Trouble shooting for die cast machine customer service department of L.K Group
A. Faults Detect and the Steps for Repair Important When faults occurred on die casting machine operation. Operators should pay a high attention to the phenomenon of fails. And, smartly investigate,find the place of fails occurred and possible causes. Operators must be reminded that the procession must be in accordance with the Working instruction which manufacturer has made, and to stop machine as soon as possible, reports the fault to professional persons. Please don t operate by violate the operation process, to avoid cause harmful events. The operators must accords with the steps below.
Attention: the steps below must been processed by a qualified professional 1. ask persons when a fault occurred, the person who want to maintain it, the first important thing is to ask the operator. Which time which position the fault occurred, and like anybody have done something for the machine? to look up the fields of fails occurred are very important
2 Investigate Investigate the operate records with equipment and repair record We are all a good policemen, to investigate the case records is very important 3 Initial detect Under ensure of safety, through the noise smell,the feels of touch,temperatures, and vibration. Investigate the phenomenon of fails of parts,to detect with the position of fails occurred initially
4 To understand the phenomenon of fails To understand the phenomenon of fails and analyze root cause by use of tool of measurement 5 Issues the planning of repair repair?replacement? modification?
6 Root cause Repair machine and implementing the countermeasure to weep the root cause out. not only restore production by the replacement of parts,to find root causes out even to focused with the phenomenon that seemed do not related with real cause,generally speaking the cause of fails is a connected links
7 test of equipment Be sure that the fails had already been sweep out. Restore production Ensure normal of safety by check. 8 Recording and interval proceed with the check
The steps above are not fixed. especially the sequence is depend on the mastering level of machine of you and to change. when implementing repair please pay attention to the several point below: 1 pay attention to all the indicate lamps thoroughly use the data that provided with equipments and other all indications Including the displays unit and terminals operation current meters, voltage meters, PCB (printed circuit board )indicating lamps. PLC. (industrial computer )indicating lamps. machine status indication. LED lamps. will provide the much useful information with your Job being simplified.
2 Ensure the root cause Before find the root case out do not urgently disassemble the machine or replace parts, be attention for that you must to fine the root cause out. ask for more :why does fails has occurred? Otherwise probably you can t repair the machine with the root cause
3 Find a good point to start your check. Find causes with the checking of the machine one by one that according to the procedure of movement of operation of machine and the signal interchange process of machine or revert the sequence of steps that from last one to first one. or you can cut into with the middle process to start. some times The last methods are very useful 4 must implements with the pre operation of equipment.not only ensure that the machine can be normally running and must ensure that safety units are with normal.
B. Classification of fails According with the causes of fail,generally Classification of causes of fails is consist with the several items below: 1 improper adjustment. the improper adjustment, for example improper adjustment of parameters of pressure, speeds, temperatures distances positions, flow amounts, times. these parameters are often use with touch screens,digital operating switches, adjusting bolt, potentiometers, handles, keyboards,to correct with.
2 Process unmatched. If equipment are not matched with the current production process or peripheral equipments.you can change to another current production process or use suitable machine to meet production demand. but with need of support of professionals. 3 Unmatched of parts Improper repair of equipment or used the unmatched fragile parts.
4 Aging Equipment aging,parts damage. has often occurred in for example the actuator of machine interface of PCB part. seal parts. 5 Designing, manufacturing, fabrication of equipment are not proper, potential defect will be revealed during the use of the equipment.
C. Hot chamber die casting machine with the common fails and method of repair For example: L.K Group manufactured AVIS DC88 TYPE, Hot chamber die casting machine.
The outline for principle of electric circuits Fig-1 Fig-2 Fig-3
The selection for point of hands: fails analyze hands on point is that whether the running indication lamp lighted or not: when machine indication lamp has damaged you will also can proceeds by the steps below:
1 14channel amplifier boards has been signaled or not 2 PLC (computer) output of module has output.
3.P.Q manifold valve current meter indicate flows of current. 4.The main pressure meter with the pressure or not.
1 No clamping phenomenon: pushed buttons of mould close with manual mode,auto/semi auto mode. With the proper position of door close,the toggle units of machine do not running. Please be attention and to study: Die clamping movement procedure The hands on point for the checking of die clamping movement procedure The method for checking every steps of die clamping movement Checking method with every parts Other simple fails of movement is also can be checking according to the checking method above.
