The conveyor belt vulcanizing machine, as the core equipment for vulcanizing and repairing conveyor belt joints, its maintenance quality directly affects the equipment’s service life, vulcanization effect and production efficiency. The following systematically introduces its maintenance methods from the dimensions of daily inspection, regular maintenance, management of vulnerable parts, fault handling and safe operation:
First, daily inspection and immediate maintenance
Appearance and connection inspection
Inspection items: Whether there is any oil leakage, cracks or deformation in the body, control box, hydraulic system and other parts.
Maintenance method: Before starting the machine every day, clean the body with a dry cloth and check whether the hydraulic pipeline joints are loose. If there is any oil leakage, replace the sealing parts immediately.
Electrical system inspection
Inspection items: Whether the power cord is damaged, and whether the display of the temperature controller, pressure gauge and other instruments is normal.
Maintenance method: Use a multimeter to test the voltage stability, calibrate the temperature sensor (the error should be ≤±2℃), and replace the instrument in time if it malfunctions.
Confirmation of the hydraulic system status
Inspection items: Hydraulic oil level, oil quality and oil temperature.
Maintenance method: When the oil level is lower than the middle line of the oil gauge, 46# anti-wear hydraulic oil should be replenished. Samples should be taken every six months to test the acid value of the oil (it should be ≤0.5mgKOH/g). If it exceeds the standard, replacement is required.
Second, regular deep maintenance
Maintenance of the hydraulic system
Filter element replacement: Replace the filter element every 500 hours of operation. When the clogging pressure exceeds 0.2MPa, it should be replaced in advance.
Inspection of cylinder sealing parts: Check the wear of the chromium plating layer on the piston rod every quarter. Replace the sealing ring when its elasticity is insufficient or cracked.
Maintenance of the heating system
Calibration of the heating plate: Every six months, use an infrared thermometer to check the temperature uniformity of the heating plate (the temperature difference should be ≤±5℃), and grind and repair the local overheated areas.
Insulation layer inspection: If the insulation cotton is found to be damaged, it should be replaced immediately to prevent heat loss and prolong the vulcanization time.
Maintenance of mechanical structure
Guide column lubrication: Apply lithium-based grease to the surface of the guide column every month and clean the residual glue residue to prevent jamming.
Crossbeam calibration: Use a level to check the parallelism of the crossbeam every quarter (the error should be ≤0.1mm/m). If the error exceeds the limit, adjust the lead screw or replace the bearing.
Third, management of vulnerable parts and consumables
Suggestions for consumables management:
Establish a warning mechanism for the inventory of vulnerable parts, and reserve one set of spare parts for key components (such as sealing rings and heating plates).
When making purchases, suppliers are required to provide material inspection reports (for example, fluororubber sealing rings need to comply with the ASTM D2000 standard).
Fourth, fault diagnosis and emergency response
De-bonding of the vulcanized joint
Reasons: Uneven temperature, insufficient pressure, and inadequate vulcanization time.
Treatment: Use a laser thermometer to detect the temperature difference of the heating plate, adjust the pressure to 1.5-2.0MPa, and extend the vulcanization time by 10%-15%.
The pressure of the hydraulic system is abnormal
Cause: The relief valve is stuck and the oil pump is leaking.
Solution: Disassemble the relief valve and clean the valve core. Use a flowmeter to measure the displacement of the oil pump (the error should be ≤5%).
The heating plate is locally overheated
Cause: The heating wire is broken and the thermocouple has poor contact.
Treatment: Use a multimeter to measure the resistance value of the heating wire (it should be within ±10% of the nameplate value), re-weld the thermocouple and apply thermal grease.
Fifth, safety operation and storage norms
Operational safety
When performing vulcanization operations, heat-insulating gloves must be worn and direct contact of the body with the heating plate is strictly prohibited.
Pressure release must be achieved through a dedicated pressure relief valve. It is strictly prohibited to forcibly open the oil cylinder.
Storage requirements
When the system is out of use for a long time, the hydraulic system should be filled with anti-rust oil and anti-rust wax should be applied to the surface of the heating plate.
The storage environment temperature should be maintained at 5-40℃, the humidity at no more than 80%, and it should be protected from corrosion by acidic or alkaline gases.
Sixth, maintain records and conduct data analysis
Establish equipment maintenance files, recording the time of each maintenance, replaced parts and the causes of faults.
Optimize the maintenance cycle through data analysis (for example, the hydraulic oil replacement cycle is extended from 500 hours to 800 hours, which requires the support of oil test data).
Regularly carry out skills training for maintenance personnel, with a focus on practical projects such as the disassembly and assembly of hydraulic systems and the repair of heating plates.
Through the above-mentioned systematic maintenance measures, the equipment failure rate can be significantly reduced (target ≤2 times per year), the service life can be extended to over 10 years, and at the same time, the qualification rate of vulcanized joints can be increased to over 99%, saving 15% to 20% of maintenance costs for enterprises.