil contained in the bearing box.During oil makeup or filling after emptying,it is essential that the fittings used for filling,such a

17、s pourers,funnels,manual pumps,be properly cleaned.j)Painting Carry out a visual inspection of coats of paint on the equipment,tank,machines,valves,pipes,etc If the coat of paint shows such defects as flaking exposing the priming coat,bubbles,etc,eliminate all of the paint that does not adhere to th

18、e base any more,deoxidize the bare surfaces,if needed,remove grease properly from the cleaned surface and,where necessary,repaint according to original painting specifications.Caution:When carrying out paint work on equipment with mechanical components in the open air,e.g.rod of pneumatic cylinders,

19、abrasion strip or disks should under no circumstances be used because of the risk of projection of abrasive dust on mechanical parts.Use metallic brushes,either manual or air-actuated.k)Components and sub-assemblies to be systematically replaced A number of components and sub-assemblies must be repl

20、aced systematically:Two circumstances should be considered:Components to be systematically replaced after removal Components to be systematically replaced in the event of a malfunction 名师资料总结-精品资料欢迎下载-名师精心整理-第 3 页，共 36 页 -Components to be systematically changed after removal The following components

21、 shall systematically be replaced after being removed and should never be re-used:-Nut or screw retainers of any type(tab washers,split pins,etc.)-Nylstop nuts and any other threaded fixing devices with plastic insert.-O-rings-V-shaped seals-Double lip seals-klingerite,butyl,etc.flat seals-Axial fac

22、e seals for pumps Components to be systematically replaced in the event of a malfunction The following components shall systematically be replaced after occurrence of a malfunction.-All hand-operated butterfly valves in water systems,regardless of ND-Low pressure spherical valves,ND 32,welding or fl

23、ange type-Roller bearings having overheating,pitting,fretting or flaking marks,even minor.-Heating batteries for strip drying units.This list is non-exhaustive and should be harmonized with MAANSHAN,s current practices.名师资料总结-精品资料欢迎下载-名师精心整理-第 4 页，共 36 页 -l)Preventive maintenance of roller bearings

24、Roller bearing condition should be checked at regular intervals to avoid line stops.There are two methods for accurately checking the condition of roller bearings when the line is in operation:temperature measurement and vibration measurement.Both types of measurements may supplement each other.Conc

25、erning vibrations the use of a portable measuring device associated with a velocimeter sensor is recommended.Of course,other methods(accelerometer sensors associated with frequency filters and appropriate software,for instance)can be used depending on MAANSHAN,s current practices.Caution:When changi

26、ng a roller bearing it is necessary,after re-assembly of the bearing,to make a record of the vibration marks on the overhauled bearing.This record will be used for comparison with the measurements to be made later on.Besides,it is recommended to make a visual check of whether rotating parts are not

27、vibrating as a result of faulty balancing.This type of vibrations are likely to entail early malfunction of cardan shafts and roller bearings.m)General recommendations for removal/re-installation and disassembly/re-assembly Before any operation,make sure that indispensable lock-outs have been carrie

28、d out.The operation shall be carried out as per assembly/sub-assembly drawings or,in complex cases,according to an intervention sheet from the relevant maintenance book.Re-installation or re-assembly shall take place according to the same documents.During a removal or disassembly operation check the

29、 components other than the defaulting one and replace or repair the components that have been found defective.The roller bearings shall be disassembled,and the components cleaned in an ultrasonic tank with a certified solvent.Roller bearings must be cleaned one after another as the components are no

30、t basically interchangeable.After cleaning and re-installation the roller bearings must be oiled immediately.Bearing seals must systematically be replaced.A removed seal must under no circumstances be re-used After each operation make a test to check for smooth running,thereby confirming the success

31、ful operation.名师资料总结-精品资料欢迎下载-名师精心整理-第 5 页，共 36 页 -Conditional maintenance Conditional or predictive maintenance is a process for determination of a machine condition during operation.Before breakdown this process is instrumental in:-making a diagnosis-providing relevant parameters for prediction of

32、 how they are likely to develop-scheduling maintenance operations-focus only on defective components-Key parameters to be monitored are:PARAMETER INSTRUMENT Temperature Digital thermometer Speed Optical speedometer Noise Electronic stethoscope Oil condition Oil testing device Vibrations and roller b

33、earing condition Vibration sensor For optimum availability of equipment checking operations must be carried out periodically(time intervals to be defined by MAANSHAN)A)Instructions for use of measuring instruments Follow the instructions of suppliers?manuals.B)Safety instructions to be observed duri

34、ng checking operations(in the event of the equipment not being equipped with permanent measuring instruments).As such checking operations are carried out when the machines are in operation,it is essential that the personnel in charge of checking operations be skilled,informed and have got good knowl

35、edge of the equipment to be maintained.The personnel shall observe and apply all the regulations related to the safety of personnel and property.In some cases,especially when due to the surroundings the personnel is not able to work safely enough and/or to have access to the components to be inspect

36、ed(difficult access due to machine complexity,movements of machine components,in areas limited by safety doors,etc),stationary measuring/checking instruments have to be installed temporarily.Installation thereof shall take place when the machines are OFF and locked out.名师资料总结-精品资料欢迎下载-名师精心整理-第 6 页，共

