重慶電機維修采用機床修復方法,可以減少修理勞動量的30%~50%,降低修理費用的65%,并可節約金屬材料的消耗量,特別是對箱體、床身、主軸、蝸輪等工藝復雜的零件,具有很大的經濟意義。現對幾種常見的機床修理的特殊工藝簡要說明如下。
1.機床鍍鉻(ge)
2種工藝是機(ji)床應(ying)用(yong)最廣的(de)(de)(de)修復磨損的(de)(de)(de)軸頸(jing)、套筒、鑲(xiang)條(tiao)、閥芯等零件(jian)(jian)的(de)(de)(de)方(fang)法(fa)。鍍(du)鉻以(yi)前應(ying)將零件(jian)(jian)精磨以(yi)獲得正(zheng)(zheng)確的(de)(de)(de)幾何形(xing)狀和良(liang)好的(de)(de)(de)表(biao)面(mian)質量,井用(yong)汽(qi)油(you)洗去油(you)污。為了使(shi)滑動表(biao)面(mian)增加對潤滑油(you)的(de)(de)(de)保持性(xing),可采用(yong)多(duo)孔性(xing)鍍(du)鉻,即在普通鍍(du)鉻完畢后使(shi)零件(jian)(jian)從負(fu)極變為正(zheng)(zheng)極,通以(yi)較小的(de)(de)(de)電流進行(xing)反(fan)鍍(du),使(shi)零件(jian)(jian)表(biao)面(mian)形(xing)成點狀的(de)(de)(de)多(duo)孔層(ceng)(約(yue)占全部鍍(du)層(ceng)厚度的(de)(de)(de)1/3),多(duo)孔層(ceng)可以(yi)儲存潤滑油(you),因(yin)而可以(yi)提高零件(jian)(jian)的(de)(de)(de)耐磨性(xing)。
2.機床黏合
金(jin)屬黏合可(ke)以用(yong)來消(xiao)除金(jin)屬鑄件(jian)(jian)的裂縫和砂眼,修復破損和磨損零(ling)(ling)件(jian)(jian),甚至可(ke)以用(yong)于(yu)制(zhi)造形(xing)狀復雜的新(xin)零(ling)(ling)件(jian)(jian)(如鑲(xiang)鋼、鑲(xiang)銅(tong)導軌)。目前使用(yong)最多的高(gao)強度黏合劑(ji)是(shi)環氧(yang)樹脂,加入6%的乙烯::胺作為硬化劑(ji)。黏合前需(xu)用(yong)四氯化碳和丙酮將(jiang)零(ling)(ling)件(jian)(jian)膠合表(biao)面(mian)(mian)的油污、涂料和氧(yang)化物清洗干凈。在黏合前還(huan)需(xu)經過表(biao)面(mian)(mian)處理,黏合后加壓并在室溫中放置2~3天。
3.機床金屬噴鍍
金屬(shu)噴(pen)(pen)鍍(du)可(ke)用(yong)以修(xiu)復軸頸、套(tao)筒、平面(mian)及(ji)修(xiu)補鑄件(jian)缺陷(xian)。鍍(du)層的(de)(de)(de)(de)厚(hou)度(du)可(ke)達o.05至1Omm,作噴(pen)(pen)鍍(du)用(yong)的(de)(de)(de)(de)原材料(liao)是鋼(gang)絲(si)或雙(shuang)金屬(shu)(鋁及(ji)鉛)及(ji)合金絲(si)。金屬(shu)噴(pen)(pen)鍍(du)的(de)(de)(de)(de)優點是:設備便(bian)宜,工(gong)藝(yi)簡(jian)單;可(ke)修(xiu)復各種尺寸和形狀(zhuang)的(de)(de)(de)(de)零(ling)件(jian);利用(yong)不同鍍(du)層材料(liao),可(ke)獲得低摩擦(ca)系數及(ji)耐(nai)(nai)磨、抗腐(fu)蝕(shi)的(de)(de)(de)(de)鍍(du)層;鍍(du)層的(de)(de)(de)(de)加工(gong)性(xing)能良好。軸類零(ling)件(jian)的(de)(de)(de)(de)金屬(shu)噴(pen)(pen)鍍(du)可(ke)在舊車床上進(jin)行,速度(du)取(qu)10—15m/min,進(jin)給量取(qu)1.2—2.5mm/r.噴(pen)(pen)鍍(du)前,先清理零(ling)件(jian)表(biao)(biao)面(mian),將寸;修(xiu)復的(de)(de)(de)(de)表(biao)(biao)面(mian)用(yong)薄鐵皮(pi)隔開。噴(pen)(pen)鍍(du)后除(chu)掉隔離層,浸入加熱的(de)(de)(de)(de)油中,在100~120~C下保溫2—6h,再以較低的(de)(de)(de)(de)切(qie)削用(yong)量加工(gong)至所需尺寸。金屬(shu)噴(pen)(pen)鍍(du)層在干摩擦(ca)時(shi)的(de)(de)(de)(de)耐(nai)(nai)磨性(xing)差,但有潤滑時(shi),比普通金屬(shu)具(ju)有更(geng)高(gao)的(de)(de)(de)(de)潤滑油保持能力.
