Two - dimensional CNC fully automatic wire bending machines play a crucial role in the metal processing industry. Their efficient and precise bending capabilities have significantly enhanced production efficiency. However, to ensure that the equipment always maintains good performance and extends its service life, proper maintenance and care are essential. The following is a detailed introduction to the relevant guide.
I. Daily Maintenance
(I) Cleaning Work
Machine Body Surface: Before and after each use of the equipment, wipe the machine body with a soft dry cloth to remove dust, iron filings, oil stains, etc. on the surface. Especially during the working process, iron filings are easy to splash and adhere to the machine body. If not cleaned in time, it will not only affect the appearance of the equipment but also may scratch the operator during subsequent operations. For some corners and gaps that are difficult to wipe, a small brush can be used to assist in cleaning.
Workbench Surface: The workbench surface is the operating area for wire bending, and it is crucial to keep it clean. After use, promptly remove the remaining wire debris and sundries on the workbench surface to prevent them from accumulating on the workbench and affecting the placement of subsequent wires and the bending accuracy. A vacuum cleaner can be used to suck up fine debris, and then wipe it clean with a clean cloth.
Mold Part: The mold is in direct contact with the wire, and iron filings and oil stains will adhere to it during the bending process. After each use, carefully clean the mold with a special mold cleaner and a soft cloth to ensure that the mold surface is smooth and free of impurities. If there are hard objects such as iron filings remaining on the mold surface, it may cause scratches on the wire surface during the next bending, affecting the product quality and also accelerating the wear of the mold.
(II) Lubrication Treatment
Sliding Parts: The sliding parts of the equipment, such as sliders and guide rails, will generate friction during operation. Good lubrication can effectively reduce wear and extend the service life of the parts. Before work every day, check the lubrication of these sliding parts and inject an appropriate amount of lubricating oil through the lubrication points on the equipment. Common lubrication methods include manual application and oil supply by an automatic lubrication system. If an automatic lubrication system is used, regularly check the oil level in the lubricating oil tank to ensure that the oil level is sufficient. Generally, for frequently used equipment, the oil level should be checked once a week, and lubricating oil should be added in a timely manner if necessary.
Transmission Parts: Transmission parts such as drive chains and gears also need to be lubricated regularly. According to the frequency of equipment use, lubricate the transmission parts at regular intervals (such as once a week or every two weeks). Use special chain lubricants or gear oils and evenly apply them to the surfaces of the chains and gears to ensure that they can transmit smoothly during operation, reducing noise and wear. When lubricating the drive chain, pay attention to cleaning the oil stains and impurities on the chain surface to avoid impurities mixing into the lubricating oil and accelerating the wear of the parts.
(III) Checking Component Connections
Mechanical Connection Parts: Check the mechanical connection parts of the equipment every day, such as whether screws, nuts, bolts, etc. are tightened. Tools such as wrenches can be used to check the connections of important parts one by one to ensure that there is no looseness. If a loose connection is found, it should be tightened in a timely manner to prevent malfunctions caused by component loosening during equipment operation, which may affect the normal operation of the equipment and even cause safety accidents. For example, if the screws at the connection between the bending shaft and the motor of the bending machine are loose, it may cause the bending shaft to rotate unstably and affect the bending accuracy.
Electrical Connection Parts: In addition to mechanical connections, electrical connection parts cannot be ignored. Regularly check whether the joints and plugs of the electrical lines are firm, and whether there are any looseness, oxidation, or damage. For some exposed electrical connection points, pay attention to keeping them clean and dry to avoid poor contact or short - circuit caused by dust, water vapor, etc. If there is a problem with the electrical connection part, it should be repaired or replaced in a timely manner to ensure the normal operation of the electrical system of the equipment. When checking the electrical connection, be sure to cut off the power supply of the equipment first to ensure personal safety.