37、 36 页 -Periodic inspection and maintenance 01-Civil engineering 02-Anchor bolts 03-Screw joints 04-Slide ways guide rods-runways 05-Moving parts 06-Cell-footlights 07-Electric auxiliary devices 08-Belts-chains-cables 09-Apparatus for pressurized fluids,hydraulic and pneumatic cylinders 10-Roll barre

38、l and roll coatings 11-Rollers,roller bearings,bronze bush 12-Gears,pinions and racks,machine and gear reducer casings 13-Brakes,clutches 14-Grease lubrication circuits 2.1.1 Abbreviations and terms used:LINE STATUS FREQUENCY SS OFF H Once an hour BB ON S Once every 8 hours D Once a day(24 hours)W O

39、nce a week M Once a month 3M Every 3 months 6M Every 6 months A Once a year 2A Every 2 years B1 See s upplier?s instructions*For standard bought-out components such as cylinders,gear reducers,couplings,etc.refer to suppliers?manuals.名师资料总结-精品资料欢迎下载-名师精心整理-第 7 页，共 36 页 -2.2 General Maintenance Manual

40、一般维修手册01 CIVIL ENGINEERING 组件进行检查或保养检测类型设备条件频率1 表面视觉检查：基础模块和地面不应因任何恶化（油，解决方案）积极代理商。提供必要的防护装置。BB A 2 FOUNDATION BLOCKS Visual inspection:check that there are no concrete splinters.This may be a sign of insufficient tightening or inadequate anchoring and requires immediate repair to prevent more serio

41、us deterioration to concrete and to equipment itself.BB A 3-CRACKS Visual inspection:this is a serious case which should not occur.Check for bolt tightening and foundation block dimensioning.Repair immediately to prevent more serious deterioration.SS A 02 ANCHOR BOLTS COMPONENT TO BE CHECKED OR MAIN

42、TAINED TYPE OF INSPECTION EQUIPMENT CONDITION FREQUENCY 1 BOLTS Check tightening of main bolts by location of screw-nut positions and by tentative tightening.SS A Tighten to the torques indicated on drawings 3 SCREWED JOINTS COMPONENT TO BE CHECKED OR MAINTAINED TYPE OF INSPECTION EQUIPMENT CONDITIO

43、N FREQUENCY 1 GENERAL Visual inspection and by tentative SS M 名师资料总结-精品资料欢迎下载-名师精心整理-第 8 页，共 36 页 -3 SCREWED JOINTS COMPONENT TO BE CHECKED OR MAINTAINED TYPE OF INSPECTION EQUIPMENT CONDITION FREQUENCY APPLICATION tightening of screws and bolts,check for nut retention devices.2 SPECIAL APPLICATION(

44、Machines subjected to shocks,vibrations,high inertia,high speed).Mandatory for movable components or associated components(e.g.uncoiled mandrel,edge trimmer slide ways).By sampling for other joints.BB W 3-GENERAL Warning:Screws and bolts must not be checked selectively.All screws and bolts must be c

45、hecked.Screws and bolts tightening torque Diameter Pitch Class 6.8 Class 8.8 Class 10.9 Class 12.9 Tightening torque(Nm)Tightening torque(Nm)Tightening torque(Nm)Tightening torque(Nm)3 0.5 0.6 0.8 1.2 1.4 4 0.7 1.5 2 2.8 3.3 5 0.8 2.9 3.9 5.4 6.5 6 1 5.0 6.7 9.3 11 8 1.25 12 16 22 27 10 1.5 26 31 43

46、 52 12 1.75 40 54 74 90 14 2 63 85 118 143 16 2 94 127 176 213 18 2.5 134 181 251 303 20 2.5 194 259 364 437 22 2.5 266 354 498 598 24 3 334 445 594 719 名师资料总结-精品资料欢迎下载-名师精心整理-第 9 页，共 36 页 -27 3 492 627 881 1057 30 3.5 640 850 1196 1430 33 3.5 865 1150 1620 1946 36 4 1114 1485 2090 2507 39 4 1440 19

47、20 2700 3240 42 4.5 1785 2380 3346 4015 48 5 2687 3583 5040 6047 The tightening torques given in the table above were calculated under the following conditions:friction coefficient:0.12(tightening with loctite or lubricant),tightening coefficient:0.65.Re,Precision:5%if 600,otherwise 10%+B19.Note:Suc

48、h rules shall be applicable to all mechanical equipment,unless otherwise specified on drawing and/or in the relevant chapter.The rules shall also be applicable when fastening any items of equipment on a steel structure,frame,metallic support.Required precision for tightening torques:class C as per t

49、able below.For precision classes:A Precision better than 5%)B Precision better than 10%)see table C Precision better than 20%)below D Precision better than 50%)Tightening torque variation in industrial environment Precision class Equipment Use of tightening torque Portable,hand-operated Portable,mot

50、or driven Stationary,motor driven D 20%50%Simple impact wrenches 50 Nm Positive clutch screw driving machines 50 Nm 名师资料总结-精品资料欢迎下载-名师精心整理-第 10 页，共 36 页 -C 10%20%Simple pneumatic screw driving machines 10 Nm Simple electric screw driving machines 10 Nm Impact wrenches with stored energy(torque rod o