4.機床刷鍍(du)
刷鍍(du)(du)(du)又稱無槽(cao)電(dian)鍍(du)(du)(du)或(huo)接觸電(dian)鍍(du)(du)(du),是(shi)一(yi)種(zhong)不(bu)把工(gong)件放在鍍(du)(du)(du)槽(cao)中,而(er)是(shi)依靠一(yi)個與陽(yang)(yang)(yang)極接觸的(de)(de)墊或(huo)刷提供電(dian)鍍(du)(du)(du)需要的(de)(de)電(dian)解液(ye)的(de)(de)電(dian)鍍(du)(du)(du)方(fang)法.電(dian)鍍(du)(du)(du)時(shi)工(gong)件為(wei)(wei)陰極,刷鍍(du)(du)(du)的(de)(de)材(cai)料為(wei)(wei)陽(yang)(yang)(yang)極,墊或(huo)刷在披鍍(du)(du)(du)的(de)(de)陰極上移動。刷鍍(du)(du)(du)的(de)(de)最初期,是(shi)利用(yong)包有吸水(shui)纖(xian)維(wei)(玻璃布(bu)、尼(ni)龍布(bu)或(huo)海綿等,其厚度為(wei)(wei)2~3nun)的(de)(de)金(jin)(jin)屬(shu)作為(wei)(wei)陽(yang)(yang)(yang)極,鍍(du)(du)(du)何(he)種(zhong)金(jin)(jin)屬(shu)層(ceng)就用(yong)該種(zhong)金(jin)(jin)屬(shu)作陽(yang)(yang)(yang)極。通電(dian)后(hou),電(dian)解液(ye)巾的(de)(de)金(jin)(jin)屬(shu)離(li)子不(bu)斷透過纖(xian)維(wei)材(cai)料,當陽(yang)(yang)(yang)極鍍(du)(du)(du)筆(bi)不(bu)斷在工(gong)件表面移動時(shi),析(xi)出的(de)(de)金(jin)(jin)屬(shu)就沉積(ji)在I件卜(bu)形成(cheng)鍍(du)(du)(du)層(ceng),并隨時(shi)間的(de)(de)增加而(er)逐漸(jian)加厚。鍍(du)(du)(du)層(ceng)的(de)(de)均勻性可(ke)由電(dian)流密度、電(dian)鍍(du)(du)(du)時(shi)間和陽(yang)(yang)(yang)極移動速(su)度來控制。
刷(shua)鍍(du)的(de)(de)(de)(de)特點是施(shi)工方便.靈活性大,適用于特大零件(不(bu)易放在鍍(du)槽中(zhong))及(ji)構造(zao)復雜的(de)(de)(de)(de)零件(如肓孔、深孔及(ji)尖角等)的(de)(de)(de)(de)鍍(du)覆(fu)。一次用的(de)(de)(de)(de)電(dian)解液少,適合于貴重(zhong)金屬的(de)(de)(de)(de)電(dian)鍍(du)。刷(shua)鍍(du)還(huan)育柔(rou)和的(de)(de)(de)(de)拋光作用,鍍(du)層的(de)(de)(de)(de)質(zhi)量好(hao)。
隨(sui)著刷(shua)鍍(du)技術在(zai)(zai)機械設備(bei)維修行業中的(de)(de)(de)(de)(de)廣泛應(ying)用(yong)(yong),作(zuo)(zuo)(zuo)為刷(shua)鍍(du)的(de)(de)(de)(de)(de)陽(yang)(yang)(yang)(yang)極(ji)(ji)材料(liao)(liao)也(ye)(ye)得(de)到了很大的(de)(de)(de)(de)(de)發展。由于可(ke)溶(rong)(rong)性(xing)(xing)陽(yang)(yang)(yang)(yang)極(ji)(ji)(金(jin)屬陽(yang)(yang)(yang)(yang)極(ji)(ji))在(zai)(zai)高(gao)(gao)電流(liu)密(mi)度(du)(du)(du)下(xia),很快就產(chan)生鈍(dun)化層,使(shi)(shi)(shi)電流(liu)急劇下(xia)降(jiang),大大降(jiang)低了沉(chen)淀速度(du)(du)(du)。其原因(yin)是所用(yong)(yong)陽(yang)(yang)(yang)(yang)極(ji)(ji)材料(liao)(liao)中含有其他金(jin)屬雜(za)質(zhi),在(zai)(zai)通電時形(xing)成高(gao)(gao)阻膜(mo)所致(zhi)。這些金(jin)屬雜(za)質(zhi)嚴重(zhong)污(wu)(wu)染了鍍(du)液。日(ri)前刷(shua)鍍(du)基本上都(dou)是應(ying)用(yong)(yong)不(bu)(bu)(bu)溶(rong)(rong)性(xing)(xing)材料(liao)(liao)作(zuo)(zuo)(zuo)陽(yang)(yang)(yang)(yang)極(ji)(ji),這些不(bu)(bu)(bu)溶(rong)(rong)性(xing)(xing)陽(yang)(yang)(yang)(yang)極(ji)(ji)材料(liao)(liao)大多數(shu)是由經過了專(zhuan)門提純,除去了大量的(de)(de)(de)(de)(de)金(jin)屬雜(za)質(zhi)的(de)(de)(de)(de)(de)高(gao)(gao)密(mi)度(du)(du)(du)石墨(mo)做成的(de)(de)(de)(de)(de)。這些石墨(mo)純度(du)(du)(du)高(gao)(gao),結構細膩。均勻,導(dao)電性(xing)(xing)好,耐高(gao)(gao)溫電解(jie)浸蝕(shi),不(bu)(bu)(bu)僅克服丁可(ke)溶(rong)(rong)性(xing)(xing)金(jin)屬陽(yang)(yang)(yang)(yang)極(ji)(ji)材料(liao)(liao)的(de)(de)(de)(de)(de)缺點,而且給陽(yang)(yang)(yang)(yang)極(ji)(ji)的(de)(de)(de)(de)(de)制(zhi)(zhi)作(zuo)(zuo)(zuo)、鍍(du)筆的(de)(de)(de)(de)(de)研制(zhi)(zhi)和使(shi)(shi)(shi)用(yong)(yong)、沉(chen)積速度(du)(du)(du)的(de)(de)(de)(de)(de)提高(gao)(gao)以及對(dui)工藝規(gui)范(fan)的(de)(de)(de)(de)(de)選(xuan)擇(ze)都(dou)帶來了很大的(de)(de)(de)(de)(de)方便(bian)。