II. Regular Maintenance
(I) Weekly Maintenance
Tool Inspection: The tool is one of the key components of the wire bending machine, and its wear directly affects the bending quality and equipment performance. Check the tool in detail every week, observe whether the cutting edge of the tool is sharp, and whether there are any wear, nicks, or deformations. If the tool is severely worn, it should be replaced in a timely manner to avoid affecting the bending effect of the wire and causing product size deviations or surface quality problems. At the same time, when installing a new tool, ensure that the tool is firmly installed and in the correct position to avoid tool loosening or deviation during use.
Electrical System Inspection: Conduct a comprehensive inspection of the electrical system of the equipment every week. Check whether there are signs of overheating or burning of the electrical components in the electrical box, and whether the wiring of each electrical component is firm, without looseness or falling off. Use professional electrical testing tools, such as multimeters, to detect whether the voltage and current of the electrical lines are normal to ensure the stable operation of the electrical system. In addition, clean the dust in the electrical box to prevent excessive dust accumulation from affecting the heat dissipation of the electrical components and triggering electrical failures.
Hydraulic System Inspection (if available): If the equipment is equipped with a hydraulic system, check the oil level and oil quality of the hydraulic oil every week. The oil level should be maintained within the specified range. If the oil level is too low, it may cause the hydraulic system to fail to work properly, resulting in problems such as insufficient pressure. Judge whether the oil quality is good by observing the color and transparency of the hydraulic oil. If the color of the hydraulic oil becomes dark, turbid, or there are impurities, it indicates that the oil quality has deteriorated and needs to be replaced in a timely manner. At the same time, check whether there are any oil leaks in the pipelines, joints, and other parts of the hydraulic system. If there is an oil leak, it should be repaired in a timely manner to avoid environmental pollution and equipment failures caused by hydraulic oil leakage.
(II) Monthly Maintenance
Accuracy Calibration: Calibrate the accuracy of the wire bending machine once a month to ensure that the equipment can continuously provide high - precision bending processing. Use professional measuring tools, such as calipers and angle gauges, to measure the key parameters of the equipment, such as bending angle and length, and compare them with the standard parameters of the equipment. If the parameter deviation exceeds the allowable range, the accuracy should be adjusted according to the operation manual of the equipment. For example, adjust the control system parameters of the equipment or the position of the mechanical parts to correct the deviation of the bending angle and length and ensure the stability of product quality.
Filter Replacement: Filters in the equipment, such as air filters and hydraulic oil filters, will filter out dust, impurities in the air, and contaminants in the hydraulic oil during use. Over time, the filters will gradually become clogged, affecting the normal operation of the equipment. According to the use of the equipment, check and replace the filters monthly. For the air filter, if there is too much dust on its surface, cleaning can be tried first, such as using compressed air to blow off the dust in the opposite direction. However, if the effect is still not satisfactory after cleaning, or if the service life of the filter has reached the specified period, a new filter should be replaced in a timely manner. The hydraulic oil filter needs to be replaced regularly according to the pollution degree of the hydraulic oil to ensure the cleanliness of the hydraulic oil and extend the service life of the hydraulic system.
Transmission System Inspection: Conduct an in - depth inspection of the transmission system of the equipment every month, including the tension of belts and chains, and the meshing of gears. For the belt drive system, check whether the belt is loose, worn, or broken, and adjust the tension of the belt by adjusting the position of the pulley to ensure that the belt does not slip during transmission. For the chain drive system, in addition to checking the tension of the chain, also check whether the chain links are loose, deformed, or severely worn, and replace them if necessary. At the same time, check whether there are any wear, cracks, or other defects on the tooth surface of the gear, and whether the meshing clearance of the gear is normal. If there are any abnormalities, they should be repaired or adjusted in a timely manner to ensure the smooth operation of the transmission system, reduce the energy consumption and noise of the equipment.
(III) Quarterly Maintenance
Comprehensive Inspection of Mechanical Parts: Conduct a comprehensive inspection of the mechanical parts of the equipment every quarter, including key parts such as bending shafts, guide rails, sliders, and bearings. Check whether the bending shaft is bent or worn, and whether the roughness of its surface meets the requirements. If there are problems, it needs to be repaired or replaced in a timely manner. For the guide rails, check their straightness and flatness, and whether the lubrication on the guide rail surface is good, and whether there are any scratches, wear, or other marks. Whether the slider runs smoothly and whether the fit clearance with the guide rail is normal. If the clearance is too large, it may cause the equipment to run unstably and affect the bending accuracy. In addition, check the rotation flexibility of the bearing, whether there is any jamming or abnormal noise. Judge the working state of the bearing by detecting its temperature. If the bearing temperature is too high, it may indicate that the bearing is damaged or the lubrication is poor, and it needs to be dealt with in a timely manner.
