WICOORCL021 A0 圆盘剪常见故障修复problem resolution on side trimmerWord格式.docx
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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;
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
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;
Stoptheline
InHMIStoptheSidetrimmer
Afterdoublecheckingtheline“QUICKSTOP”,cutoffmanuallythetrimmededgeofthestripattheoperatorsidefirstandthenatthedriveside;
Picture1–steelcutterscissor;
Pressthebutton“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：
Toremovesidetrimmeroutoftheline,followtheitem“standardoperationofsidetrimmer”;
Fillingouttheworkpermitselectingtherightoneslockouts（thebladegapandthebladepenetrationsteppermotorsatthetopbladeshaft/widthadjustingdrive）;
FillingouttheTASKSAFETYANALYSIS;
Gettingtheapprovalfortheworkpermitandtasksafetyanalysiswiththeshiftleaderandforemanbeforestartingtheactivities;
Askformaintenanceteamtodotheelectricaland/ormechanicallockoutofthedrives;
DoublecheckthelockoutsaftermaintenanceteamfinishtheelectricalandmechanicallockoutsdoingsometestdrivesonHMIandonsite（localpanel）;
Preparationofmaterial（rags,degreaser,compressedairgunandtoolsneededtoolstobechecked）andcleaningactivities:
Cleaningthezincdustofthe2lubricationdeviceoftheshearblades（topandbottomshaft）;
Inspectionontheblades（nobrokenparts）;
Inspectiononthesupportingrings（topandbottomshaft）;
Cleaningthezincdustofthe2scrapguides（1intheoperatorsideand1inthedriveside）;
Checkinglevelofthelubricationdevice（canbefilledwiththeprotectiveoilfromtheoilermachine）;
Cleannessoftheconveyorssystem;
Cleannessoftheareaaroundthescrappit（noscrapsoutsideneitheraroundthepit）;
Whenthelinestopsduetoequipmentfailuresandsoon:
因生产不足、定期检修、设备故障等原因）停机时：
Ifsidetrimmerisinlineposition,removeoutoftheline.
-将切边剪移出线外（如在线）；
Whenthelineisrunning:
当生产线运行时：
Whensidetrimmerisnottrimming,thescrapevacuationsystemmustbe“stop”;
Whensidetrimmerisoutofthelineandthenextcoilneedstobetrimmed,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:
Edgewaves:
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。
Smallnotchedand/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）；
Stripripped:
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；
MistrackingattheCPC:
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。
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:
Easilytoseeitonthetrimmededgesattheverticalinspection.Theoperatorhastodiscusswiththequalityinspectorinordertoseewhatisthebesttimetoturntheturretheadtrimmingshearwithburrmasher;
Afterturningtheturretheadtrimmingshearwithburrmasher,contactthemaintenanceshiftteamorzoneresponsibleinordertofixtheproblem.
Incaseofreplacingshearblade:
dismountingthehydraulicnut,takeoutthesupportingring,takeouttheshearbladeandputtinganewoneandmountingagain;
Afterthat,maintenanceteamhastosendouttheshearbladesforgrindingattheworkshop;
Reportingtheproblemsandtheactionplanwhichhappenedintheshiftreport.
Inordertoquicktroubleshooting,itwillbeinterestingkeepsomesparepartonsite.
b.Whenthesupportingringsaredamaged:
Easilytoseeitonthetrimmededgesatthehorizontalandverticalinspection.Thetrimmededges（drivesideand/oroperatorside）willbeabitbendedcontinuouslywheninuse.
Theoperatorhastodiscusswiththequalityinspectorinordertoseewhatisthebesttimetoturntheturretheadtrimmingshearwithburrmasher;
Inthiscaseonlyreplacingthesupportingrings:
dismountingthehydraulicnut,takeoutthesupportingring,replaceitforanewoneandmountingagain;
Afterthat,maintenanceteamhastosendoutthesupportingringsforrecoatingitattheworkshop;
2）SCRAPCUTTER碎边剪
2.1）Standardoperationofscrapcutter
Whattodoincaseofproblemswithscrapcutterwhenthelineisrunningandtrimmingtheedges:
Removeoutofthelinethesidetrimmerandscrapcutter;
Followtheitem1.1“Standardoperationofsidetrimmer”;
Atthelocalpanelpress“OUTLINE”theSCRAPCHOPPER;
Cleannessandinspectionofscrapcutter:
碎边剪的清洁和检查：
每当停机超过2小时/定期检修/产品切换时：
Removeoutoflinethescrapcutter（seeitem“standardoperationofsidetrimmerandscrapcutter”）;
IntheHMIsidetrimmerscreen,pre-setinthe“Manual”field“OperatorSideGAP（mm）”and“DriveSideGAP（mm）”:
zeroandthen,clickon“HoldManual”;
Fillingouttheworkpermitselectingtherightoneslockouts（widthadjustingdrive/twocuttingdriveswithservomotors/knifegapadjustmentsteppermotorsatthetopknifeshafts/twooilpumpdevice）;
Askformaintenanceteamtodotheelectricallockoutofthedrives;
Doublecheckthe
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