但石墨(mo)陽(yang)(yang)(yang)(yang)極(ji)(ji)經長(chang)期使(shi)(shi)(shi)用(yong)(yong)后,特別在(zai)(zai)高(gao)(gao)電壓、大電流(liu)密(mi)度(du)(du)(du)下(xia)長(chang)期使(shi)(shi)(shi)用(yong)(yong)后,表面也(ye)(ye)會被腐(fu)蝕(shi)。為了提高(gao)(gao)石墨(mo)陽(yang)(yang)(yang)(yang)極(ji)(ji)的(de)(de)(de)(de)(de)抗(kang)腐(fu)蝕(shi)性(xing)(xing)能,防止鍍(du)層被污(wu)(wu)染,在(zai)(zai)制(zhi)(zhi)作(zuo)(zuo)(zuo)時可(ke)將(jiang)陽(yang)(yang)(yang)(yang)極(ji)(ji)表面浸上—層酚醛樹脂(zhi)膠。另外,在(zai)(zai)不(bu)(bu)(bu)同的(de)(de)(de)(de)(de)場(chang)合(he),還可(ke)選(xuan)用(yong)(yong)鉑銥(yi)合(he)金(jin)、不(bu)(bu)(bu)銹鋼、鉑、鈦(tai)等材料(liao)(liao)制(zhi)(zhi)作(zuo)(zuo)(zuo)陽(yang)(yang)(yang)(yang)極(ji)(ji)。在(zai)(zai)特殊場(chang)合(he)下(xia),有時也(ye)(ye)用(yong)(yong)可(ke)溶(rong)(rong)性(xing)(xing)材料(liao)(liao)制(zhi)(zhi)作(zuo)(zuo)(zuo)陽(yang)(yang)(yang)(yang)極(ji)(ji)。
5.機床環氧耐膳涂層【重慶電機維修】
環氧耐磨涂(tu)層應用于機床導軌或其他摩擦表面(mian)的制造和修理,其特點如下(xia):
(1)工(gong)(gong)(gong)藝簡單(dan)方(fang)便(bian),容易掌握,并可以(yi)節(jie)約時(shi)(shi)間和(he)人力。由于(yu)涂層(ceng)技(ji)術是采(cai)用復印(yin)成形的方(fang)法(fa)宋制造或(huo)修復摩(mo)(mo)擦(ca)表面(mian)(mian)的,即在摩(mo)(mo)擦(ca)副的一個(ge)面(mian)(mian)涂以(yi)涂層(ceng)材料,然后靠(kao)其經加工(gong)(gong)(gong)達到使用要求的配對摩(mo)(mo)擦(ca)面(mian)(mian)復印(yin)咸形.這樣就(jiu)減少了(le)(le)一個(ge)摩(mo)(mo)擦(ca)面(mian)(mian)的精加工(gong)(gong)(gong),省占了(le)(le)人工(gong)(gong)(gong)刮(gua)研,大大減少了(le)(le)加工(gong)(gong)(gong)工(gong)(gong)(gong)時(shi)(shi),降低了(le)(le)加工(gong)(gong)(gong)技(ji)術難度和(he)復雜性。
(2)適用范(fan)圍廣(guang),工(gong)藝(yi)性(xing)好。耐磨(mo)涂(tu)層既(ji)可(ke)(ke)用于(yu)制造(zao)大尺寸或配(pei)合精度高(gao)而無法用機械加工(gong)方(fang)法達到(dao)的(de)零(ling)、部(bu)件配(pei)合面,還可(ke)(ke)用于(yu)恢復磨(mo)損尺寸或某(mou)些有(you)缺陷的(de)零(ling)、部(bu)件。這一點,對(dui)于(yu)不具備大型(xing)(xing)零(ling)、部(bu)件加工(gong)能(neng)力的(de)中、小型(xing)(xing)工(gong)廠(chang)尤(you)其重要。
一、電動(dong)機(ji)的日常檢(jian)查與維護保養(yang)
電(dian)動機(ji)(ji)由定子架、繞(rao)組及(ji)絕(jue)緣(yuan)材(cai)料、轉(zhuan)子、兩端(duan)軸承(cheng)及(ji)端(duan)蓋等組成(cheng),比較簡單。電(dian)動機(ji)(ji)故(gu)障的原(yuan)因有:電(dian)源(yuan)斷(duan)相、電(dian)壓或頻率不(bu)(bu)(bu)對,繞(rao)組短路、斷(duan)路、接地軸承(cheng)運轉(zhuan)不(bu)(bu)(bu)良(liang),內、外部臟,散(san)熱(re)不(bu)(bu)(bu)好(hao),外部涂油漆(qi)太(tai)厚(hou)也(ye)是散(san)熱(re)不(bu)(bu)(bu)好(hao)的原(yuan)因和自帶(dai)冷卻風扇壞(huai),通風不(bu)(bu)(bu)暢與機(ji)(ji)械裝備不(bu)(bu)(bu)良(liang),長(chang)期高負(fu)荷運行,環境溫度高,等等。電(dian)動機(ji)(ji)的損壞(huai)90%以上都(dou)是維修人員日常檢查不(bu)(bu)(bu)細(xi)、維護保養不(bu)(bu)(bu)足(zu)造成(cheng)的,只要堅持認真看(kan)、聽、摸(mo)、測、做(zuo),絕(jue)大(da)多數故(gu)障都(dou)可以預防和避免。
1.看
每天巡查時(shi)看(kan)(kan)電(dian)動(dong)機(ji)工(gong)作電(dian)流的(de)大小和變化,看(kan)(kan)周(zhou)圍(wei)有沒有漏水、滴水,是否會因絕緣(yuan)低擊(ji)穿(chuan)繞阻(zu)而燒壞電(dian)機(ji)。還要(yao)看(kan)(kan)電(dian)動(dong)機(ji)外(wai)圍(wei)是否有影響其通風散熱(re)環境的(de)物件,看(kan)(kan)風扇端蓋(gai)、扇葉和電(dian)動(dong)機(ji)外(wai)部(bu)是否過臟需要(yao)清潔,要(yao)確保其冷卻(que)散熱(re)效(xiao)果。無(wu)論誰(shui)發現(xian)問(wen)題(ti),都應及(ji)時(shi)處(chu)理。