The signal process for the valve of die clamping AC220Vpower voltage stabilize power (AC220V/DC24V) main control command PLC input PLC output 14channel amplifier boards lead level oil valve main oil valve oil cylinder The pressure signal process for die clamping movement. AC220V power voltage stabilizer power(ac220v/dc24v) P-01board pressure meter counter PLC pressure signal output PQ valve relief valve pressure start up. Die clamping oil channel drawing 14channel amplifier P-01board
1 Checking the clamping indicator lamp been lighted or not. 2 When die clamping indicator lamp is off, checking the input condition of computer has bee satisfied: check door closed in proper position(or push die clamping button by two hands)with the hand mode die lamping button plunger back in proper position ejector pin back in the specified position,before die clamping movement the core extract 1 and core extract 2 has in the specified position after die clamping the movement will be back to specified position. 3 Checking the 14 channel amplifier board
4 when die clamping indicator lamp lighted check if main pressure meter has pressure or not. 5 when main pressure meter hasn t pressure, to checking the setting of die clamping pressure, if setting is correct to proceeded as fails of system of main pressure. 6 When main pressure meter has pressure, checking the wire connecting of die clamping and the relay connect status of die closing with reach to the specified position.
AVIS DC88change of die clamping pressure speed
7 when system have pressure,die clamping valve got electricity signal checking valve core of die clamping has chocked or not. to judging with investigate the die clamping pipe. 8 checking toggle has chock up or not. 9 check the oil cylinder of die clamping has leakage or not.
2 no open of die 1 check die open lamp is lighted or not 2 check the computer input condition been satisfied or not: with hand mode check the plunger back in the specified position or not, and input of seconds speed crutches,of die open buttons, die clamping buttons,shooting buttons and die open finishing switches have has no input,before the core extract with die clamping movement has in the proper position,after die clamping will back to the specified position. 3 Check the 14Channel amplified board.
4 When die opening indicator lamp lighted, check main pressure meter has pressure or not. 5 When main pressure have no pressure, check the setting of main pressure the setting of die opening pressure, if setting is correct proceeded as the fails of system main pressure does not work. 6 If main pressure have pressure, check the wire connecting of die open valve.
7,AVIS DC88 speed change of mould open,as the charts below. 88
7 system has pressure, when die opening valve got electricity. checks die opening valve core has chock up or not with investigate the oil pipe of mould open. 8 check the toggle has chock up or not. 9 checks die clamping oil cylinders has severe oil leakage or not.
10 After stops the machine with the die clamping tightened,when a long time past can causes the no open of die,in this case of adjust the main pressure with 99, select the high speed mode of die open and push the pressure start buttons, and push the die opening buttons to doing die open operation. drop the die fix screws and doing die opening with in needs of.
3 No injection 1 checks the injection indicator lamps is lighted or not 2 when injection lamp does not lighted. check computer input conditions has been satisfied or not :with hand mode to check die close button, injection button, door closed with the required position, confirm the finish of die close, check before nozzle forwards with required position, core extract with the required position has been inputted. 3 check 14 channel amplifier.
4 Auto mode Check the value of digital counter of injection time identify the nozzle fix time has already up. 5 when injection indicator lamp lighted, check main pressure meters with the indicate of pressure or not. 6 when main pressure indicating with no pressure, check the setting of main pressure meters, if setting is correct, proceed as the fails of main pressure of system does not work.
7 main pressure indicating with pressure, check whether injection pressure is too low or not. 8 check the wire connects of injection valve 9 check relay: including the relay of door close with proper position, relay of die clamping with proper position,the contact point of relay for before nozzle forwards with proper position whether bourn down or not. 10 If system has pressure, injection valve got electricity, to check plunger is chock up or not. 11 check injection valve core is chocked up or not
4.No enough force with injection 1 check if pressure is too low or not with during injection procession,there should be within10% of working pressure to dropping normally. If pressure of nitrogen is enough or too high. check the piston type of charge accumulator has a larger of hydraulic oils entered into the gas cavity. 2 check pressure of charge accumulators for product extractors, for example the classic DC88 hot chamber air bag is 40~45har,AVIS DC88 piston type charge accumulators pressure of nitrogen is 50~60bar Hot chamber N2
3 The adjusting of the first speeds and seconds speeds is properly or not 4 check 14 channel amplifier check that the seconds speeds volume has got electricity. 5 first speeds forward distance is too long or not 6 setting of pressure values of main pressure meter is too low or not.
7 whether the metal bottle and metal tube has bee jammed or not, the cut face of dimensions has be reduced or not. and nozzle header has bee jammed or not. 8 the tube of metal bottle or steel rings has been worn or not. 9 plunge shaft is too long or not. 10 the weights of product is too light or not. Stroke of injection has not reached with the 1/3 of injection stroke the injection process already finished.
