1. Scientific analysis of the value of air compressors, reasonable selection of maintenance and renewal
Under the action of various forces, the air compressor causes the parts to be physically worn, deformed and damaged, resulting in changes in the dimensional shape and precision of the parts, or the physical wear caused by the natural force of the air compressor during the idle process. Such as metal parts rust, corrosion, rubber parts aging, etc., these physical wear reduces the performance of the air compressor, thereby affecting product quality. The advancement of science and technology has enabled the more perfect and more efficient air compressors to emerge, and the invisible wear of air compressors has led to the depreciation of the original air compressors. The invisible wear of the air compressor is not caused by the physical friction or the natural force in the production process, but the value of the air compressor caused by the change of the social and economic environment is the result of technological progress. Invisible wear is divided into two forms.
(1) The first type of invisible wear:
The technical structure and performance of the air compressor have not changed, but due to technological advances, the air compressor manufacturing process has been continuously improved, and the socially necessary labor required to produce the same machine air compressor has been reduced, thereby making the original machine air compressor market price Reduced, resulting in the corresponding value of the original air compressor replacement value. For example, the rapid development of the automotive industry has prompted the price of automobiles to decline year by year. This invisible wear causes the value of the air compressor to depreciate, but the technical characteristics and functions of the air compressor itself are not affected, and the use value of the air compressor does not change accordingly, so there is no problem of replacing the existing air compressor in advance. .
(2) The second invisible wear:
Due to the emergence and application of new technologies, new processes and new materials, new air compressors with more advanced structure, better performance, higher efficiency and less energy consumption are continuously innovated. The old machine air compressors have not been reached. Its physical life (operating life), but its productivity has been much lower than the social average. Due to the invention and application of the more technologically advanced new air compressor, the use value of the original air compressor will be partially or completely lost, which leads to the problem of replacing the existing old air compressor with a new air compressor. If you continue to use it, the cost of producing the product will be much higher than the average cost of the society, resulting in an increase in the cost per unit of product and lack of competitiveness in the market. For example, the replacement of the S7 series by the S9 series and the S9 series by the S9 series are becoming more and more energy efficient. To this end, when the air compressor needs overhaul, we need to conduct a comprehensive investigation of the technical status of the air compressor, do a good job in economic analysis, what is the condition of the physical wear and invisible wear of the air compressor, and whether the air compressor is economical, or It is more economical to eliminate, and if the performance is degraded, the function is backward, or the high-energy elimination air compressor that is stipulated by the state is eliminated, there is no need for overhaul and it will be scrapped.
2. Carry out maintenance methods based on condition detection to reduce maintenance costs
With the development of science and technology and social productivity, production efficiency and automation are getting higher and higher. At the same time, air compressors are becoming more and more complex, and the correlation between various parts is getting closer. The small faults in a certain part are continuously reacted, resulting in the whole process. Air compressors and even environmental damage related to air compressors, through the state monitoring of key parts to understand the operating conditions of air compressors, such as monitoring the operating speed of air compressors, oil temperature, sound, etc., so that air compressors can be discovered in time Partial abnormal conditions, timely targeted maintenance, to avoid damage to the air compressor, reduce maintenance costs.
3. Use market maintenance resources to achieve professional maintenance
Under the market economy system, efficiency has become the fundamental and core of enterprise survival. As an important carrier of the operation of modern enterprises, how to adapt the air compressor and its maintenance management to the market requirements, it will be transformed from a means of purely production service to an important lever for the enterprise to pursue the maximum benefit. Market resources, reasonable use of maintenance funds, and cost-effective maintenance benefits with limited maintenance funds. For example, some air compressors with professional speciality, or air compressors that are not qualified for overhaul, the enterprise can contact the manufacturer of the air compressor to be repaired, and entrust the manufacturer to carry out overhaul or trade-in. For example, many companies use the old-fashioned approach to forklift overhaul. For example, the numerical control air compressor and machining center with high precision requirements are sent to the original manufacturer for overhaul, so that the precision performance of the air compressor is effectively guaranteed, thus ensuring the repair quality of the air compressor and improving the equipment quality of the enterprise.