2.聽
認真(zhen)細聽(ting)(ting)電(dian)動(dong)(dong)(dong)(dong)機(ji)(ji)的運行聲音(yin)是否異常。因機(ji)(ji)房(fang)噪(zao)音(yin)較(jiao)大,可借助于螺絲(si)刀或(huo)聽(ting)(ting)棒等輔助工(gong)具,貼近(jin)電(dian)動(dong)(dong)(dong)(dong)機(ji)(ji)兩端聽(ting)(ting)。如果經常聽(ting)(ting),不但能(neng)發(fa)現電(dian)動(dong)(dong)(dong)(dong)機(ji)(ji)及其(qi)拖動(dong)(dong)(dong)(dong)設備的不良振動(dong)(dong)(dong)(dong),連內部軸(zhou)(zhou)(zhou)承油(you)的多少(shao)都能(neng)判(pan)斷,從而及時作(zuo)出(chu)添(tian)加(jia)軸(zhou)(zhou)(zhou)承油(you),或(huo)更(geng)換新軸(zhou)(zhou)(zhou)承等相應的措施處(chu)理(li),避免(mian)電(dian)動(dong)(dong)(dong)(dong)機(ji)(ji)軸(zhou)(zhou)(zhou)承缺油(you)干(gan)磨(mo)而堵轉、走外圓、掃膛(tang)燒壞(huai)。
多(duo)數廠家(jia)考慮到(dao)大型電動(dong)機解體更換(huan)軸承的困(kun)難,會(hui)采用開(kai)式軸承,定(ding)期(2000h),用油槍加油時(shi)需注(zhu)意使用電機名牌標示軸承油(-35℃—+140℃),并將下端放油口打開(kai)或另一邊的悶(men)頭螺絲拆卸開(kai),以(yi)便將舊油擠換(huan)出來(注(zhu)意補充(chong)油定(ding)額),防止(zhi)加油時(shi)因壓力大把(ba)油擠到(dao)電動(dong)機內部,運轉時(shi)濺到(dao)定(ding)轉子上,影響電動(dong)機的散(san)熱(re)功能(neng)等。
3.摸
用(yong)手背探模電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)周圍(wei)的(de)(de)溫(wen)(wen)(wen)度(du)(du)(du)(du)。在軸(zhou)(zhou)承(cheng)狀況(kuang)(kuang)較(jiao)(jiao)好情況(kuang)(kuang)下(xia),一般(ban)兩(liang)端的(de)(de)溫(wen)(wen)(wen)度(du)(du)(du)(du)都會低(di)于中間(jian)繞組(zu)段的(de)(de)溫(wen)(wen)(wen)度(du)(du)(du)(du)。如果(guo)兩(liang)端軸(zhou)(zhou)承(cheng)處(chu)溫(wen)(wen)(wen)度(du)(du)(du)(du)較(jiao)(jiao)高,就要結合所(suo)測(ce)的(de)(de)軸(zhou)(zhou)承(cheng)聲音情況(kuang)(kuang)檢查(cha)軸(zhou)(zhou)承(cheng)。如果(guo)電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)總體溫(wen)(wen)(wen)度(du)(du)(du)(du)偏高,就要結合工作(zuo)電(dian)(dian)(dian)(dian)(dian)流檢查(cha)電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)的(de)(de)負載、裝(zhuang)備和通風(feng)等情況(kuang)(kuang)并進(jin)行相應處(chu)理。 根(gen)據電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)的(de)(de)所(suo)用(yong)絕(jue)緣(yuan)材料的(de)(de)絕(jue)緣(yuan)等級(ji),可以確定電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)運行時繞組(zu)絕(jue)緣(yuan)能長期(qi)使用(yong)的(de)(de)極限溫(wen)(wen)(wen)度(du)(du)(du)(du),或者說電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)的(de)(de)允許溫(wen)(wen)(wen)升(sheng)(sheng)(電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)的(de)(de)實際溫(wen)(wen)(wen)度(du)(du)(du)(du)減去環境溫(wen)(wen)(wen)度(du)(du)(du)(du))。各國絕(jue)緣(yuan)等級(ji)標準有所(suo)差異,但基(ji)本分為:Y、A、E、B、F、H、C 這(zhe)幾個(ge)等級(ji),其中Y級(ji)的(de)(de)允許溫(wen)(wen)(wen)升(sheng)(sheng)最(zui)低(di)(45℃),而C級(ji)的(de)(de)允許溫(wen)(wen)(wen)升(sheng)(sheng)最(zui)高(135℃以上)。從軸(zhou)(zhou)承(cheng)油(you)和其他材料方面考慮,用(yong)溫(wen)(wen)(wen)度(du)(du)(du)(du)表(biao)貼親電(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)測(ce)量的(de)(de)溫(wen)(wen)(wen)度(du)(du)(du)(du)最(zui)好控制(zhi)在85℃以下(xia)。
4、測(ce)
