注塑机保养手册-卧式注塑机

嘉兴昌机械工业有限公司【注塑机保养手册】1. 保养及检查Maintenance and Examination日常保养及检查机器寿命是非常重要,预防重于治疗，然而对于机器而言，当然是保养重于修理了，射出成型机是一种高运转的机器，一天可能接近 24 小时操作，若以一个月 25 个工作天而言，每一月累积 600 个操作小时，一年将达 7200 小时，几乎是一般工具机4-5 倍长之操作时间。 保持良好的保养是减少及防止机器发生故障的最有效途径。以下资料提供给用户 , 使用机器时必须仔细阅读, 给机器定期检查保养及维护.It is important to maintain and examine the machine everyday. We are alwaystoldthatpreventionis betterthan cure,as well as machine, maintenance is betterthan repair. Injection molding machine as a kind of high operation machines, maywork near 24 hours in one day, ifitkeep working 25 days every month, then itwillaccumulate 600 operation hours within a month,7200 hours in a year, which is 4-5times longer than general machine. Maintaining a good maintenance is the mosteffective way to reduce and prevent the malfunction of machine. The followinginformation is provided to user, and please keeps careful reading before using the machine as well as examines and maintains regularly.1.1 清洗 Washing机器经过长时间使用后 , 所有滑动导杆、油缸的轴芯、滑面等会被沙尘等物质沾污 , 若不及时清理 , 滑动导杆、油缸轴芯及滑面会容易磨损 , 尤其对油缸轴芯油封为甚。保持清洁可防止由杂物引起磨损、堵塞、水份引起的锈蚀和及早发觉漏油情况。所以经常要清洗机器。请勿使用酒清、挥发性油、汽油、石油等制品擦拭人机屏幕，必须使用一般家庭擦试玻璃用清洁剂擦拭。Aftera long time using,allthe slidinglead-screw 、axis core of oilcylinder、sliding surface and so on will be stained by the sand flying in the air. If notcleaning in time,those placestalked above may be abradedeasily, especially theaxis core of oil cylinder. Keeping clean can avoid detritions、plugging causingby sundries and rustiness causing by water, and also easy to find the oil spill.Please use the general household glass cleaning agent to wipe the human-computerscreen, but not alcohol、volatile oil、gasoline 、 oil or other products.1.2 润滑系统 Lubrication Systems有足够润滑可减少机件磨损, 必须经常加注润滑油及油脂于机件如射台导杆、锁模导杆及有润滑标识处 . 机台 KS55C和 KS55T的注油点如下图所示 :Ifthere s enough lubrication,itcan reduce mechanical detritions.Organ likeinjection stage lead-screw、clamping lead-screw and lubrication identificationmust be oftenadded oilor grease.Machine oilinjectionpointof KS55Cand KS55Tas shown in the following figure:射台油缸射出组注黄油座台油缸关模油缸嘉兴昌机械有限公司润滑示意图标记 处数更改文件号签字日期设 计标准化图样标记版本数量重量比例校 对审 定001530.1321:12审 核KS25T普通机KS25T-000工 艺日 期2014-06-26共页第页此处注入润 滑 油此处注入此处注入润 滑 油润 滑 油射出部装此处注入锁模部装润 滑 油用户必须注意以下几点 :( 一) 润滑油之选择（1）耐高负载性（2）氧化稳定性（3）防锈性佳（4）适用 30# 40#（二）每个工作班的操作者必须检查润滑油喉能否向摩擦零件部位供油 , 不允许供油喉塞、脱落。（三）检查油脂润滑摩擦表面的润滑油膜状况, 不允许出现干摩擦 , 及时加注润滑脂。User must pay attention to the following point:(一)Choice of lubrication oil(1) High load resistance(2)Oxidation stability(3)Good rustproofness(4)Apply to 30# 40#(二)Each work shift operator must check the oil throat whether it supply oil to friction parts, without oil throat plug or shed.(三)Check the condition of lubrication film on the grease lubricated surface, and dry friction is not allowed, filling grease in time.1.3 液压系统 Hydraulic pressure system液压油箱必须经常存有足够液压油, 可从装置于油箱外之油尺检查油位, 如果发觉油位低于要求 ,应及补充。Hydraulicfluidtank shouldbe oftenstoring withenoughhydraulicoil, andoillevelcanbeexaminedbyusingthedipstickwhich isfixedoutsidethe oilbox. If finding that oil level is lower than requirement,it should be replenished in time., 应采用高质素之液压油 , 液压油在摄氏很多液压系统毛病起源于已污染之液压油30-50 度, 粘度在 150-225SUS或动动粘度 40-60厘澌最为适合。本司推荐使用46#液压油 .Lots of errorsof hydraulicsystem originate from the pollutedhydraulicoil,so high qualityhydraulicoil isbetter.The suitablestateof thehydraulicoilis in30-50 degree（temperature ）、150-225SUS（viscosity ）and 40-60ls (kinematicviscosity).Our company recommends #46 of hydraulic oil.