How to carry out routine maintenance and maintenance of programming-free mini intelligent bending unit?

The routine maintenance of the programming-free mini intelligent bending unit needs to be carried out around the core components (bending machine, robot, fixture), control system and auxiliary system (lubrication, pneumatic), with the emphasis on "preventive maintenance" to avoid production interruption due to component wear or failure and prolong the service life of the equipment. The following are the specific maintenance processes and operation points:

I. Daily maintenance: It must be done before starting/after production, and it can be completed in 5-10 minutes.

The core of daily maintenance is to "check the status, remove impurities and confirm safety" to ensure the stable operation of the equipment when it is turned on.

Points for attention in maintenance operation of maintenance parts

Equipment appearance and cleaning 1. Wipe the surface of the workbench, robot arm and fixture of the bending machine with a dry rag to remove iron filings, oil stains and dust;

2. Clean the area around the equipment to ensure that there is no debris blocking the robot's movement track or the feeding/discharging channel. Avoid using a high-pressure water gun to directly flush equipment (especially electrical cabinets and sensors) to prevent short circuit in water.

Safety system inspection 1. Check whether the emergency door and emergency stop button are in good condition: after closing the emergency door, the equipment should be able to start normally; Press the emergency stop, and all actions shall be stopped immediately;

2. Check the safety grating (if any): When the grating is blocked, the bending machine/robot needs to stop running. If the safety component fails, it is forbidden to start the machine, and maintenance personnel should be contacted to handle it. It is forbidden to temporarily shield the safety function.

Lubrication system inspection 1. Check the lubricating oil level (oil mark or display prompt) of the slider and guide rail of the bending machine to ensure that the oil level is between "MIN-MAX";

2. Confirm whether the automatic lubricating pump works normally (no oil leakage and no alarm). If the lubricating point is manually lubricated, the lubricating oil should be supplemented as specified (generally 46# antiwear hydraulic oil is used). It is forbidden to mix different types of lubricating oil. When the oil level is lower than MIN, it is necessary to replenish the same type of oil in time.

Inspection of pneumatic system 1. Check the pneumatic triplex (filter, pressure reducing valve and oil mist device):

-Drainage: Open the drain valve at the bottom of the filter to drain the condensed water;

-Oil mist device: check the oil level (generally use 22# pneumatic lubricating oil) and replenish it when it is insufficient;

-pressure: the pressure of the relief valve should be 0.5-0.6MPa (adjusted according to the equipment manual);

2. Check whether there is air leakage in the trachea and connector (listen to the sound and observe bubbles with soapy water). Drainage should be carried out before startup or after shutdown to avoid impurities entering the system due to drainage under pressure.

Inspection of fixture and die 1. Check the bending die (upper die/lower die): there is no crack or edge collapse, the cutting edge is not seriously worn, and the mounting bolt is not loose;

2. Check the robot fixture: the clamping jaw is free from deformation and wear, and the clamping force is normal (it can be tested whether the grasped workpiece is stable and free from slipping);

3. Clean the clamp jaws to remove residual iron filings (to avoid scratching the workpiece or affecting the positioning accuracy). If the cutting edge of the mold is worn, it needs to be ground and repaired in time; When the wear of the clamp jaw exceeds the limit, the accessories need to be replaced.

Control system inspection 1. Check the touch screen/operation panel after startup: there is no error code (such as "insufficient lubrication" and "low air pressure"), and the parameters are displayed normally;

2. Check data backup: confirm that the production data of the previous day has been automatically backed up (if manual backup is supported, it is recommended to manually back up once a week). If there is an error, please check it according to the prompt (such as replenishing lubricating oil and checking air pressure). If it cannot be solved, contact the manufacturer.

Second, weekly maintenance: in-depth inspection of key components, completed in 30-60 minutes.

Weekly maintenance needs to focus on "easy-to-wear parts and precision-related parts" to prevent long-term operation from reducing precision or damaging parts.

Inspection of core components of bending machine

Slide block and guide rail: use feeler gauge to check the clearance between slide block and guide rail (generally ≤0.05mm). If the clearance is too large, contact maintenance personnel for adjustment;

Bending machine workbench: check whether the workbench is deformed or sunken. If it is slightly damaged, it can be polished with fine sandpaper to avoid affecting the positioning of the workpiece.

Mould locating pin/slot: clean the locating pin and apply a small amount of antirust oil to ensure accurate positioning and no jamming during mould installation.

