《注塑機保養(yǎng)手冊-臥式注塑機》由會員分享，可在線閱讀，更多相關《注塑機保養(yǎng)手冊-臥式注塑機（33頁珍藏版）》請在裝配圖網上搜索。

1、 嘉興昌機械工業(yè)有限公司 【注塑機保養(yǎng)手冊 】 1. 保養(yǎng)及檢查 Maintenance and Examination 日常保養(yǎng)及檢查機器壽命是非常重要 , 預防重于治療，然而對于機器而言，當然是保 養(yǎng)重于修理了，射出成型機是一種高運轉的機器，一天可能接近 24 小時操作，若以一個月 25 個工作天而言，每一月累積 600 個操作小時，一年將達 7200 小時，幾乎是一般工具機 4-5 倍長之操作時間。 保持良好的保養(yǎng)是減少及防止機器發(fā)生故障的最有效途徑。 以下資料 提供給用戶 , 使用機器時必須仔細閱讀 , 給機器定期檢查保養(yǎng)及維護 ..

2、 It is important to maintain and examine the machine everyday. We are always told that prevention is better than cure, as well as machine, maintenance is better than repair. Injection molding machine as a kind of high operation machines, may work near 24 hours in one day, if it keep

3、working 25 days every month, then it will accumulate 600 operation hours within a month,7200 hours in a year, which is 4-5 times longer than general machine. Maintaining a good maintenance is the most effective way to reduce and prevent the malfunction of machine. The following inform

4、ation 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 機器經過長時間使用后 , 所有滑動導桿、油缸的軸芯、滑面等會被沙塵等物質沾污 , 若不及時清理 , 滑動導桿、油缸軸芯及滑面會容易磨損 , 尤其對油缸軸芯油封為甚。保持清潔可防止由雜物引起磨損、堵塞、水份引起的銹蝕和及早發(fā)覺漏油情況。所以經常要清洗機 器。請勿使用酒清、揮發(fā)性油、汽油、石油等

5、制品擦拭人機屏幕，必須使用一般家庭擦試玻璃用清潔劑擦拭。 After a long time using, all the sliding lead-screw 、axis core of oil cylinder 、 sliding surface and so on will be stained by the sand flying in the air. If not cleaning in time, those places talked above may be abraded easily, especially the axis core of oi

6、l cylinder. Keeping clean can avoid detritions 、plugging causing by 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-computer screen, but not alcohol 、volatile oil 、gasoline 、 oil or other p

7、roducts. 1.2 潤滑系統(tǒng) Lubrication Systems 有足夠潤滑可減少機件磨損 , 必須經常加注潤滑油及油脂于機件如射臺導桿、 鎖模導桿 及有潤滑標識處 .. 機臺 KS55C和 KS55T的注油點如下圖所示 : If there ’s enough lubrication, it can reduce mechanical detritions. Organ like injection stage lead-screw 、clamping lead-screw and lubrication identification m

8、ust be often added oil or grease.. Machine oil injection point of KS55Cand KS55T as shown in the following figure: 射臺油缸 射出組 注黃油 座臺油缸 關模油缸 嘉興昌

9、機械有限公司 潤滑示意圖 標記 處數 更改文件號 簽 字 日期 設 計 標準化 圖樣標記 版本 數量 重量 比例 校 對 審 定 00 1 530.132 1:12 審 核  KS25T普通機 KS25T-000 工 藝 日 期 2014-06-26 共 頁 第 頁 此處注入 潤 滑 油 此處注入 此處注入 潤 滑 油 潤 滑 油 射出部

10、裝 此處注入 鎖模部裝 潤 滑 油 用戶必須注意以下幾點 : ( 一) 潤滑油之選擇 （1）耐高負載性 （2）氧化穩(wěn)定性 （3）防銹性佳 （4）適用 30# ~ 40# （二）每個工作班的操作者必須檢查潤滑油喉能否向摩擦零件部位供油 , 不允許供油喉塞、脫落。 （三）檢查油脂潤滑摩擦表面的潤滑油膜狀況 , 不允許出現(xiàn)干摩擦 , 及時加注潤滑脂。 User must pay attention to the following point: ( 一)Choice of lubrication oil