用户亦须定期检查液压油，若果需要更换液压油，把原有液压油抽掉，清洗油箱后，再加注全新液压油于油箱内（新旧液压油不能混合）, 同时清洗油筛。Users also should check the hydraulicoilregularly. If it needs to renewalthe hydraulic oil, firstly, take out the original hydraulic oil and wash thetank. And then in pour the new hydraulic oil (oil and new hydraulic oil can notbe mixed together.), wash the oil screen at the same time.机器在正常运作时，液压系统温度不能超过摄氏55 度。在超过情况下工作，液压系统会产生以下现象：When the machine works regularly, the temperature of hydraulic pressure system can not overtake 55 degree. If it is exceeded, the hydraulic pressure system will come with the follow phenomenon:（一）液压油氧化加速，提前变质。Oxidation of hydraulic oil is accelerated, and deteriorate in advance.（二）粘度降低导致油泵及其他阀体受损.Viscosity reducing cause damage to pumps and other parts.（三）油封加快老化。Oil seal accelerate to ageing.若发觉 If find that（一）液压油出泡沫If hydraulic oil bubble,（ 1）应检查油泵吸油管的密封性。Check the leak-tightness of the oil pump suction pipe.（ 2）应检查液压油是否充足。Check the hydraulic oil whether it is sufficient.（ 3）应检查回油管是否沉入液压油内。Check back the oil tube whether it is sinking into the hydraulic oil.（二） 液压油呈悬浮状态白色If hydraulic oil appear in white suspended state,（ 1） 应检查油箱密封性，可能由于空气潮湿，空气中水氛进入液压油内。Check the leak-tightness of the oil tank whether liquid watercontent in the air get into the hydraulic oil.（ 2） 应检查热闪换器水管是否损坏导致冷却水混入液压系统内。Check the Hot Flash Converter water pipe whether it is damage resulting in cooling water mixing into the hydraulic system.1.4 液压泵及液压阀Hydraulic pump and hydraulic valve由于液压泵及液压阀结构精密及复杂, 维修保养必须由技术人员处理。装拆时，要加倍小心以免损坏零件。Due to the precision and complex of hydraulic pump and hydraulic valve structures, maintenance and repair must be dealt with by the technical staff. When assemble and disassemble, be careful so as not to damage the parts.s1.5 油隔 Grease trap油隔功能是把液压油被油泵吸入前经过油隔而过滤异物。必须经常检查油隔，若油隔严重受污染油泵吸油管产生真空导致油泵损坏。The function of the grease trap is that filters the foreign matter before hydraulic oil being sucked by the oil pump. Check the grease trap usually, andif the grease trap is polluted seriously, the oil pump suction pipe will emerge vacuum causing the oil pump damaged.1.6油封 Grease seal所有密封填充圈是装于油缸及阀体上, 当密封圈损坏时 , 会影响机器工作性能 , 甚至泄油。需要时，应及早更换损坏之密填封圈。Allsealed filledcircles are installedon the oiltank and valve body, andwhen the sealed circlesis damaged, itwillaffect theperformance of the machineand even oil drainage.1.7电路控制 Circuit control在正常运作时 , 防止水及其他杂物进入电箱, 电箱门应紧密关闭 . 遇到电路故障时应由合资格的工作人员负责维修。台电部份联接螺丝应紧固，防止因松脱而导致危险。经常检查电箱温度不能太高，防止影响电子零件的正常运作。同时定期检查安全门电器互锁及行程咭掣以免发生意外。In normal operation, prevent water and other debris getting box and the door of the electric box should be closed tightly.intoWhenitthe electricencountersa circuit fault, eligible staff should be responsible for maintenance.1.8 电热 Electric heat应经常检进电热 . 电热不正常会产生注塑总是导致产品质素低.Check the electric heat regularly. Abnormal electric heat can produce plastic injection resulting in a low quality of product.（一）检查积各段电热是否正常。Check each part of electric heat whether it is normal.（二）检查温度控制状态。Check the control status of the temperature.（三）检查控温线端与熔胶筒接触状况。Check the contact status between temperature control terminal and melt adhesive cylinder.1.9熔胶筒及螺杆更换联结Melt adhesive cylinder and screw replacing the coupling assembly（一）对射咀进行拆除或移开，必须先浅放掉料管内部的塑料产生的压力。Beforedismantlingor removing the shoot mouth, pressureproduced by the plasticinsidethe material pipe should be unhanded lightly.因为有时温度会对封闭式料管内部的塑胶产生化学反应，并于料管内产爆炸性的压力。