How to maintain the flattening machine?

How to maintain the flattening machine?  
Flattening machine is a device used in the field of metal processing, widely used in the processing of metals such as aluminum, copper, stainless steel, etc. The flattening machine reduces the thickness, increases the width, and changes the shape of metal sheets, profiles, and other objects through pressing action. The operation and high-intensity operation of the flattening machine require that its maintenance work be highly valued. Proper maintenance and upkeep can not only extend the service life of equipment, but also ensure production efficiency, reduce the occurrence of failures, and ensure work safety.
This article will provide a detailed introduction to the daily maintenance, regular maintenance, common fault diagnosis and handling of the flattening machine.

1、 Structure and working principle of flattening machine
The flattening machine mainly consists of the following parts:
Hydraulic system: The hydraulic pump station, hydraulic cylinder, and hydraulic valve constitute the hydraulic system, which is used to provide the power for compression.
Drive system: usually composed of an electric motor and a transmission system, used to drive the flattening machine to work.
Workbench and work rolls: The workbench provides the position of the material to be processed, and the work rolls press the material by rotating.
Control system: The electronic control system is used to regulate the working pressure, speed, and operating time of the flattening machine.
The working principle of a flattening machine is mainly to apply tremendous pressure to the material through a hydraulic system, causing its thickness to decrease and shape to change. The hydraulic system adjusts the working pressure and speed through the control system to ensure the compression process and stability.

2、 Daily maintenance of flattening machine
1. Cleaning work
Cleaning is an important means to keep the flattening machine running. After daily work, the flattening machine should be cleaned to prevent the accumulation of metal shavings, oil stains, and dust. Especially during the processing, waste and metal particles will flow out with the work, and long-term failure to clean them may increase the frictional resistance of the equipment, affecting the efficiency of machine operation.
Cleaning hydraulic system: Leakage and contamination of hydraulic oil are common problems, and it is necessary to regularly clean the oil tank, pipelines, and hydraulic components to ensure the smooth operation of the hydraulic system.
Clean the workbench and rollers: Metal shavings, oil stains, etc. on the workbench and rollers should be cleaned in a timely manner to avoid excessive accumulation that affects the quality of work and equipment operation.
2. Check and lubricate with oil
Many components of the flattening machine, such as the transmission system, hydraulic system, bearings, etc., require lubrication. Regular refueling and inspection of the lubrication system are key to maintaining the normal operation of the equipment.
Lubricating oil replacement: Check the oil level and quality of hydraulic oil, gear oil, and other lubricating oils every month or at regular intervals, and replace them if necessary.
Lubrication point inspection: Especially for bearings, gears, and other moving parts, it is necessary to regularly add lubricating oil. Check whether the lubricating oil has deteriorated or been contaminated, and clean the oil tank and oil system in a timely manner.
3. Check the hydraulic system
The hydraulic system is the core part of the flattening machine, and ensuring its stability and sealing is the foundation for maintaining the long-term normal operation of the equipment.
Hydraulic oil inspection: Check the oil level and quality to ensure the cleanliness of the hydraulic oil and avoid contamination of the oil. When the hydraulic oil is insufficient, it should be replenished in a timely manner, and when the oil is contaminated, it needs to be replaced.
Hydraulic pipeline inspection: Regularly check for leaks in hydraulic pipelines. If aging or cracks are found in the pipelines, they should be replaced in a timely manner.
Hydraulic cylinder inspection: The sealing ring of the hydraulic cylinder may be worn out. Regularly check the condition of the sealing components and replace them if necessary.
4. Check the electrical system
The electrical system involves control and drive systems, and maintaining the stability of the electrical system can prevent equipment from shutting down due to electrical faults.
Electrical control system inspection: Check whether the wiring inside the electrical control cabinet is loose, damaged, or aged, ensure that the wiring terminals are securely fastened, and inspect the working status of electrical components such as switches and relays.
Motor inspection: Regularly check the operating status of the motor, check the temperature, noise, etc. of the motor, and promptly handle any abnormalities found.
5. Adjustment and Calibration
After long-term use, the working accuracy of the flattening machine may deviate, and regular adjustment and calibration are necessary steps to ensure equipment accuracy and production efficiency.
Pressure adjustment: Regularly adjust the working pressure of the hydraulic system according to production needs to ensure that the pressure remains within an appropriate range.
Roller alignment: Regularly check the alignment of the working roller to prevent uneven pressing caused by roller offset, which may affect product quality.
Speed adjustment: Adjust the working speed of the flattening machine according to the type of material and processing requirements to ensure stable working output.
6. Check the safety protection device
Safety protection devices are an important guarantee for ensuring the safety of operators. Regularly check the effectiveness of safety protection devices to ensure the safety of the working environment.
Protective device inspection: Ensure that the protective railing, safety switch, and emergency stop button of the flattening machine are functioning properly.
Alarm device inspection: Check whether the alarm system of the equipment is sensitive, ensure that it can issue an alarm in a timely manner in case of equipment failure, and avoid accidents.