11、 (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 lubr

12、icated surface, and dry friction is not allowed, filling grease in time. 1.3 液壓系統(tǒng) Hydraulic pressure system 液壓油箱必須經常存有足夠液壓油 , 可從裝置于油箱外之油尺檢查油位 , 如果發(fā)覺 油位低于要求 , 應及補充。 Hydraulic fluid tank should be often storing with enoughhydraulic oil, and oil

13、level can be examined by using the dipstick which is fixed outside the oil box. If finding that oil level is lower than requirement, it should be replenished in time. , 應采用高質素之液壓油 , 液壓油在攝氏 很多液壓系統(tǒng)毛病起源于已污染之液壓油 30-50 度, 粘度在 150-225SUS或動動粘度 40-60 厘澌最為適合。本司推薦使用 46#液壓 油 .

14、 Lots of errors of hydraulic system originate from the polluted hydraulic oil, so high quality hydraulic oil is better. The suitable state of the hydraulic oil is in 30-50 degree（temperature ）、150-225SUS（viscosity ）and 40-60ls (kinematic viscosity).Ou

15、r company recommends #46 of hydraulic oil. 用戶亦須定期檢查液壓油，若果需要更換液壓油，把原有液壓油抽掉，清洗油箱 后，再加注全新液壓油于油箱內（新舊液壓油不能混合） , 同時清洗油篩。 Users also should check the hydraulic oil regularly. If it needs to renewal the hydraulic oil, firstly, take out the original hydraulic oil and wash the tank. A

16、nd then in pour the new hydraulic oil (oil and new hydraulic oil can not be mixed together.), wash the oil screen at the same time. 機器在正常運作時，液壓系統(tǒng)溫度不能超過攝氏 55 度。在超過情況下工作，液壓 系統(tǒng)會產生以下現(xiàn)象： When the machine works regularly, the temperature of hydraulic pressure system can not overtake 55 degree.

17、 If it is exceeded, the hydraulic pressure system will come with the follow phenomenon: （一）液壓油氧化加速，提前變質。 Oxidation of hydraulic oil is accelerated, and deteriorate in advance. （二）粘度降低導致油泵及其他閥體受損 . Viscosity reducing cause damage to pumps and other parts. （三）油封加快老化。 Oil seal accel

18、erate to ageing. 若發(fā)覺 If find that （一）液壓油出泡沫 If hydraulic oil bubble, （ 1） 應檢查油泵吸油管的密封性。 Check the leak-tightness of the oil pump suction pipe. （ 2） 應檢查液壓油是否充足。 Check the hydraulic oil whether it is sufficient. （ 3） 應檢查回油管是否沉入液壓油內。 Check back the oil tube whether it is sink

19、ing into the hydraulic oil. （二） 液壓油呈懸浮狀態(tài)白色 If hydraulic oil appear in white suspended state, （ 1） 應檢查油箱密封性，可能由于空氣潮濕，空氣中水氛進入液壓油內。 Check the leak-tightness of the oil tank whether liquid water content in the air get into the hydraulic oil. （ 2） 應檢查熱閃換器水管是否損壞導致冷卻水混入液壓系統(tǒng)內。 Check t

20、he Hot Flash Converter water pipe whether it is damage resulting in cooling water mixing into the hydraulic system. 1.4 液壓泵及液壓閥 Hydraulic pump and hydraulic valve 由于液壓泵及液壓閥結構精密及復雜 , 維修保養(yǎng)必須由技術人員處理。裝拆時，要 加倍小心以免損壞零件。 Due to the precision and complex of hydraulic pump and hydraulic valve s

21、tructures, maintenance and repair must be dealt with by the technical staff. When assemble and disassemble, be careful so as not to damage the parts.  ’s 1.5 油隔 Grease trap 油隔功能是把液壓油被油泵吸入前經過油隔而過濾異物。必須經常檢查油隔，若油 隔嚴重受污染油泵吸油管產生真空導致油泵損壞。 The function of the grease trap is that filters