4. Optimize air compressor overhaul management to reduce maintenance waste
Air compressor overhaul is an important part of air compressor maintenance management. During the overhaul process, air compressors involve many factors, which often cause overhaul air compressors to be delivered in time, or overhaul quality cannot meet the specified acceptance criteria. . Therefore, only the main factors affecting the repair quality, repair time, repair cost, etc. during the overhaul process of the air compressor are controlled to ensure that these processes are carried out under controlled conditions, in order to facilitate the timely and quality maintenance of the air compressor and timely delivery. To reduce the manpower and financial resources of overhaul and improve the economic efficiency of enterprises.
(1) Preparing for pre-repair is the basis for ensuring the implementation of overhaul
Pre-repair preparation includes pre-repair technical preparation and pre-treatment material preparation, that is, random files, original records and basis are retrieved from the air compressor file; pre-inspection details on the operation of the air compressor, problems, structure, precision, etc. Understand the technical documents and drawings drawn, and then determine the pre-preparation material preparation according to the technical preparation. Therefore, the perfection and timeliness of the pre-repair preparation work directly affects the quality of the air compressor repair, the number of days of rest and economic benefits, and control. Good air compressor pre-repair preparation, grasp the pre-inspection of air compressor pre-repair, reasonably prepare overhaul technical documents, correctly draw drawings of parts and work inspection tools, fully prepare qualified self-made spare parts, purchase outsourcing accessories, special inspection It will help the air compressor overhaul construction in an orderly manner, ensure the quality of the air compressor overhaul, and complete the overhaul task on time or in advance.
For example, the production of multi-cylinder diesel engine body spindle hole composite fine boring machine (complex coefficient machine 45), due to performance degradation affects product quality, but the air compressor is the key single air compressor for the production of 480, 485 diesel engine, shutdown overhaul press The relevant standard takes more than 100 days to calculate the production of 181 diesel engines in two shifts per day. A total of more than 18,100 480 and 485 diesel engines are produced. The net profit of each diesel engine is 5.2 yuan, which will cause nearly 100,000 yuan loss to the company. . In order to solve the contradiction between production and maintenance, on the one hand, increase production tasks before stopping repairs, to make up for the number of bodies that are stopped for repair and less production, on the other hand, actively prepare for pre-repair, in order to shorten the overhaul time, according to the main body of the machine The drawings and pre-inspection of the hole composite fine boring machine determine the seals and spare parts that should be replaced. Draw the drawing of the spindle hole, clamp, raft, sleeve, etc. of the machine body. Because of the high requirements of the clamp, raft, and sleeve processing, all of them are entrusted with external processing, especially the rafting and sleeve matching gap is only 8um, which has been commissioned by several manufacturers. After failing to meet the requirements of the drawings, a satisfactory part was produced in a factory in Wuxi. Due to sufficient preparation, the part did not affect the execution of the overhaul plan, and the pre-repair preparation was sufficient. The air compressor overhaul did not cause economic losses to the company, and The accuracy performance of the air compressor was restored, the equipment quality of the enterprise was improved, the production stamina of the enterprise was enhanced, the technical requirements of the product were met, and the economic benefits were improved.
