WICOORCL021 A0 圆盘剪常见故障修复problem resolution on side trimmer.docx
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WICOORCL021A0圆盘剪常见故障修复problemresolutiononsidetrimmer
文件编号DocumentNo:
WI-COORCL-021
受控标识Controlstatus:
发放号IssueNo:
华菱安赛乐米塔尔汽车板有限公司
ValinArcelorMittalAutomotiveSteelCo.,Ltd.
圆盘剪常见故障修复
problemresolutiononsidetrimmer
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周煌辉Compiler:
Zhouhuanghui
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2014-0728
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1.目的Target
1.1修复圆盘剪故障Solutiontheproblemofthesidetrimmer
2.适用区域Applicationarea
2.1圆盘剪。
Sidetrimmer
3.实施人员Followperson
3.1圆盘剪操作人员。
Sidetrimmeroperators
4.安全Safety
4.1必须穿戴劳保用品。
MandatoryPPE(PersonalProtectiveEquipment)
4.2风险提示:
划伤,挤伤和摔伤。
Risks:
scratch,hurt,injury.
4.2.1在以下情况下,穿戴好劳保手套:
Wearglovesandprotectiveclothswhen:
Ø处理溢出废边时;handlingscraps;
Ø处理刀片崩刀时;handlingbladecollapse;
4.3操作安全。
Safetyduringtheoperation.
4.3.1在修复圆盘剪故障前必须停止出口界面。
BeforetherepairsidetrimmerfailurefollowthestandardoperationdescribedintheitemOperationprocedure.
4.3.2处理未切断的废边,必须借助于废边剪等工具处理,不能徒手拉废边。
Handlenottocutofftheremovalscrap,mustusethescrapcuttingtools,Don’tusehandtopullthewastscrap.
Picture6
5.工具tools
5.1废边剪handshear
6.操作步骤OperationProcedure
6.1.主要常见故障majorfailure:
6.1.1圆盘剪出口导槽卡住,Thedisccutexportguidestuck;
修复repair:
全线停机allfrontsofhalt,打开出口导槽清理废边Opentheexportguidegroove,cleanupthewasteedge。
6.1.2圆盘剪刀片崩刀Thesidetrimmerbladesbroken(掉肉);
修复repair:
更换刀片renewalblade,用专用打磨机修复刀片Grindingtorepairtheblade。
6.1.3毛刺太多burrtanto;
修复repair:
调整重叠量和间隙量Adjusttheamountofoverlapandgap,或者更换刀片perhapsrenewalblade。
6.1.4刀片钝化;Thebladebluntness
修复repair:
更换刀片renewalblade,修磨刀片Grindingtorepairtheblade。
6.1.5如切边碎片致导槽堵塞,线停圆盘剪离线,切断清空碎片后才能重启圆盘剪。
Ifthescrapisblokedinguides,putthemachineofflineandcutthescrap.Solvetheproblem,machineoffline,thenre-startsidetrimming.