(1)離線:在電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)停止(zhi)運行時(shi),要(yao)定期(每月)用絕(jue)(jue)緣(yuan)(yuan)(yuan)表測量其各相(xiang)對(dui)的(de)或相(xiang)間(jian)絕(jue)(jue)緣(yuan)(yuan)(yuan)電(dian)(dian)(dian)阻(zu),并與上月測試(shi)結果相(xiang)比較(jiao),以便及時(shi)發現絕(jue)(jue)緣(yuan)(yuan)(yuan)缺陷。發現不良(liang)時(shi)用烘(hong)(hong)潮(chao)(chao)燈(deng)烘(hong)(hong)烤以提(ti)高絕(jue)(jue)緣(yuan)(yuan)(yuan),避(bi)免因絕(jue)(jue)緣(yuan)(yuan)(yuan)太低(推(tui)薦值>1兆歐)擊穿繞(rao)組燒(shao)壞(huai)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)。設(she)有烘(hong)(hong)潮(chao)(chao)電(dian)(dian)(dian)加熱的(de)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)除(chu)非特殊情況(kuang),不要(yao)隨意關(guan)掉加熱開關(guan)。在潮(chao)(chao)濕天氣和冬季時(shi)要(yao)特別(bie)注意電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)的(de)防水(shui)、防潮(chao)(chao)和烘(hong)(hong)干。對(dui)露(lu)天及潮(chao)(chao)濕場所的(de)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)要(yao)特別(bie)注意水(shui)密(mi);對(dui)懷(huai)疑嚴(yan)重受(shou)潮(chao)(chao)或濺(jian)過水(shui)的(de)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji),使(shi)用前(qian)更應(ying)認真檢(jian)查(cha)。如果發現電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)浸泡(pao)水(shui),只(zhi)要(yao)將電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)解體后(hou)抽出轉子,并用壓縮空氣吹干后(hou),再用烤燈(deng)從電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)定子內兩端烘(hong)(hong)烤,直(zhi)止(zhi)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)絕(jue)(jue)緣(yuan)(yuan)(yuan)升至(zhi)正常(chang)。有些(xie)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)繞(rao)組的(de)引線只(zhi)有三根,不能檢(jian)測繞(rao)組間(jian)絕(jue)(jue)緣(yuan)(yuan)(yuan),重繞(rao)電(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)的(de)絕(jue)(jue)緣(yuan)(yuan)(yuan)電(dian)(dian)(dian)阻(zu)一般不應(ying)低于5兆歐。
(2)在線: 在電(dian)(dian)(dian)(dian)動機(ji)(ji)運行(xing)時,可測量(liang)其三(san)相(xiang)工作電(dian)(dian)(dian)(dian)壓和(he)電(dian)(dian)(dian)(dian)流(liu)(liu),看是否均(jun)衡。電(dian)(dian)(dian)(dian)壓應基本相(xiang)等,各(ge)相(xiang)電(dian)(dian)(dian)(dian)流(liu)(liu)與平均(jun)值的(de)(de)誤差不(bu)應超10%,如(ru)用(yong)鉗形(xing)(xing)表測得的(de)(de)各(ge)相(xiang)電(dian)(dian)(dian)(dian)流(liu)(liu)差值太大(da),則可能有匝間短路。有時需要脫(tuo)開負載測量(liang)空載電(dian)(dian)(dian)(dian)流(liu)(liu)大(da)小,一般2極(ji)約(yue)2800rpm,1/3 Ie(額定電(dian)(dian)(dian)(dian)流(liu)(liu)),4極(ji)約(yue)1600rpm,40%左右 Ie,6極(ji)約(yue)900rpm,55% Ie。它(ta)會因(yin)極(ji)數與容(rong)量(liang)的(de)(de)不(bu)同(tong)而不(bu)同(tong)。另外電(dian)(dian)(dian)(dian)動機(ji)(ji)的(de)(de)Y、△形(xing)(xing)接法不(bu)能搞(gao)錯(cuo),若錯(cuo)將Y形(xing)(xing)接成△形(xing)(xing),工作電(dian)(dian)(dian)(dian)流(liu)(liu)會增(zeng)大(da),反之,則減(jian)(jian)小。同(tong)時,如(ru)電(dian)(dian)(dian)(dian)動機(ji)(ji)的(de)(de)繞組(zu)接線錯(cuo)誤,或繞組(zu)匝數減(jian)(jian)少,舊電(dian)(dian)(dian)(dian)動機(ji)(ji)的(de)(de)定轉子間氣隙過(guo)大(da)(正常0.2-1.0mm)都(dou)會使空載電(dian)(dian)(dian)(dian)流(liu)(liu)加大(da),這些要點可以幫助我(wo)們判斷日常運行(xing)電(dian)(dian)(dian)(dian)動機(ji)(ji)狀況(kuang)的(de)(de)好壞。
5、做
不(bu)(bu)但要對檢查中發(fa)現的問題(ti)及時(shi)采取補救(jiu)措施,還要按保(bao)(bao)養周期,(每月(yue))對電(dian)動(dong)(dong)(dong)機(ji)進行螺絲、接(jie)線緊(jin)固(gu),拆解檢查、清潔保(bao)(bao)養等。如(ru):電(dian)動(dong)(dong)(dong)機(ji)端蓋4個(ge)固(gu)定螺絲全部(bu)松脫,造(zao)(zao)成(cheng)(cheng)掃(sao)膛(tang)運(yun)轉(zhuan)燒壞(huai);電(dian)動(dong)(dong)(dong)機(ji)接(jie)線螺栓松動(dong)(dong)(dong)虛(xu)接(jie),造(zao)(zao)成(cheng)(cheng)缺相(xiang)燒壞(huai);電(dian)動(dong)(dong)(dong)機(ji)風扇葉(xie)脫落抵住機(ji)體,造(zao)(zao)成(cheng)(cheng)堵(du)轉(zhuan)而(er)燒壞(huai);電(dian)動(dong)(dong)(dong)機(ji)軸(zhou)承潤滑(hua)(hua)不(bu)(bu)良、運(yun)行溫度高(gao),而(er)未(wei)及時(shi)補充潤滑(hua)(hua)油或(huo)更換軸(zhou)承,造(zao)(zao)成(cheng)(cheng)電(dian)動(dong)(dong)(dong)機(ji)燒壞(huai);電(dian)動(dong)(dong)(dong)機(ji)因(yin)天(tian)氣潮濕絕(jue)緣(yuan)(yuan)電(dian)阻下降,不(bu)(bu)及時(shi)烘烤提高(gao)絕(jue)緣(yuan)(yuan)造(zao)(zao)成(cheng)(cheng)擊穿。工段內電(dian)動(dong)(dong)(dong)機(ji)燒壞(huai)是因(yin)為沒有及時(shi)檢查、緊(jin)固(gu)所致,還是因(yin)為雖已發(fa)現問題(ti),但沒做(zuo)維(wei)護保(bao)(bao)養補救(jiu)所致。無論是不(bu)(bu)看(kan)不(bu)(bu)做(zuo),還是只看(kan)不(bu)(bu)做(zuo),最終都會造(zao)(zao)成(cheng)(cheng)故(gu)障或(huo)事故(gu)。
拆(chai)檢電動機時如需(xu)更換軸承(cheng)(cheng),要(yao)盡可能(neng)用(yong)進口(kou)的(de),國內的(de)會有(you)不少是(shi)(shi)翻新(xin)的(de)舊軸承(cheng)(cheng),質量(liang)難以保(bao)證。如發現軸承(cheng)(cheng)外圓與端蓋(gai)軸承(cheng)(cheng)座配(pei)合(he)不緊密,即軸承(cheng)(cheng)走外圓時,要(yao)根據其程度(du)不同(tong),視情(qing)(qing)況采用(yong)端蓋(gai)軸承(cheng)(cheng)座內圈打麻點、墊銅皮或(huo)鑲銅套消除,一定(ding)要(yao)定(ding)準(zhun)中心點否則不久又會損壞(huai)。投入(ru)運行前,要(yao)再次確認軸伸出端徑向擺動與端蓋(gai)等(deng)緊固情(qing)(qing)況,轉(zhuan)子轉(zhuan)動是(shi)(shi)否靈活,繞組(zu)引(yin)線連接是(shi)(shi)否正(zheng)確,等(deng)等(deng)。
還有(you)許多(duo)電(dian)動(dong)(dong)(dong)(dong)(dong)機(ji)(ji),當與(yu)(yu)其連(lian)接使用(yong)的(de)泵(beng)漏(lou)(lou)(lou)水時(shi),通常(chang)都(dou)去加(jia)壓(填料(liao)函)滅(mie)漏(lou)(lou)(lou),有(you)經驗(yan)的(de)維修工在加(jia)、換盤(pan)根時(shi),都(dou)會先用(yong)手(shou)盤(pan)轉一下(xia),看(kan)轉動(dong)(dong)(dong)(dong)(dong)情況(kuang),均衡(heng)上緊(jin)壓蓋螺(luo)絲,再短時(shi)起(qi)(qi)、停兩三次(ci),看(kan)看(kan)工作(zuo)(zuo)電(dian)流等是(shi)否正(zheng)常(chang);而沒有(you)經驗(yan)的(de)新(xin)維修工,只(zhi)知(zhi)道上緊(jin)滅(mie)漏(lou)(lou)(lou),不注(zhu)意與(yu)(yu)之(zhi)相關的(de)電(dian)動(dong)(dong)(dong)(dong)(dong)機(ji)(ji),結果導致電(dian)動(dong)(dong)(dong)(dong)(dong)機(ji)(ji)因堵轉起(qi)(qi)動(dong)(dong)(dong)(dong)(dong)電(dian)流太大,熱過載保(bao)護(hu)來不及動(dong)(dong)(dong)(dong)(dong)作(zuo)(zuo)而擊穿(chuan)繞組(zu)燒壞。另外(wai),在對(dui)由(you)電(dian)動(dong)(dong)(dong)(dong)(dong)機(ji)(ji)驅(qu)動(dong)(dong)(dong)(dong)(dong)的(de)機(ji)(ji)械設備(bei)(bei)(減速(su)機(ji)(ji)、水泵(beng)、油泵(beng)等)維修保(bao)養、拆檢裝復時(shi),也(ye)應認真查(cha)驗(yan)和校(xiao)正(zheng)電(dian)動(dong)(dong)(dong)(dong)(dong)機(ji)(ji)與(yu)(yu)被驅(qu)動(dong)(dong)(dong)(dong)(dong)機(ji)(ji)械的(de)軸心線,確保(bao)對(dui)中良好,用(yong)手(shou)轉動(dong)(dong)(dong)(dong)(dong)聯軸器時(shi)應輕(qing)便、靈活。只(zhi)有(you)切(qie)實、認真、細致地做好每(mei)一步,才能提高設備(bei)(bei)的(de)完好率(lv)。
二(er)、控制系(xi)統的(de)日常(chang)檢查與(yu)維護保養
電(dian)動機的(de)控(kong)(kong)制(zhi)系統由開關、保險(xian)絲、主副接觸器(qi)(qi)、繼電(dian)器(qi)(qi)、溫度、感(gan)應(ying)裝置等組(zu)成(cheng),相(xiang)對(dui)較復雜。故障多種多樣(yang),常需(xu)要借助控(kong)(kong)制(zhi)原理圖分析排查。