(2) Overhaul construction is the key to guarantee the quality of overhaul
Overhaul construction is a concrete manifestation of the implementation of the overhaul plan. It is the main link to change the condition of the air compressor. The overhaul construction includes various aspects such as dismantling, assembly, painting, debugging, etc., while controlling the dismantling, assembly and operation in the construction. The inspection link is the key link to control the construction process. The control and demolition inspection can ensure that the replaced parts can be replaced. The repaired parts can be repaired. The maintenance parts can be well maintained, especially if they can be exposed during the pre-examination. The problem so that it can be resolved at any time with remedial measures. For example, when overhauling a C620-1 type ordinary lathe, the A50 sector gear on the I-axis of the headstock was found to be damaged due to the over-tightening or looseness of the friction plate during use. Quality, timely replenishment of this part, to ensure smooth construction. Control overhaul assembly links to ensure that construction is carried out in accordance with technical drawings, to avoid rework, and to ensure that overhauls are completed on time.
(3) Overhaul acceptance is an evaluation of the quality of overhaul
Overhaul acceptance is an objective evaluation of the quality of overhaul. It is an important means to comprehensively assess whether the quality of air compressor overhaul meets the quality standards of overhaul, and provides a basis for the smooth delivery of air compressors. For example, a special machine tool for producing multi-cylinder diesel engines, after two months of overhaul of the air compressor, the finished products are continuously discarded. The workshop is not in-depth investigation, and the quality of the overhaul is not up to the repair quality. The department took out the evidence of overhaul acceptance, and believed that the accuracy of the waste product and the overhaul air compressor did not meet the requirements. After the air compressor department checked and verified the inspection record of the overhaul, the air compressor overhaul was in line with the product process. Finally, it was found that this quality accident was caused by serious tool wear and improper operation of the operator, which caused the product to be out of tolerance, avoiding the contradiction between the unit of the air compressor and the maintenance unit.
(4) The quality of the major is the guarantee of overhaul
The main repair personnel are the implementers of the overhaul work. Their work ability and technical level are related to the success or failure of the overhaul task. Due to the particularity of the overhaul work, the quality of the main repair personnel is put forward. The senior personnel should have the familiarity. Press structure, understand the performance of air compressor, have a certain theoretical maintenance of air compressor maintenance, especially the basic knowledge of fitter and rich practical operation experience, the ability to find problems and solve problems, and have a high sense of responsibility, Ken Drill down. Therefore, it is necessary to carry out maintenance quality group activities frequently and organize special discussions so that maintenance personnel can continuously improve the maintenance level and improve the quality of maintenance personnel.
(5) Organization and management are the means to achieve overhaul
The overhaul process involves manpower, material resources, financial resources, control over the quality of overhaul, repair time, and repair costs. It involves the management level of the enterprise overhaul, because the types of work involved in overhaul are more complicated, and there are more departments, such as the air compressor department. The machine repair workshop, the use unit, the finance department, the procurement department and other departments participate. Therefore, it is necessary to organize, manage, and coordinate the various types of work and their mutual cooperation. The plan is implemented, the funds are in place, the materials supply is timely, and the quality is guaranteed. For example, when implementing the overhaul plan, organize personnel reasonably, and select more repairing personnel with higher technical level for complex air compressors. For simple air compressors, workers with slightly lower technical grades should be properly matched to make various skill levels. The staff are able to fully display their talents and make the best use of their talents. On the other hand, it is necessary to improve the economic benefits of overhaul and reduce the cost of overhaul, so that the life cycle cost of air compressors is the most economical. For example, if you are overhauling an ordinary lathe, according to the pre-inspection information, you need to replace the spindle box. After analyzing and comparing the market conditions, you need to purchase 5000 yuan for the purchased spindle, and the internal self-made unit only needs 3,000 yuan. Only this box part saved 2,000 yuan.
(6) Summary, data archiving is an inevitable link in overhaul
The summary of the repair is not only a summary of the lessons learned from this overhaul, but also provides valuable reference materials for future overhauls. Therefore, after the overhaul air compressor is used, the repair data must be sorted and archived in time.
Optimize air compressor maintenance management, timely eliminate the failure of production air compressors, ensure normal production, help improve the equipment quality of enterprises, reduce the waste of human and financial resources, and avoid conflicts between air compressors and maintenance departments. Improve the economic efficiency of the company.