22、the foreign matter before hydraulic oil being sucked by the oil pump. Check the grease trap usually, and if 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 所有密封填充圈是裝于油缸及閥體上 , 當密封圈損壞時 , 會影響機器工作性能 ,

23、甚至 泄油。需要時，應及早更換損壞之密填封圈。 Allsealed filled circles are installed on the oil tank and valve body, and when the sealed circles is damaged, it will affect the performance of the machine and even oil drainage. 1.7 電路控制 Circuit control 在正常運作時 , 防止水及其他雜物進入

24、電箱 , 電箱門應緊密關閉 . 遇到電路故障時應 由合資格的工作人員負責維修。臺電部份聯(lián)接螺絲應緊固，防止因松脫而導致危險。經常檢查電箱溫度不能太高，防止影響電子零件的正常運作。同時定期檢查安全門電器互鎖及行程咭掣以免發(fā)生意外。 In normal operation, prevent water and other debris getting box and the door of the electric box should be closed tightly.  into Whenit  the electric encounters

25、 a circuit fault, eligible staff should be responsible for maintenance. 1.8 電熱 Electric heat 應經常檢進電熱 . 電熱不正常會產生注塑總是導致產品質素低 . Check the electric heat regularly. Abnormal electric heat can produce plastic injection resulting in a low quality of product. （一）檢查積各段電熱是否正常。 Check each p

26、art of electric heat whether it is normal. （二）檢查溫度控制狀態(tài)。 Check the control status of the temperature. （三）檢查控溫線端與熔膠筒接觸狀況。 Check the contact status between temperature control terminal and melt adhesive cylinder. 1.9 熔膠筒及螺桿更換聯(lián)結 Melt adhesive cylinder and screw replacing the coupling a

27、ssembly （一）對射咀進行拆除或移開，必須先淺放掉料管內部的塑料產生的壓力。 Before dismantling or removing the shoot mouth, pressure produced by the plastic inside the material pipe should be unhanded lightly. 因為有時溫度會對封閉式料管內部的塑膠產生化學反應，并于料管內產爆炸性的壓力。 Because that sometimes temperature can lead to that plastic take pla

28、ce chemical reactions and cause a explosive pressure inside the closed material tube. 將料管的溫度降下及降低內部的壓力，按下松退鍵讓螺桿向后退。 Pressing the loose back key and making the screw back can lower the temperature and pressure inside the material tube. （二）塑膠于料管內加熱時間太長是相當的危險的，因為長時間的對塑膠加溫產生的毒的氣體，并經由射嘴噴出來。 I

29、t 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）料咀跑入異物時，不可以加高溫度或高壓力將體更擠出來。 If there ’ s some foreign matter come from the material mouth, do

30、 not rise up the temperature and pressure to squeeze it out strongly. 必須關掉電源并將漏斗內時，然后再將異物清除。 Turn off the power and use a funnel to clear the foreign matter. （四）當硬物掉入送料漏斗時， ，要取出時必須相當的小心。 If the hard objects fall down into the feed funnel, pay more attention when take it out. （五）拆下料管的

31、護蓋前必須先確認關閉總電源開關。 Be sure the main power is off before removing the material tube ’ s cover. （六）嚴禁將潤滑油涂抹于射出螺桿、料管、電熱片上。 Lubricant applied to injection screw 、 material tube 、electric flake is forbidden. （七）清洗或更換零件時，必須拆除熔膠筒、螺桿及止逆閥等零件。先選擇手動方式。 Washor change the parts, must dismantle mel

32、t adhesive cylinder 、screw and lock check gate first. Select manually first. 按以下步驟更換熔膠筒： Replacing the melt adhesive cylinder according to the following steps: 1) 關閉料斗閘板，采用手動或自動清洗功能把剩余塑料從熔膠筒打出。 Close the hopper gate, and choose manual or automatic cleaning function to whip out the remain

33、ing plastic from the melt adhesive cylinder. 2) 操作射臺至最后位置。 Transfer operation injection stage to final position. 3) 關掉電源，拆除電熱圈。 Turn off the power, removal the electric circle. 4) 松掉熔膠筒，鎖緊螺母。 Loose the melt adhesive cylinder, and lock the nut tightly. 5) 松掉螺桿端與傳動軸之聯(lián)結組件。 Loose

34、 the coupling components between screw terminal and drive shaft. 6) 采用車間行車把熔膠筒穩(wěn)固吊著，后把熔膠筒從射臺拉出。 Use a workshop bridge crane to hang the melt adhesive cylinder stably, and then pull it out from the injection stage. 按以下步驟更換螺桿： Replacing the screw according to the following steps: 1) 關閉料斗

35、閘板，采用手動或自動清洗功能把剩余塑料從熔膠筒打出。 Close the hopper gate, and choose manual or automatic cleaning function to whip out the remaining plastic from the melt adhesive cylinder. 2) 操作射出臺至最后位置。 Transfer operation injection stage to final position. 3) 逆時針方向搖擺射臺（先松掉或拆除有關之螺絲或另件） 。 Swing the injecti

36、on stage in a counterclockwise direction (loose or remove the relevant screws or others first). 4) 松掉螺桿端與傳動軸之聯(lián)結。 Loose the coupling components between screw terminal and drive shaft. 5) 拆除射咀及射咀法蘭。 Remove the shooting mouth and shooting mouth flange. 6) 操作螺桿“倒索“動作把螺桿端與傳動軸脫離，必要時，用木方

37、枕著螺桿端與傳動軸之間。 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) 操作射膠動作把螺桿推出。 Pull the screw out by the operation injection action. 注意 : 為安全起見

38、 , 把射膠壓力及速度數值調低 , 由于熔膠筒已被加熱 , 拆除時小心被燙傷。 Note: for security, lower the numerical of injection pressure and speed. As the melt adhesive cylinder is heated, be careful when dismantle. 本機螺桿前端裝有標準型之止逆閥組件，止逆閥組件采用左牙螺紋與螺桿連接。當螺桿轉動時不容易把止逆閥松出，松脫時請留意旋向 . There is a standard lock check gate which is

39、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 定期檢查 Regular checking （一）每天檢查一次 Check it once a day. （ 1）當機器運作時，檢測電馬達、油泵、油管及油閥發(fā)出聲音及震動狀況。 W

40、hen the machine is moving, check the sound and vibration condition of electric motors 、 pump、 oil pipe and oil discharge valve. （ 2）檢查系統(tǒng)壓力及油溫，若溫度過高，檢杳冷卻系統(tǒng)部份。 Check the system pressure and temperature. If the temperature is too high, check the cooling system, too. （ 3）觀察液壓系統(tǒng)之管道接口、閥體、法蘭等有否泄油。

41、 Observe the pipe ’ s interfaces 、valve 、 flange of the hydraulic system if there ’s a oil leakage. （ 4）觀察冷卻系統(tǒng)管道有否漏水。 Observe the cooling system if there  ’s a water leakage. （ 5）檢查安全裝置、緊急停止按扭及指示燈狀況。 Check the safety device 、emergency stop button and pilot lamp. （ 6）檢查螺絲、螺母等

42、緊固狀況。 Check the screw 、 nut. （ 7）檢查潤滑系統(tǒng)。 Check the lubrication systems. （二）每星期檢查一次 Check it once a week: （ 1）檢查加注潤滑點。 Check it lubrication points. （ 2）檢查電路如電熱圈、控熱線、行程咭掣等按線狀況。 Check the circuit ’ s wiring state, like electric hotline 、travel cards for appliances and

43、 so on.  heating  loop 、control （ 3）緊固可能松脫之螺絲、螺母及聯(lián)結法蘭。 Fixture those may loosened screw 、nut and fitting flange. （ 4）清洗機器上所有滑動之機件，以免被沙塵覆蓋容易受損。 Wash all the slidingable organs of the machine, so that it will not be easy to damage caused by the dust. （三）每月檢查一次 Check it once

44、 a month: （ 1）檢查安裝裝置 Check the install device. （ 2）檢查閥體之線圈是否松脫。 Check the coil of the valve whether it is loosened. （ 3）檢查液壓油是否保持良好質素。 Check the hydraulic fluid whether it keeps a good situation. （ 4）更換已磨損之機件。 Change the wearer. （四）每年檢查一次 Check it once a year: （ 1）