Because that sometimes temperature can lead to that plastic take place chemical reactions and cause a explosive pressure inside the closed material tube.将料管的温度降下及降低内部的压力，按下松退键让螺杆向后退。Pressing the loose back key and making the screw back can lower the temperature and pressure inside the material tube.（二）塑胶于料管内加热时间太长是相当的危险的，因为长时间的对塑胶加温产生的毒的气体，并经由射嘴喷出来。It is dangerous to heat the plastic cement inside the material tube too long time.Because of that long time heating the plastic will produce the toxic gases and spraying out from the shoot mouth.（三）料咀跑入异物时，不可以加高温度或高压力将体更挤出来。If there s some foreign matter come from the material mouth, do not rise up the temperature and pressure to squeeze it out strongly.必须关掉电源并将漏斗内时，然后再将异物清除。Turn off the power and use a funnel to clear the foreign matter.（四）当硬物掉入送料漏斗时， ，要取出时必须相当的小心。If the hard objects fall down into the feed funnel, pay more attention when take it out.（五）拆下料管的护盖前必须先确认关闭总电源开关。Be sure the main power is off before removing the material tube s cover.（六）严禁将润滑油涂抹于射出螺杆、料管、电热片上。Lubricant applied to injection screw、 material tube、electric flake is forbidden.（七）清洗或更换零件时，必须拆除熔胶筒、螺杆及止逆阀等零件。先选择手动方式。Washor change the parts, must dismantle melt adhesive cylinder 、screw and lock check gate first. Select manually first.按以下步骤更换熔胶筒：Replacing the melt adhesive cylinder according to the following steps:1) 关闭料斗闸板，采用手动或自动清洗功能把剩余塑料从熔胶筒打出。Close the hopper gate, and choose manual or automatic cleaning function to whip out the remaining plastic from the melt adhesive cylinder.2) 操作射台至最后位置。Transfer operation injection stage to final position.3) 关掉电源，拆除电热圈。Turn off the power, removal the electric circle.4) 松掉熔胶筒，锁紧螺母。Loose the melt adhesive cylinder, and lock the nut tightly.5) 松掉螺杆端与传动轴之联结组件。Loose the coupling components between screw terminal and drive shaft.6) 采用车间行车把熔胶筒稳固吊着，后把熔胶筒从射台拉出。Use a workshop bridge crane to hang the melt adhesive cylinder stably, and then pull it out from the injection stage.按以下步骤更换螺杆：Replacing the screw according to the following steps:1) 关闭料斗闸板，采用手动或自动清洗功能把剩余塑料从熔胶筒打出。Close the hopper gate, and choose manual or automatic cleaning function to whip out the remaining plastic from the melt adhesive cylinder.2) 操作射出台至最后位置。Transfer operation injection stage to final position.3) 逆时针方向摇摆射台（先松掉或拆除有关之螺丝或另件） 。Swingthe injectionstage in a counterclockwisedirection(loose or removethe relevant screws or others first).4) 松掉螺杆端与传动轴之联结。Loose the coupling components between screw terminal and drive shaft.5) 拆除射咀及射咀法兰。Remove the shooting mouth and shooting mouth flange.6) 操作螺杆“倒索“动作把螺杆端与传动轴脱离，必要时，用木方枕着螺杆端与传动轴之间。Use the“fall cable ” movement of the operation screw to separate the screw terminal and drive shaft. If necessary, pillow with a squared timber between screw terminal and drive shaft.7) 操作射胶动作把螺杆推出。Pull the screw out by the operation injection action.注意 : 为安全起见 , 把射胶压力及速度数值调低, 由于熔胶筒已被加热 , 拆除时小心被烫伤。Note: for security, lower the numerical of injection pressure and speed. As the melt adhesive cylinder is heated, be careful when dismantle.本机螺杆前端装有标准型之止逆阀组件，止逆阀组件采用左牙螺纹与螺杆连接。当螺杆转动时不容易把止逆阀松出，松脱时请留意旋向 .There is a standard lock check gate which is use the left tooth screw thread to connect with screw on this machine. When turning around the screw, if it is not easy to loose the lock check gate. Pay attention to the turn when doffing.1.10 定期检查 Regular checking（一）每天检查一次Check it once a day.（ 1）当机器运作时，检测电马达、油泵、油管及油阀发出声音及震动状况。