6.2Standardoperationofsidetrimmer
Whattodoincaseofproblemswithsidetrimmerwhenthelineisrunningandtrimmingtheedges:
Removingoutofthelinethesidetrimmer;
ØStoptheline
ØInHMIStoptheSidetrimmer
ØAfterdoublecheckingtheline“QUICKSTOP”,cutoffmanuallythetrimmededgeofthestripattheoperatorsidefirstandthenatthedriveside;Picture1–steelcutterscissor;
ØPressthebutton“OUTLINE”atSIDETRIMMERHEADWITHADJUSTMENTonthelocalpanel;
P.S.:
Openingthegaps,overlapsandtheburrmasher(canbedoneonsiteatlocalpanel)ifnecessary(onlyincaseofnopossibilitytogiveaGROUPJOGGINGBACKWARDorFORWARD);
Cleannessandinspectionofsidetrimmer
WHEN:
Everytimewhenthelineisstoppedlongerthan2hours/preventivemaintenance/setupofcampaign:
每当停机超过2小时/定期检修/产品切换时:
ØToremovesidetrimmeroutoftheline,followtheitem“standardoperationofsidetrimmer”;
ØFillingouttheworkpermitselectingtherightoneslockouts(thebladegapandthebladepenetrationsteppermotorsatthetopbladeshaft/widthadjustingdrive);
ØFillingouttheTASKSAFETYANALYSIS;
ØGettingtheapprovalfortheworkpermitandtasksafetyanalysiswiththeshiftleaderandforemanbeforestartingtheactivities;
ØAskformaintenanceteamtodotheelectricaland/ormechanicallockoutofthedrives;
ØDoublecheckthelockoutsaftermaintenanceteamfinishtheelectricalandmechanicallockoutsdoingsometestdrivesonHMIandonsite(localpanel);
ØPreparationofmaterial(rags,degreaser,compressedairgunandtoolsneededtoolstobechecked)andcleaningactivities:
ØCleaningthezincdustofthe2lubricationdeviceoftheshearblades(topandbottomshaft);
ØInspectionontheblades(nobrokenparts);
ØInspectiononthesupportingrings(topandbottomshaft);
ØCleaningthezincdustofthe2scrapguides(1intheoperatorsideand1inthedriveside);
ØCheckinglevelofthelubricationdevice(canbefilledwiththeprotectiveoilfromtheoilermachine);
ØCleannessoftheconveyorssystem;
ØCleannessoftheareaaroundthescrappit(noscrapsoutsideneitheraroundthepit);
Whenthelinestopsduetoequipmentfailuresandsoon:
因生产不足、定期检修、设备故障等原因)停机时:
ØIfsidetrimmerisinlineposition,removeoutoftheline.
-将切边剪移出线外(如在线);
Whenthelineisrunning:
当生产线运行时:
ØWhensidetrimmerisnottrimming,thescrapevacuationsystemmustbe“stop”;
ØWhensidetrimmerisoutofthelineandthenextcoilneedstobetrimmed,sidetrimmercannotstoptheline.Ifcannotputitinlineandstartingtrimmingduetoanyproblem,removeoutoftheline(seeitem“Standardoperationofsidetrimmer”);
-当切边剪不切边时,废边移除系统必须“停止”;
-如果因任何问题不能在线运行,则移出线外;
Whattodoincaseofdamageinthesteelstripasfollow:
ØEdgewaves:
Themaintoperatormustdoanevaluationoftheedgewavesandtakingthedecisiontoremoveornotremoveoutofthelinethesidetrimmer;Itwillgenerateirregulartrimmingedgeswithpossibilitytobreakthebladesshear;
边浪:
操作员必须对边浪进行评估,并决定是否应移出切边剪;该缺陷将造成不规则切边,并可能损坏刀片。
ØSmallnotchedand/Cuttingedgeofthenotchesdamageinsomewhereinthelineduetomechanicalshocks:
Themainoperatormustdoanevaluationofthesmallnotchesandtakingthedecisionoftoputinlineornotthesidetrimmer(incaseoftheactualcoilwithoutsidetrimmerandthenextcoilwithsidetrimmer/ifsidetrimmerisalreadytrimmingthedecisionmustbekeepinlineorremoveoutofthelinethesidetrimmer);
由机械冲击造成的小缺口和/月牙边部破损:
操作员必须对小缺口做出判断、并决定是否应将切边剪设成在线工作(如果该卷未切边而下一卷已切边/如果切边剪正在工作,则做出决定:
将其留在线上还是移出线外);
ØStripripped:
Themainoperatormustdoanevaluationofthedamagedpartandtakingthedecisiontoremoveornotremoveoutofthelinethesidetrimmer;
带钢撕裂:
操作员对破损部分进行评估、并决定是否应将切边剪移出线外;
ØMistrackingattheCPC:
ExitoperatormustpayattentionattheCPCandmustdoanevaluationofthemistrackingandtakingthedecisiontoremoveornotremoveoutofthelinethesidetrimmer;
Ifthereisabigmistracking,oneofthetrimmingedges(operatorsideordriveside),mightbelowerthan5mm(minimumtrimmingatsidetrimmer-technicalspecificationofsidetrimmer)andpossibilityofcreatingproblemsintheexitsection;
CPC跑偏:
出口操作员必须时刻关注CPC,对跑偏做出判断、并决定是否应将切边剪移出线外;
如果跑偏严重,其中一侧切边(操作侧或传动侧)可能低于5mm(切边剪的最小切边值——参见切边剪技术文件),并有可能造成出口段的其他问题。
P.S.:
Regardingthedamagedpartsonthestrip,theoperatorscanwatchbythecameras(insidethepulpits)andvisualinspectiononthesteelstripinthepasslineandfollowingtheitem1.1“Standardoperationofsidetrimmer”toremoveoutoftheline;
另外:
关于带钢破损部分,操作员可在室内通过摄像头观察到 ,并可在生产线旁进行目视检查。
Repairingifnecessary:
a.Whentheshearbladesaredamaged:
ØEasilytoseeitonthetrimmededgesattheverticalinspection.Theoperatorhastodiscusswiththequalityinspectorinordertoseewhatisthebesttimetoturntheturretheadtrimmingshearwithburrmasher;
ØAfterturningtheturretheadtrimmingshearwithburrmasher,contactthemaintenanceshiftteamorzoneresponsibleinordertofixtheproblem.