Robot system inspection

Robot joints and cables: check whether there is abnormal sound at joints (during operation), whether cables (power lines and signal lines) are damaged or aging, and whether the cable towing chain is smooth and free from jamming;

Robot zero calibration: If the robot's grasping position is found to be deviated (such as the workpiece can't be aligned with the bending machine), it is necessary to perform "zero calibration" according to the instructions (generally, it is calibrated by one button on the operation panel without professional programming);

Fixture driving parts: if it is a pneumatic fixture, check whether there is air leakage and slow action in the cylinder; If it is an electric fixture, check whether the motor wiring is firm and there is no abnormal heat during operation.

Auxiliary system maintenance

Cooling system (if any): check the cooling fan/cooler of the hydraulic system of the bending machine and clean the dust on the heat sink (to avoid overheating of hydraulic oil, which will affect the bending accuracy);

Loading/unloading conveyor belt (if any): check the tension of the conveyor belt, and adjust the tensioner if it is loose; Clean the surface of the conveyor belt, remove impurities and prevent the workpiece from slipping when conveying.

Third, monthly maintenance: in-depth maintenance of parts, which will be completed in 1-2 hours.

The monthly maintenance should be aimed at "components that are easy to wear and tear after long-term operation and affect the service life of the equipment", and they should be disassembled and inspected if necessary (it is recommended to be operated by trained personnel).

Deep maintenance of hydraulic system

Quality inspection of hydraulic oil: take a small amount of hydraulic oil, observe the color (light yellow normally, and replace it if it is black or turbid), and detect the viscosity with a viscometer (generally 46# or 68# hydraulic oil meets the equipment requirements);

Replacement of hydraulic filter element: replace the oil return filter element and oil absorption filter element of the hydraulic oil tank (according to the instruction cycle, usually once a month, if the oil pollution is serious, it needs to be replaced in advance);

Hydraulic valve group inspection: check whether the wiring of hydraulic valves (such as proportional valves and overflow valves) of the bending machine is firm and free from oil pollution (oil pollution may lead to short circuit of wiring terminals), and manually test whether the valve core moves flexibly.

Electrical system maintenance

Cleaning of electrical cabinet: after power failure, open the electrical cabinet, and use dry compressed air (pressure ≤0.4MPa) to blow off the dust in the cabinet (focusing on frequency converter, PLC and relay) to avoid overheating of components caused by dust accumulation;

Wiring terminal inspection: check whether all wiring terminals (especially power line terminals) in the electrical cabinet are loose and tighten them gently with a screwdriver (to avoid poor contact caused by long-term vibration);

Sensor calibration: calibrate the rear positioning sensor of the bending machine and the visual positioning sensor of the robot (if any): test the detection accuracy of the sensor with standard parts (such as steel plates with standard length), and calibrate according to the instructions when the deviation exceeds the limit.

Lubrication and rust prevention of mechanical parts

Robot joint lubrication: according to the requirements of the manual, fill special grease (generally lithium-based grease) to each joint of the robot to avoid joint wear;

Anti-rust of mold and fixture: If the equipment needs to be shut down for more than 1 day, apply a thin layer of anti-rust oil on the cutting edge of bending mold and the surface of fixture jaw (to avoid oxidation and rust);

Screw/bolt fastening: check the fixing bolts of all key parts of the equipment (such as the bending machine body, robot base and workbench support) and tighten them with a torque wrench according to the specified torque (to prevent loosening caused by long-term vibration and affect the stability of the equipment).

Fourth, maintain precautions and taboos

Safety first: before all maintenance operations, power and gas must be cut off (turn off the main power switch and pneumatic main valve), and a sign "No startup is allowed under maintenance" should be hung next to the equipment;

Fitting of oil products/accessories: Strictly use lubricating oil, hydraulic oil, filter element, seals, etc. of the models specified in the equipment manual, and it is forbidden to mix substitute accessories (if ordinary butter is used instead of special grease for robots, joint wear will be accelerated);

Recording and tracing: Establish the Equipment Maintenance Record Form to record the date, location, operation content, replacement parts model and abnormal situation of each maintenance (such as "2024.XX.XX, hydraulic filter of bending machine is replaced, and the oil is normal"), so as to facilitate the subsequent tracing of the cause of the failure;

Professional fault handling: If you encounter complex faults (such as the robot can't be calibrated, and the precision of the bender is seriously deviated), it is forbidden to disassemble the core components (such as PLC and robot servo motor) by yourself, and you need to contact the equipment manufacturer or authorized maintenance personnel to avoid expanding the fault range.

Through the above hierarchical maintenance of "daily-weekly-monthly", it can ensure that the programming-free mini intelligent bending unit can maintain a stable running state for a long time, reduce the downtime, maintain the bending accuracy (such as angle error ≤ 0.5), and extend the service life of the equipment (generally it can reach 5-8 years, and it can be longer if properly maintained).