3、 Regular maintenance of flattening machine
1. Inspection of hydraulic system
The hydraulic system is a critical part of the flattening machine, and regular inspections are very important.
Hydraulic oil replacement: Regularly replace hydraulic oil based on equipment usage and hydraulic oil quality. It is generally recommended to replace hydraulic oil every 6 months to 1 year, and if the oil quality is poor, it needs to be replaced in advance.
Cleaning or replacement of filter element: The oil filter element in the hydraulic system needs to be cleaned or replaced regularly to prevent impurities from entering the hydraulic system and affecting the working efficiency of hydraulic components.
Hydraulic component inspection: Regularly inspect hydraulic components such as hydraulic pumps, hydraulic cylinders, valves, etc. to ensure that they have no leaks, wear, or abnormal noise.
2. Maintenance of motors and electrical components
Motor lubrication: Check the lubrication condition of the motor bearings. If insufficient or deteriorated lubricating oil is found, it should be replenished or replaced in a timely manner.
Electrical system cleaning: Dust and debris inside the electrical cabinet need to be cleaned regularly to avoid affecting the heat dissipation and normal operation of the electrical system.
Wire and cable inspection: Regularly check whether the outer skin of the wire and cable is damaged, whether the joints are loose, and repair and replace them in a timely manner.
3. Maintenance of bearings and transmission systems
The bearings and transmission system of the flattening machine bear a huge load, and regular inspection and maintenance can effectively extend its service life.
Bearing lubrication: Regularly check the lubricating oil of the bearings to ensure that it is sufficient and clean. For high load working environments, high-performance lubricants or greases should be considered for use.
Transmission chain inspection: Check the wear of components such as chains, gears, belts, etc. in the transmission system. If looseness or excessive wear is found, adjust or replace them in a timely manner.
Transmission system cleaning: Clean the dirt on the transmission components to prevent dust, metal shavings, and other debris from entering the transmission system, which can lead to increased wear.
4. Whole machine inspection and calibration
Flattening accuracy calibration: Regularly calibrate the accuracy of the flattening machine to ensure that the position accuracy and working accuracy of components such as the workbench and rollers meet the requirements.
Pressure testing: Conduct pressure testing on the hydraulic system to ensure its stability and ability to operate normally under high load conditions.
Functional testing: Check if all functions are functioning properly, including hydraulic system, drive system, control system, etc.

4、 Common fault diagnosis and handling
1. Hydraulic system malfunction
Fault symptoms: Insufficient hydraulic system pressure, slow action, or inability to function properly.
Reason for malfunction: Insufficient or contaminated hydraulic oil, damaged hydraulic pump, oil pipe leakage.
Solution: Check the hydraulic oil level, replenish the hydraulic oil, and replace the oil filter element; Check whether there is oil leakage in the oil pipes, joints, etc., and repair the leakage points; Check the working status of the hydraulic pump and hydraulic cylinder, and replace them if necessary.
2. Electrical system malfunction
Fault symptoms: The motor cannot start, the control system fails, and the alarm system does not respond.
Reason for malfunction: Loose electrical circuit, damaged electrical components, control system malfunction.
Solution: Check if the electrical circuit is normal and ensure that the wiring terminals are secure; Check if electrical components are damaged, such as relays, contactors, etc., and replace them in a timely manner.
3. Transmission system malfunction
Fault phenomenon: Abnormal noise, vibration, and poor transmission of transmission components.
Reason for malfunction: Loose transmission chain, worn gears, insufficient lubricating oil.
Solution: Check if the chain is loose, adjust or replace it; Check the wear of the gears and replace them if necessary; Check the lubricating oil, replenish or replace the lubricating oil.

5、 Summary
As a high-precision and high load metal processing equipment, the flattening machine requires regular maintenance and upkeep to ensure its long-term stable operation. Daily cleaning, lubrication, inspection of hydraulic and electrical systems, adjustment of equipment accuracy, and other maintenance work are all key to ensuring the normal operation of equipment. