The following is the diagnosis and treatment of several common faults of the vacuum suction cup crane vacuum system to talk about their own views.
1.The phenomenon of vacuum system failure and maintenance
The specific performance is: the vacuum system has no vacuum degree or the vacuum degree decreases, the lifting capacity decreases or the objects fall off easily in the lifting process. This indicates that the vacuum system has a problem and the spreader is no longer able to continue to use. If you continue to use it, it may cause a major safety accident due to the object falling off and hitting people and equipment, so you should overhaul it as soon as possible to find out the cause of the failure and restore the original performance of the equipment. The best solution is to use the exclusion method to investigate the parts that can cause equipment failure one by one.
1.1. Vacuum pump
1.1.1. Pump can not run
Cause analysis: the power supply is not connected, the power supply voltage does not match, the overload protector starts; the vacuum pump or motor jammed, motor damage, etc. Inspection and maintenance: check whether the power supply is powered, whether the power cord connection is solid and reliable; whether the power supply voltage is consistent with the voltage required by the pump motor (within ±10%). Check whether the vacuum pump or motor is stuck and damaged, if so, remove the stuck object or replace the vacuum pump.
1.1.2. The pump can not reach the required vacuum degree or the time to reach vacuum degree becomes longer
Reason analysis: The inlet or exhaust pipe is blocked; the exhaust filter and oil filter are blocked; there is no oil or lack of oil in the oil tank; the oil is polluted. Inspection and maintenance: Clean the air inlet and exhaust pipeline and oil filter. Replace the exhaust filter. Check the oil level of the oil tank, insufficient oil; oil is contaminated when the oil needs to be replaced with new oil. Note here: the exhaust filter is paper, can not be cleaned only replaced, filled with the same pump oil as the original grade.
1.1.3. The pump runs weakly cause analysis: the motor is out of phase, the voltage of the power supply is abnormal or there is a foreign body in the pump.
Inspection and maintenance: check whether the fuse is fused, if damaged, change the new fuse. Contactor of the static and dynamic contact poor contact for replacement. Test whether the voltage of power supply matches with the motor (within ±10%); if there is foreign matter inside the vacuum pump, remove it.
1.1.4. Vacuum pump noise
Reason analysis: Insufficient oil or oil deterioration of vacuum pump; internal oil filter is blocked. The silencer hole is blocked, the elastic coupling elastic pad is damaged, and there is a large amount of air leakage in the vacuum system. Inspection and maintenance: clear the debris in the silencer hole and oil filter; check the oil level of the oil tank, the oil quantity is insufficient and needs to be refueled, and the deteriorated oil should be replaced with new oil; check the elasticity of the elastic coupling gasket wear, and replace the new parts when it is broken; check the leakage point of the vacuum system for treatment.
1.1.5. The temperature of the pump is too high
Reason and analysis: Inlet and exhaust filters are blocked or oil filter is blocked; insufficient oil in the oil tank or oil is overheated and deteriorated, cooling fan is damaged, etc. Inspection and maintenance: clean or replace the air intake filter and oil filter, replace the exhaust filter; check the oil level of the oil tank, insufficient oil refueling or new oil; check the cooling effect of the cooling fan, and deal with any problems.
1.1.6. Pump pumping speed is too slow
Reason analysis: The air inlet or air inlet pipe is blocked. Check and repair: clean the air inlet pipe, clean or replace the air inlet filter; the exhaust filter is blocked, replace the exhaust filter; the diameter of the vacuum pipe connecting the suction cup is too small or the pipe is too long, use a large enough diameter or short connecting pipe.
1.2. Vacuum solenoid valve
Solenoid valve is not sensitive or not commutation reason analysis: the production process may occur accidental collision, electromechanical components aging wear, production site dusty and other reasons caused by the valve body deformation slide valve jammed, alignment spring broken, seal damage, solenoid coil burned out, electrical circuit damage, etc. lead to commutation valve does not work.
Inspection and maintenance: replace the vacuum solenoid valve.
1.3. Vacuum suction cup
Vacuum suction cup hanging suction cup is a rubber product, due to the production of direct contact with the plate and other objects, easy to occur wear and deformation. In the actual work sometimes also collide with the object, causing the lip to crack damage and air permeability; suction cup bottom plane sticky debris, rubber cracking aging, etc., will also lead to the suction cup and the plate between the contact is not strict, affecting the sealing performance, resulting in a decline in vacuum. Inspection and maintenance: remove the debris on the suction cups and replace the suction cups.
1.4. Other factors
Loose fixing screws of the cantilever beam or deformation of the U-connector can make a large gap between the cantilever beam and the main beam, which causes different heights of the suction cups after lifting and reduces the suction cups’ load-absorbing capacity. When this situation occurs, the cantilever screw must be fastened firmly, and if there is still a gap after fastening, shims should be added under the U-connector to eliminate it. The installation position of each suction cup connecting rod on the beam should be the same, otherwise the height of the suction cup is not the same.
Otherwise, the height of the suction cups is also different, which also affects the bearing capacity of the suction cups, so it should be adjusted. The vacuum connection hose will produce aging cracks, collapse and poor sealing of the joint in long-term use, which can directly cause the vacuum system to breathe, and is one of the main reasons to affect the vacuum degree.
1.5. Vacuum suction cup hanging fault analysis flow chart.
- Conclusion
Lifting spreader in the use of the process is very easy to appear equipment failure and safety aspects of the hidden danger, if not timely diagnosis and maintenance of good, the light affect the production schedule and product quality, the heavy is likely to happen major personal injury and equipment accidents, therefore must cause us to pay great attention. Only by continuously improving the professional and technical level of equipment maintenance personnel, so that they are proficient in equipment maintenance methods and techniques, in order to ensure personal safety and good performance of equipment, and promote the smooth development of enterprise production and operation.