In - depth Maintenance of the Electrical System: During quarterly maintenance, conduct in - depth maintenance of the electrical system. In addition to the routine work of checking electrical connections and cleaning the electrical box, also check and maintain the control system of the equipment. Back up the data of the control system of the equipment to prevent data loss. Check whether the software version of the control system is the latest, and if necessary, upgrade the software in a timely manner to obtain better equipment performance and function optimization. At the same time, detect the grounding of the electrical system to ensure that the grounding resistance meets the requirements and guarantee the electrical safety of the equipment. Use professional electrical testing equipment, such as insulation resistance testers, to test the insulation performance of the electrical lines. If the insulation resistance is too low, there may be a risk of electric leakage, and the cause needs to be found and repaired in a timely manner.
Hydraulic System Maintenance (if available): If the equipment is equipped with a hydraulic system, conduct a comprehensive maintenance of the hydraulic system every quarter. In addition to replacing the hydraulic oil and filter, also check the working performance of the hydraulic pump, test whether its output pressure is stable, and whether the flow rate meets the working requirements of the equipment. Check whether the valve core of the hydraulic valve is flexible, without jamming, and whether the sealing performance of each hydraulic valve is good. If there is a leak, replace the sealing parts in a timely manner. In addition, conduct a comprehensive inspection of the pipelines of the hydraulic system, check whether the pipelines are aging, damaged, or deformed. Replace the pipelines with potential safety hazards in a timely manner to ensure the safe and reliable operation of the hydraulic system.
(IV) Annual Maintenance
Overall Cleaning and Maintenance of the Equipment: Conduct a comprehensive cleaning and maintenance of the equipment once a year, including disassembling, cleaning, and reassembling each part of the equipment. Thoroughly clean the machine body, workbench, mold, transmission parts, electrical box, and other parts of the equipment to remove long - accumulated oil stains, dust, iron filings, and other impurities. For some parts that are difficult to clean, special cleaning agents and tools can be used for treatment. During the cleaning process, carefully check the wear of each part. For parts that are severely worn or have reached the end of their service life, replace them in a timely manner. For example, after disassembling and cleaning the guide rails of the equipment, check the wear degree of the guide rails. If the wear amount exceeds the specified range, replace the new guide rails to ensure the running accuracy and stability of the equipment.
Performance Testing and Debugging: During annual maintenance, conduct a comprehensive testing and debugging of the equipment performance. Use professional testing equipment and tools to test the key performance indicators of the equipment, such as bending accuracy, speed, and force, and compare the test results with the factory standards of the equipment. If the equipment performance shows deviations, the equipment needs to be debugged and optimized. For example, adjust the mechanical structure, electrical parameters, or hydraulic system pressure of the equipment to improve the performance of the equipment. At the same time, check and test the safety protection devices of the equipment to ensure that their functions are normal, such as whether the emergency stop button is sensitive and reliable, and whether the interlock device of the protective door is effective, to ensure the safety of the equipment during operation.
Replacement of Vulnerable Parts: According to the use of the equipment and maintenance records, conduct a comprehensive inspection and replacement of the vulnerable parts of the equipment every year. Vulnerable parts include tools, molds, belts, chains, bearings, seals, etc. These parts are prone to wear or damage during the long - term operation of the equipment. Regular replacement of vulnerable parts can effectively prevent equipment failures and ensure the normal operation of the equipment. When replacing vulnerable parts, select high - quality accessories that are reliable in quality and meet the equipment specifications, and install them strictly in accordance with the installation requirements of the equipment to ensure that the replaced parts can work properly. At the same time, record and analyze the replaced vulnerable parts to understand their service life and failure reasons, providing a reference for subsequent maintenance work.
