Daily maintenance and care tips for medium and large turning centers

In the field of mechanical processing, medium and large turning centers are high-precision and high-efficiency core equipment, and their operating stability directly affects production efficiency and processing quality. Through scientific daily maintenance and care, not only can the equipment life be extended and the failure rate be reduced, but also the downtime cost can be significantly reduced. This article will summarize a set of systematic maintenance solutions based on actual application scenarios.

 

1. The principle of "three inspections and three cleanings" before daily startup

Check the status of the lubrication system

 

Confirm that the oil circuits of key parts such as the spindle box, guide rails, and lead screws are unobstructed, and observe whether the amount of lubricating oil meets the standard (it is recommended to use the lubricating oil of the specified model of the equipment).

 

Manually press the lubrication pump to test the oil supply to avoid dry friction caused by oil pipe blockage.

 

Clean up chips and coolant residues

 

Use a magnetic separator to clean iron chips, and use a high-pressure air gun to blow hidden areas such as the workbench and the inside of the turret (pay attention to wearing protective glasses).

 

Check the coolant concentration (recommended ratio 1:10-1:15), and replenish or replace the deteriorated liquid in time to prevent tool rust.

 

Detect air pressure and hydraulic stability

 

Confirm that the air source pressure is stable at 0.5-0.7MPa, and check whether the air pipe joint is leaking; the hydraulic system needs to observe whether the cylinder movement is smooth and check for oil leakage.

 

2. "Sensory Monitoring Method" in Operation

Abnormal sound identification and positioning

 

If there is a sharp whistle when the spindle accelerates, it may be due to insufficient bearing preload; if the turret rotates with a dull impact sound, it is necessary to check the wear of the positioning pin.

 

Temperature abnormality warning

 

Use an infrared thermometer to monitor the temperature of the front bearing of the spindle (normal range ≤65℃). If the temperature rises by more than 10%, the machine should be stopped immediately for investigation.

 

Quantitative management of vibration amplitude

 

When the X/Y/Z axis moves, use a handheld vibration meter to detect the vibration value (usually <2.5mm/s). Abnormal vibration may indicate damage to the screw support bearing.

 

3. Key points of periodic deep maintenance

(Must do every week)

Special maintenance of guide rails and lead screws

Remove the protective cover, wipe the raceway surface with non-woven cloth dipped in special guide rail oil (such as ISO VG68), remove hard particles, and prevent scratches on the precision track.

 

Tool magazine system optimization

Check the positioning accuracy of the tool change manipulator, use the gauge block to test the repeated positioning error (allowable value ≤0.02mm), adjust the spring tension or replace the worn cam.

 

(Must do every month)

Electrical system deep inspection

Use a megohmmeter to measure the insulation resistance of the motor (standard ≥5MΩ), clean the dust on the filter of the electric control cabinet, and tighten the servo drive terminal.

 

Comprehensive cleaning of the cooling system

Disassemble the filter to clean the scale, and use 5% citric acid solution to circulate and flush the pipes to completely kill anaerobic bacteria and eliminate odors.

 

4. Application of intelligent maintenance tools

Equipment Health Management System (PHM)

By installing vibration sensors and temperature sensors to collect data in real time, combined with AI algorithms to predict the remaining life of bearings, preventive maintenance can be achieved.

 

Electronic inspection QR code system

Post QR codes on key parts of the equipment. Scan the code to call up the maintenance video, spare parts model and replacement standard process of the component.

 

V. Sealing protection for long-term shutdown

If the equipment is out of service for more than 30 days, the following shall be performed:

 

Apply anti-rust grease to each guide rail surface (lithium-based grease is recommended)

 

Run the spindle at 50% rated speed for 30 minutes to evenly distribute the lubricating oil

 

Release the pressure of the hydraulic system before cutting off the main power supply to avoid long-term compression and deformation of the seal

 

The maintenance of medium and large turning centers is not a simple cleaning and refueling, but requires the establishment of a full life cycle management system from daily inspection to predictive maintenance. By cultivating the "equipment health management awareness" of operators and combining the application of digital tools, the overall equipment efficiency (OEE) can be effectively improved, providing a solid guarantee for the lean production of enterprises