ØIncaseofreplacingshearblade:
dismountingthehydraulicnut,takeoutthesupportingring,takeouttheshearbladeandputtinganewoneandmountingagain;Afterthat,maintenanceteamhastosendouttheshearbladesforgrindingattheworkshop;
ØReportingtheproblemsandtheactionplanwhichhappenedintheshiftreport.
P.S.:
Inordertoquicktroubleshooting,itwillbeinterestingkeepsomesparepartonsite.
b.Whenthesupportingringsaredamaged:
ØEasilytoseeitonthetrimmededgesatthehorizontalandverticalinspection.Thetrimmededges(drivesideand/oroperatorside)willbeabitbendedcontinuouslywheninuse.
ØTheoperatorhastodiscusswiththequalityinspectorinordertoseewhatisthebesttimetoturntheturretheadtrimmingshearwithburrmasher;
ØAfterturningtheturretheadtrimmingshearwithburrmasher,contactthemaintenanceshiftteamorzoneresponsibleinordertofixtheproblem.
ØInthiscaseonlyreplacingthesupportingrings:
dismountingthehydraulicnut,takeoutthesupportingring,replaceitforanewoneandmountingagain;Afterthat,maintenanceteamhastosendoutthesupportingringsforrecoatingitattheworkshop;
ØReportingtheproblemsandtheactionplanwhichhappenedintheshiftreport.
P.S.:
Inordertoquicktroubleshooting,itwillbeinterestingkeepsomesparepartonsite.
2)SCRAPCUTTER碎边剪
2.1)Standardoperationofscrapcutter
Whattodoincaseofproblemswithscrapcutterwhenthelineisrunningandtrimmingtheedges:
Removeoutofthelinethesidetrimmerandscrapcutter;
ØFollowtheitem1.1“Standardoperationofsidetrimmer”;
ØAtthelocalpanelpress“OUTLINE”theSCRAPCHOPPER;
Cleannessandinspectionofscrapcutter:
碎边剪的清洁和检查:
WHEN:
Everytimewhenthelineisstoppedlongerthan2hours/preventivemaintenance/setupofcampaign:
每当停机超过2小时/定期检修/产品切换时:
ØRemoveoutoflinethescrapcutter(seeitem“standardoperationofsidetrimmerandscrapcutter”);
ØIntheHMIsidetrimmerscreen,pre-setinthe“Manual”field“OperatorSideGAP(mm)”and“DriveSideGAP(mm)”:
zeroandthen,clickon“HoldManual”;
ØFillingouttheworkpermitselectingtherightoneslockouts(widthadjustingdrive/twocuttingdriveswithservomotors/knifegapadjustmentsteppermotorsatthetopknifeshafts/twooilpumpdevice);
ØFillingouttheTASKSAFETYANALYSIS;
ØGettingtheapprovalfortheworkpermitandtasksafetyanalysiswiththeshiftleaderandforemanbeforestartingtheactivities;
ØAskformaintenanceteamtodotheelectricallockoutofthedrives;
ØDoublecheckthe