III. Maintenance in Special Situations
(I) Restart after Long - term Shutdown
Comprehensive Inspection: When the equipment is restarted after a long - term shutdown (such as more than one month), first conduct a comprehensive inspection of the equipment. Check whether the appearance of the equipment is damaged or deformed, and whether the connections of each part are loose. Clean the dust and sundries on the surface and inside of the equipment, especially in the electrical box, transmission parts, and other parts, to prevent dust and other impurities from affecting the normal operation of the equipment.
Lubrication Treatment: Re - lubricate all the lubrication points of the equipment to ensure that each part can be well lubricated after startup. Long - term shutdown may cause the lubricating oil to dry up or drain away, so it is crucial to replenish the lubricating oil before restarting. For some equipment with an automatic lubrication system, check the oil level and oil quality of the lubricating oil tank, and replace the new lubricating oil if necessary. At the same time, start the lubrication system of the equipment and let the lubricating oil circulate inside the equipment for a period of time to ensure that each lubrication part can be fully lubricated.
Electrical System Inspection: Carefully check the electrical system, including whether the connections of the electrical lines are firm, and whether there are any short - circuits or open - circuits. Use an insulation resistance tester to detect the insulation performance of the electrical lines to ensure that the insulation resistance meets the requirements. Check whether there are any signs of moisture or rust on the electrical components in the electrical box. If necessary, clean and dry the electrical components. In addition, check the control system of the equipment to ensure that it can be started and operated normally, and back up and restore the data of the control system to ensure that the control parameters of the equipment are correct.
No - load Test Run: After completing the above inspections and treatments, conduct a no - load test run of the equipment. First, start the auxiliary systems of the equipment, such as the lubrication system and the cooling system, and observe whether they are operating normally. Then, slowly start the main motor of the equipment according to the operating procedures of the equipment, and let the equipment run under no - load conditions for a period of time (such as 15 - 30 minutes). During the test run, closely observe the operation of the equipment, such as whether there is any abnormal noise, vibration, and whether the movement of each part is smooth. At the same time, check the various parameters of the equipment, such as temperature, pressure, and rotation speed, to see if they are normal. If there is any abnormality, stop the machine immediately for inspection and troubleshooting. Only after the equipment runs normally can it be put into formal production.
(II) After the Equipment Malfunctions
Immediately Stop the Machine: Once a malfunction is detected in the equipment, such as abnormal noise, vibration, smoking, strange smell, or sudden stop of the equipment operation, immediately press the emergency stop button of the equipment to stop the equipment operation, avoid the further expansion of the malfunction, and ensure the personal safety of the operator.
Troubleshooting: Under the condition of ensuring safety, conduct troubleshooting on the equipment. First, observe the fault phenomenon of the equipment, such as the operating state of the equipment when the fault occurs, alarm information, etc., and initially judge the type of the fault and the possible parts where the fault occurs. Then, according to the maintenance manual and fault diagnosis process of the equipment, gradually check each system and component of the equipment. For example, if the equipment gives an electrical fault alarm, first check whether the electrical components in the electrical box are damaged, short - circuited, etc., and then check whether the connections of the electrical lines are normal; if the equipment has a mechanical fault, such as component jamming or unsmooth movement, check whether the relevant mechanical parts are worn, deformed, loose, etc. During the troubleshooting process, some professional testing tools, such as multimeters, oscilloscopes, vibration testers, etc., can be used to help accurately judge the cause of the fault.
Repair and Treatment: According to the results of troubleshooting, repair and treat the equipment. For some simple faults, such as loose screws and dirty component surfaces, they can be repaired by the operator or maintenance personnel themselves. However, for more complex faults, such as electrical control system failures and hydraulic system leaks, contact the equipment manufacturer or a professional maintenance institution in a timely manner for repair. During the repair process, the maintenance personnel should strictly operate in accordance with the repair manual and operating procedures of the equipment to ensure the repair quality. At the same time, record the repair process, including fault phenomena, fault causes, repair measures, replaced parts, etc., for subsequent reference