When the machine is moving, check the sound and vibration condition of electric motors 、 pump、 oil pipe and oil discharge valve.（ 2）检查系统压力及油温，若温度过高，检杳冷却系统部份。Check the system pressure and temperature. If the temperature is too high, check the cooling system, too.（ 3）观察液压系统之管道接口、阀体、法兰等有否泄油。Observe the pipe s interfaces 、valve 、 flange of the hydraulic system if there s a oil leakage.（ 4）观察冷却系统管道有否漏水。Observe the cooling system if theres a water leakage.（ 5）检查安全装置、紧急停止按扭及指示灯状况。Check the safety device、emergency stop button and pilot lamp.（ 6）检查螺丝、螺母等紧固状况。Check the screw、 nut.（ 7）检查润滑系统。Check the lubrication systems.（二）每星期检查一次Check it once a week:（ 1）检查加注润滑点。Check it lubrication points.（ 2）检查电路如电热圈、控热线、行程咭掣等按线状况。Checkthe circuit s wiringstate,likeelectrichotline、travel cards for appliances and so on.heatingloop 、control（ 3）紧固可能松脱之螺丝、螺母及联结法兰。Fixture those may loosened screw、nut and fitting flange.（ 4）清洗机器上所有滑动之机件，以免被沙尘覆盖容易受损。Wash all the slidingable organs of the machine, so that it will not be easy to damage caused by the dust.（三）每月检查一次Check it once a month:（ 1）检查安装装置Check the install device.（ 2）检查阀体之线圈是否松脱。Check the coil of the valve whether it is loosened.（ 3）检查液压油是否保持良好质素。Check the hydraulic fluid whether it keeps a good situation.（ 4）更换已磨损之机件。Change the wearer.（四）每年检查一次Check it once a year:（ 1）更换已磨损之机件。Change the wearer.（ 2）检查系统压力，必要时重新调节。Check the system pressure, and adjust again if necessary.（ 3）检查熔胶转动轴承状况，加注润滑油脂。Check the condition of melt spinning bearings, and add some grease lubricant.（ 4）清洗热交换器。Wash the heat exchanger.1.11 机器的储存 Keep of machine如果机器长期不生产运作，请在检查机器之后用保护膜罩好，以防杂尘物进入。Ifthe machine doesn t work for a long time,please use a protectivefirmcoverthe machine before checking, in case of the dust going into.2. 常见故障及排除方法Common Troubles and Excluded Solutions2.1. 报警及排除 Alarm and exclude常见报警原因及排除方法common alarmCause and excluded solutions当顶针两个限们开关同时压合 (X013、 x014 同时亮：查看两个接线点处是否有短路 S，行程开关们置是否松动或不恰当 )脱模失败Whentwo limit switch of the centrepress at the sametimeFail to knockout(X013、 x014 lightsimultaneously:Check whether there sa short circuitS at the connection, and limit switch isloosed or improper.机械手失败机械手操作中，机械手未能复位（功能页面机械手选择使用）When the manipulator is operating, it failed to resetFail in manipulator(manipulator select function page )射嘴护罩打开射胶安全门（ X514）未关Open the injectionInjection safety doors (X514) is closed.mouth cover自动过程中，在熔胶计时内未能完成熔胶动作：熔胶时间、行熔胶未定时完成程的设定是否正确，料筒时有无料，熔胶压力、流量是否够大In the process of automatically, failed to complete theMelt adhesive is notmelt in the melttiming action: whether the melt timeandscheduled to completetrip setting is correct and if theres material in thebarrel; whether melt pressure and flow is large enough.开锁模计时内，未能完成开模动作： 开锁模时间设定是否正确，开模未定时完成开模压力、流量是否够大，此时循环不能继续Opening mould is notFailed to complete the opening mould action in time:scheduled to completewhether the setting time is correct and the pressure、flow is large enough; cycling cannot continue开模计时内，未能完成锁模动作：开锁模时间设定是否正确，关模未到定位锁模压力、流量是否够大Closing mould doesn tFailed to complete the closing mould action in time:reach positionwhether the setting time is correct and the pressure、flow is large enough; cycling cannot continue开模未到定位作顶针动作时，开模终止行程（开模二慢）未到或限位咭制（X013）未压合Opening mould doesn tIn centre action, opening mould end the route isnot reachreach positionor limit cards (X013) are not pressed.座退未到定位作滑模或转盘动作时，座退终止开关（X007）未压合Seat back doesntWhendo sliding or turntableaction,seat back end switchreach position(X007) is not pressed.