5.The hydraulic system without main pressure 1 button of pressure start is normal or not 2 pressure manifold valve current meter has current flows or not 3 if has no current flows check amplify boards is normal or not, wire ring of electric P.Q valve has shorted or not 4 if has current flow to checks the adjustments of overflow valve is proper or not,whether is chock up or not. 5 electric P.Q manifold valve has chock up or not 油 路 图
6 check the hydraulic pressure pump rotating with reversely or not the correct rotating directions is clockwise when looking from the machine body side 7 oil level is proper or not oil quality is severely change or the temperature of oil is too high or not 8 the oil pump has been damaged or not 9 General pressure digital counter is normal or not 10 if hydraulic system is severely leaked within inside. 11 PLC(computer)is normal or not.
6 No spray 1 check the lamps of spray is normal or not, if don t be on check spray buttons, die opening finishing buttons should has the input, check 14 channel amplifier boards. In the auto mode select spray button, die opening finishing buttons the door closed with proper positions should has the input, the counter of spray warding time is correct and checking 14 channel amplified boards.
2 If indicator lamp be on,check the pressure of spray warding pressure, spray warding valve, the wire connecting between spray warding and control box is proper or not spray warding tube is flowing freely or not. 3 check the bottles of die open spray on the proper place or not 4 the die open spray is too high of viscosity. we suggest for use the 22zn types of die open spray,that manufactured by shanghai derunbao special die open spray manufacturer.(die-lubric 22zntype)
7 No before nozzles forwarding 1 if indicator lamp is not lighted, with the hand mode check the before nozzle forwarding buttons should has inputs and after nozzle forwarding has no input. with the auto mode die is close should be in the proper positions when door is closed with the proper positions and core extract is on the proper position and checking the 14 channel amplified boards. 2 If no indicator lamp is no check the setting of valve of injection pressure is too low or not, check the before nozzle forwarding valve and the connects between the before nozzle forwarding and electricity control box.
8 No after nozzle forwarding 1 if indicator lamp is not be on with the hand mode check after nozzle forwarding button and plunger back to the specified position has the input, before nozzle for forwarding has no input.with the auto mode plunger back to the specified position, disengage select switch has the input and nozzle disengage time has been up or not. 2 if indicator lamp be on,check the 14channel amplifier the pressure of die open (disengagement use the settings value of die close,connecting between the disengagement and control box is proper or not.
9 Can not die adjusting 1 if can not adjust the die thickness to check the input of the die thickness button and die thin button and no input with the auto mode and sweeper back to the specified position with the semiautomatic mode ( no need with no select of sweepers )and the input of the die adjust selector.
2 if indicating lamp is in on check the if setting of pressure of ejector pin is too low,valve of ejector, pin,the connects between valve of ejector pin and electric control box.check if the oil tank of eject pin has severe leaks or not,if die ejector pin is too tights or not.
3. when cannot doing the die thin adjustment,to check the input for die thin adjustment, no input with the die thickness adjust buttons and auto mode and semi auto mode, sweepers back to limits position (no need for no select) the select input for die adjust. 4.when use hydraulic for die adjustment,check setting value of pressure, valve for die adjustment. Hydraulic motor for die adjustment. When use motors for die adjustment to check the connectors, thermo relay,motors.
10,No eject forwarding 1 If the lamp is not lighted, check the input of eject forwarding buttons die open to specified position with hand mode, has no input for eject pin forwarding to limit place, core extract will back to proper place when select core extract. Die open to specified position with auto mode,no input with eject forwarding to limit,core extract to the limit place when select core extract, the setting values fore eject frequency and time of eject is correct,to check 14 amplified boards.
11 No ejection 1 if indicator lamp is on "check plunger buttons with hand mode, the input with finishing of die open. to check the plunger choice switch with auto mode,the counter of plunger time,finishing of die open,the limit of eject pin forwarding should input. check 14 channel amplifier. 2 If the lamp is on check the pressure of plunger, valve of plunger,the connect between the valve of plungers and electrical box and air cylinder.
12 high pressure with system 1 ejector pin has reached with correct position, if not after running the machine that will increasing the pressure of ejector pin. 2 If valve core of P.Q electric manifold has chock up. 3 if the P.Q electric manifold was in normal or not. If the basic current is too larger or not. 4 if overflow valves has been check up or not 5 The sampling screw of P.Q pressure manifold has loosened