45、更換已磨損之機件。 Change the wearer. （ 2）檢查系統(tǒng)壓力，必要時重新調節(jié)。 Check the system pressure, and adjust again if necessary. （ 3）檢查熔膠轉動軸承狀況，加注潤滑油脂。 Check the condition of melt spinning bearings, and add some grease lubricant. （ 4）清洗熱交換器。 Wash the heat exchanger. 1.11 機器的儲存 Keep of machine

46、如果機器長期不生產運作，請在檢查機器之后用保護膜罩好，以防雜塵物進入。 If the machine doesn’ t work for a long time, please use a protective firm cover the machine before checking, in case of the dust going into. 2. 常見故障及排除方法 Common Troubles and Excluded Solutions 2.1. 報警及排除 Alarm and exclude 常見報警 原因及排除方法 comm

47、on alarm Cause and excluded solutions 當頂針兩個限們開關同時壓合 (X013、 x014 同時亮：查看兩個 接線點處是否有短路 S，行程開關們置是否松動或不恰當 ) 脫模失敗 Whentwo limit switch of the centre press at the sametime Fail to knockout (X013、 x014 light simultaneously: Check whether there ’ s a short circuit S at the connecti

48、on, and limit switch is loosed or improper. 機械手失敗 機械手操作中，機械手未能復位（功能頁面機械手選擇使用） When the manipulator is operating, it failed to reset Fail in manipulator (manipulator select function page ) 射嘴護罩打開 射膠安全門（ X514）未關 Open the injection Injection safety doors (X514)

49、 is closed. mouth cover 自動過程中，在熔膠計時內未能完成熔膠動作：熔膠時間、行 熔膠未定時完成 程的設定是否正確，料筒時有無料，熔膠壓力、流量是否夠大 In the process of automatically, failed to complete the Melt adhesive is not melt in the melt timing action: whether the melt time and scheduled to complete trip setting i

50、s correct and if there ’s material in the barrel; whether melt pressure and flow is large enough. 開鎖模計時內，未能完成開模動作： 開鎖模時間設定是否正確， 開模未定時完成 開模壓力、流量是否夠大，此時循環(huán)不能繼續(xù) Opening mould is not Failed to complete the opening mould action in time: scheduled to complete whether the setting ti

51、me is correct and the pressure 、 flow is large enough; cycling cannot continue 開模計時內，未能完成鎖模動作：開鎖模時間設定是否正確， 關模未到定位 鎖模壓力、流量是否夠大 Closing mould doesn ’t Failed to complete the closing mould action in time: reach position whether the setting time is correct and the

52、 pressure 、 flow is large enough; cycling cannot continue 開模未到定位 作頂針動作時，開模終止行程（開模二慢）未到或限位咭制 （X013）未壓合 Opening mould doesn ’t In centre action, opening mould end the route is not reach reach position or limit cards (X013) are not pressed.

53、 座退未到定位 作滑模或轉盤動作時，座退終止開關（ X007）未壓合 Seat back doesn ’t Whendo sliding or turntable action ,seat back end switch reach position (X007) is not pressed. 滑模未到定位 作鎖模、頂針動作時，滑模終止開關（ X403、X404）未壓合 Sliding mould doesn ’t When do closing mould and centre action, sli

54、ding mould reach position end switch (X403 、X404)is not pressed. 頂退未到定位 作鎖模、滑模或轉盤動作時，頂退終止開關（ X011、X013）未 壓合 Drift doesn ’ t reach When do the closing mould 、 sliding mould and turntable position action, drift end switch（X011、X013） is not pressed

55、. 定位上未到定位 作鎖模、頂針動作時，定位上終止開關（ X516）未壓合 Position up doesn ’ t Whendo the closing mould and centre action, position up reach position end switch （X516） is not pressed. 定位下未到定位 作滑?；蜣D盤動作時，定位下終止開關（ X517）未壓合 Position down doesn ’t Whendo the sliding mould and tu