滑模未到定位作锁模、顶针动作时，滑模终止开关（X403、X404）未压合Sliding mould doesntWhen do closing mould and centre action, sliding mouldreach positionend switch (X403 、X404)is not pressed.顶退未到定位作锁模、滑模或转盘动作时，顶退终止开关（ X011、X013）未压合Drift doesn t reachWhen do the closing mould 、 sliding mould and turntablepositionaction, drift end switch（X011、X013） is not pressed.定位上未到定位作锁模、顶针动作时，定位上终止开关（X516）未压合Position up doesn tWhendo the closingmould and centreaction, positionupreach positionend switch （X516） is not pressed.定位下未到定位作滑模或转盘动作时，定位下终止开关（X517）未压合Position down doesn tWhendo the slidingmould and turntable action,positionreach positiondown end switch （X517） is not pressed.开模总数已到实际开模次数到达时间页面内“开模限数”的设定值Reach the openingmouldReal opening mould times reach the setting point on thetotalitytime table.润滑油位低润滑油箱内的润滑油低于润滑油位开关（X405）Low lubrication oilLubrication oil in the tank is lower than the oil levellevelswitch （X405）料筒温度太高料筒的实际温度高于设定温度加上高温偏差Material barrelsReal temperature of material barrel is higher than thetemperature is toohighdesign temperature pulsing the deviation料筒的实际温度低于设定温度减去低温偏差， 此时不能进行射料筒温度太低胶、熔胶、抽胶动作Real temperature of material barrel is lower than theMaterial barrelsdesign temperaturecuttingthedeviation,andnotemperature is too lowinjection 、melting and taking out the glue action thismoment.2.2. 故障及排除Failures and Trouble Exclude故障现象原因及排除方法Fault symptomCause and excluded solutions1、检查开关电源保险管系统不上电Check the protector tube of power switch2、检查开关电源各路输出是否正常System can not reachCheck the output line of power switchthe power3、检查主机板保险管Check the protector tube of mainboard.1、检查各动作输出条作是否满足Check whether allthe output action is reach the condition2、检查外部相关行程开关是否有坏Check whether relevant route switch outside is broken.I/Olwg 出现不正常3、检查输入输出检测页面相应点是否输出，如有输出则页面更改输入输出点，相应调换输入输出点I/Olwg is not normalCheckwhetherthe input/outputdetectionpage scorresponding points is output, if output, then change the output and input point.4、通知生产厂Inform the producer.1、对比度是否调好，调对比度Contrast might not be adjusting well.2、面板后盖的稳压管7805 是否插好Voltage-stabilizingtube of thepanel s back cover7805有背光无字might not be plugging well.3、程序是否插好Back light withoutProcedure might not be plugging well.words4、液晶模块与显示板的连线是否插好The linebetween liquid crystalmodule and displaypanelmight not be plugging well.5、通知生产厂Inform the producer.1、连结线是否松动，把连结线螺丝旋紧The line might be loosed. Screw the screws lightly.2、电源问题，查看电源盒 +12V，+24V1A是否正常有字无背光Power problems. Check the power box +12V ， +24V1AWords without back3、显示板与键盘板，液晶模块的背光线是否插好lightdisplaypanel and keyboard panel 、the back light of liquidcrystal module might not be plugging well.4、通知生产厂Inform the producer.1、联结线是否松动，把联结线螺丝旋紧The line might be loosed. Screw the screws lightly.显示闪动2、电源问题，面板后盖的稳压管7805 没插好或坏Display flashingtube of thePower problems. Check the Voltage-stabilizingpanel s back cover 7805.3、外围供电电 220VACA或 380VAC）低或不稳Check whether the external power supply 220VACA或 380VAC is too low or unstable.4、通知生产厂Inform the producer.1、联结松动，把联结线螺丝旋紧The line might be loosed. Screw the screws lightly.2、电源问题，查看电源盒电源是否正常： 板面后盖的稳压管 7805无显示无背光是否插好 , 显示板灯是否亮No display and no backPower problems. Check the power box: Voltage-stabilizinglighttube of the panel s back cover 7805; whether the lightof display panel is light.3、通知生产厂Inform the producer.1、电池电压低（一般不能低于3V）换电池Low voltage of battery (generallydon t lessthan3V );记忆丢失change the battery.2、记忆块坏（ 256）坏Memory lossMemory block (256) is brok