平時(shi)要(yao)注意保(bao)持(chi)控制(zhi)箱(xiang)內、外清潔干燥,不(bu)(bu)(bu)能有(you)水、油污,定期(qi)(每(mei)周)用(yong)小風機(ji)吹干凈(jing)箱(xiang)內各元件(jian)及(ji)接(jie)(jie)線(xian)柱、排(pai)上的灰塵,或(huo)用(yong)刷子蘸(zhan)電(dian)器(qi)清潔劑(ji)刷干凈(jing),以免影響接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)器(qi)、繼(ji)電(dian)器(qi)的工作或(huo)絕緣(yuan)。設有(you)烘潮電(dian)阻的控制(zhi)箱(xiang),一(yi)般不(bu)(bu)(bu)要(yao)隨意關掉(diao)加熱開關。還應保(bao)持(chi)箱(xiang)體接(jie)(jie)地可靠,預防觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)電(dian)。 要(yao)定期(qi)(每(mei)月)檢查(cha)箱(xiang)內接(jie)(jie)線(xian)和螺(luo)絲的緊(jin)固(gu)情(qing)況(kuang),防止(zhi)接(jie)(jie)線(xian)和螺(luo)絲松脫。查(cha)看開關、接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)器(qi)、繼(ji)電(dian)器(qi)等組件(jian)有(you)無損壞(huai)或(huo)燒(shao)蝕燒(shao)焦現象,各元件(jian)工作狀態及(ji)起、停、連鎖功(gong)能是否正常。要(yao)保(bao)持(chi)接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)器(qi)動(dong)、靜(jing)(jing)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)吸合、接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)良(liang)好,避免因觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)不(bu)(bu)(bu)好引起電(dian)動(dong)機(ji)缺相(xiang)運行而燒(shao)壞(huai)。如(ru)果觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)表面(mian)良(liang)好,僅(jin)是發黑,可用(yong)粗(cu)布擦一(yi)擦,不(bu)(bu)(bu)要(yao)輕易打(da)磨(mo)掉(diao)表面(mian)的耐熱合金層,否則將縮短觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)壽命;若(ruo)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)表面(mian)燒(shao)蝕比(bi)較(jiao)嚴重,可用(yong)“0”號沙紙(zhi)將其磨(mo)平。動(dong)、靜(jing)(jing)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)需(xu)保(bao)持(chi)線(xian)接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)或(huo)面(mian)接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu),而不(bu)(bu)(bu)是點接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)。接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)情(qing)況(kuang)好壞(huai)可在動(dong)、靜(jing)(jing)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)之間放張紙(zhi)條來檢查(cha),吸合時(shi)如(ru)夾不(bu)(bu)(bu)緊(jin),說明觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)頭(tou)(tou)或(huo)彈簧需(xu)要(yao)調整或(huo)更換。這一(yi)點需(xu)要(yao)引起重視(shi),輕的時(shi)候,因接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)不(bu)(bu)(bu)良(liang)會(hui)產生較(jiao)大的接(jie)(jie)觸(chu)(chu)(chu)(chu)(chu)(chu)(chu)電(dian)阻(電(dian)流),也就(jiu)意味(wei)著負載(zai)增大,導致(zhi)過載(zai)保(bao)護繼(ji)電(dian)器(qi)動(dong)作跳閘(zha),重則會(hui)引起電(dian)動(dong)機(ji)缺相(xiang)運行而燒(shao)壞(huai)。
更換繼電(dian)器(qi)、接觸器(qi)時需要(yao)注意電(dian)磁(ci)線圈(quan)工作電(dian)壓,以免換錯燒壞線圈(quan)。一般有(you)24V、220V和380V,對時間繼電(dian)器(qi),除了要(yao)注意線圈(quan)電(dian)壓要(yao)求(qiu)外,還要(yao)弄清時間繼電(dian)器(qi)的時間調節單位(wei)(時、分、秒)及范(fan)圍(wei),熱(re)繼電(dian)器(qi)整定電(dian)流是否(fou)合理適當。
對(dui)采用(yong)(yong)星形(xing)-三角形(xing)(Y-△)方(fang)法啟(qi)(qi)動(dong)(dong)(dong)的(de)(轉換(huan)延(yan)時約(yue)5秒)電(dian)動(dong)(dong)(dong)機(ji)(ji),要(yao)察(cha)看其(qi)轉換(huan)啟(qi)(qi)動(dong)(dong)(dong)情況是否正常(chang)。通常(chang),生產廠家(jia)對(dui)電(dian)動(dong)(dong)(dong)機(ji)(ji)的(de)啟(qi)(qi)動(dong)(dong)(dong)周期(qi)(即每分鐘啟(qi)(qi)動(dong)(dong)(dong)次數(shu))有嚴格規(gui)定(ding),會在(zai)起動(dong)(dong)(dong)控制箱上(shang)貼(tie)上(shang)警示標貼(tie),提(ti)醒使用(yong)(yong)者防(fang)止電(dian)動(dong)(dong)(dong)機(ji)(ji)因頻繁啟(qi)(qi)動(dong)(dong)(dong)而損壞;同時,也為防(fang)止起動(dong)(dong)(dong)控制箱內的(de)一(yi)些電(dian)器組件(如起動(dong)(dong)(dong)電(dian)抗(kang)器等)發熱燒毀。所(suo)以,對(dui)起停頻繁或電(dian)流大的(de)電(dian)動(dong)(dong)(dong)機(ji)(ji)控制系統,應(ying)縮短檢查保(bao)養周期(qi)。定(ding)期(qi)檢查熱過(guo)載繼電(dian)器的(de)保(bao)護(hu)功能(可(ke)撥動(dong)(dong)(dong)旁邊的(de)小紅標色制)其(qi)設定(ding)動(dong)(dong)(dong)作值(zhi)(zhi)不要(yao)超過(guo)電(dian)動(dong)(dong)(dong)機(ji)(ji)銘牌的(de)額定(ding)電(dian)流值(zhi)(zhi),確保(bao)能起到過(guo)載保(bao)護(hu)的(de)作用(yong)(yong)。
三(san)、振動電機的維護、保養
振動(dong)電(dian)機一般運行(xing)半年左(zuo)右小檢(jian)修(xiu)一次,一年大檢(jian)修(xiu)一次。小修(xiu)主要是(shi)(shi)清(qing)除機體(ti)(ti)積塵(chen),檢(jian)查(cha)線(xian)圈的(de)(de)絕緣電(dian)阻(zu)、接(jie)線(xian)是(shi)(shi)否(fou)牢固,及(ji)(ji)時清(qing)除隱患保證振動(dong)電(dian)機的(de)(de)正常運行(xing)。大修(xiu)時應打開(kai)電(dian)機清(qing)除機體(ti)(ti)內外積塵(chen),檢(jian)查(cha)軸承的(de)(de)磨損(sun),檢(jian)查(cha)接(jie)頭、接(jie)地及(ji)(ji)各(ge)緊固螺栓是(shi)(shi)否(fou)松動(dong),并及(ji)(ji)時緊固更換新的(de)(de)潤滑脂。振動(dong)電(dian)機在運轉(zhuan)(zhuan)工作中(zhong)如發現有異常響聲(sheng)時,應立即停機檢(jian)查(cha)排除故障后方可重新啟動(dong)運轉(zhuan)(zhuan)。
(1)振(zhen)動電機的(de)軸(zhou)(zhou)承應(ying)定期補充(chong)油(you)(you)脂,一般2-3個月補油(you)(you)一次。在(zai)振(zhen)動電機處用油(you)(you)槍(qiang)從油(you)(you)嘴處注(zhu)入或(huo)進行拆卸注(zhu)油(you)(you)。注(zhu)油(you)(you)量為軸(zhou)(zhou)承室容積的(de)三分(fen)之一至二分(fen)至一。
(2)振(zhen)動(dong)電(dian)機(ji)允許有適(shi)量(liang)的(de)軸(zhou)向游(you)隙,如采用(yong)單列圓錐滾子軸(zhou)承的(de)振(zhen)動(dong)電(dian)機(ji),軸(zhou)向游(you)隙必須控制(zhi)在0.30-0.40mm之(zhi)間,否則極易損壞電(dian)機(ji)。如更換新(xin)軸(zhou)承時應選用(yong)原軸(zhou)承型號。
(3)安裝偏(pian)(pian)心塊(kuai)調(diao)整(zheng)激振力時,兩內側為(wei)固定(ding)偏(pian)(pian)心塊(kuai),應在軸向(xiang)方向(xiang)上(shang)保持(chi)重合,再將(jiang)兩端軸上(shang)的外側可調(diao)偏(pian)(pian)心塊(kuai)向(xiang)同(tong)一個(ge)方向(xiang)調(diao)整(zheng)為(wei)相(xiang)同(tong)的角度,否則電機(ji)(ji)產生(sheng)巨大的錯向(xiang)激振力,會發生(sheng)損(sun)壞振動機(ji)(ji)械的現(xian)象。
(4)電機的線(xian)圈(quan)綁扎及螺栓緊固必(bi)須(xu)牢固可靠,電纜線(xian)、油封及防塵墊必(bi)須(xu)完好無(wu)破損。振動電機必(bi)須(xu)存放在(zai)通風干燥無(wu)腐蝕性氣體的倉庫(ku)對新儲存振動電機應定期(qi)檢查有無(wu)受(shou)潮、受(shou)凍(dong)、發銹及潤(run)滑脂變(bian)質等情況。
四、電(dian)動機故障
電機是影響安全生產的最主要因素之一。電動機損壞原因和本身質量、工作環境、運行狀態、保護電路、操作維護、使用年限等有直接關系,異步電動機正常使用和周期維護是確保其安全運行的基礎。 電動機故障大部分都是缺相、超載、人為因素和電動機本身原因造成。線路部分應該做到開機前必查,啟動完畢也應該查看三相電流是否均衡。工作環境的好壞決定電動機的保養周期。潮濕大,粉塵多,露天的工作環境就要經常檢查保養。工作環境差的,建議每月檢查一次,看看接線接頭是否松動,軸承是否損壞,是否缺少油脂。只要通過系統分析,采取相應的措施,加強電動機的管理水平,做好定期檢查,就能大大減少電動機故障和事故,從而提高電動機的使用效率。在實際工作中,只要我們在施工時執行“規范”,認真安裝,在正常運行及維護檢修過程中總結經驗,熟悉電動機常見故障和其原因,做到定期檢查,就可以確保電動機安全可靠的運行。【重慶直流電機維修】
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