56、rntable action, position reach position down end switch （X517） is not pressed. 開模總數已到 實際開模次數到達時間頁面內“開模限數”的設定值 Reach the opening mould Real opening mould times reach the setting point on the totality time table. 潤滑油位低 潤滑油箱內的潤滑油低于潤滑油位開關（ X405） Low lubri

57、cation oil Lubrication oil in the tank is lower than the oil level level switch （X405） 料筒溫度太高 料筒的實際溫度高于設定溫度加上高溫偏差 Material barrel ’s Real temperature of material barrel is higher than the temperature is too high design temperature pulsing the deviation

58、 料筒的實際溫度低于設定溫度減去低溫偏差， 此時不能進行射 料筒溫度太低 膠、熔膠、抽膠動作 Real temperature of material barrel is lower than the Material barrel ’s design temperature cutting the deviation, and no temperature is too low injection 、melting and taking out the glue action this

59、 moment. 2.2. 故障及排除 Failures and Trouble Exclude 故障現(xiàn)象 原因及排除方法 Fault symptom Cause and excluded solutions 1、檢查開關電源保險管 系統(tǒng)不上電 Check the protector tube of power switch 2、檢查開關電源各路輸出是否正常 System can not reach Check the output line of power switch the power 3、檢查主

60、機板保險管 Check the protector tube of mainboard. 1、檢查各動作輸出條作是否滿足 Check whether all the output action is reach the condition 2、檢查外部相關行程開關是否有壞 Check whether relevant route switch outside is broken. I/Olwg 出現(xiàn)不正常 3、檢查輸入輸出檢測頁面相應點是否輸出， 如有輸出則頁面更改 輸入輸出點，相應調換輸入輸出點 I/Olwg

61、 is not normal Check whether the input/output detectionpage’ s corresponding points is output, if output, then change the output and input point. 4、通知生產廠 Inform the producer. 1、對比度是否調好，調對比度 Contrast might not be adjusting well. 2、面板后蓋的穩(wěn)壓管 7805 是否插好 Voltage-s

62、tabilizing tube of the panel ’ s back cover 7805 有背光無字 might not be plugging well. 3、程序是否插好 Back light without Procedure might not be plugging well. words 4、液晶模塊與顯示板的連線是否插好 The line between liquid crystal module and display panel might not be pluggi

63、ng well. 5、通知生產廠 Inform the producer. 1、連結線是否松動，把連結線螺絲旋緊 The line might be loosed. Screw the screws lightly. 2、電源問題，查看電源盒 +12V，+24V1A是否正常 有字無背光 Power problems. Check the power box +12V ， +24V1A Words without back 3、顯示板與鍵盤板，液晶模塊的背光線是否插好 light displa

64、y panel and keyboard panel 、the back light of liquid crystal module might not be plugging well. 4、通知生產廠 Inform the producer. 1、聯(lián)結線是否松動，把聯(lián)結線螺絲旋緊 The line might be loosed. Screw the screws lightly. 顯示閃動 2、電源問題，面板后蓋的穩(wěn)壓管 7805 沒插好或壞 Display flashing tube of the Power problems. Ch

65、eck the Voltage-stabilizing panel ’ s back cover 7805. 3、外圍供電電 220VACA或 380VAC）低或不穩(wěn) Check whether the external power supply 220VACA或 380VAC is too low or unstable. 4、通知生產廠 Inform the producer. 1、聯(lián)結松動，把聯(lián)結線螺絲旋緊 The line might be loosed. Screw the screws lightly. 2、電源問題，查看電

66、源盒電源是否正常： 板面后蓋的穩(wěn)壓管 7805 無顯示無背光 是否插好 , 顯示板燈是否亮 No display and no back Power problems. Check the power box: Voltage-stabilizing light tube of the panel ’s back cover 7805; whether the light of display panel is light. 3、通知生產廠 Inform the producer. 1、電池電壓低（一般不能低于 3V）換電池 Low voltage of battery (generally don’ t less than 3V ); 記憶丟失 change the battery. 2、記憶塊壞（ 256）壞 Memory loss Memory block (256) is brok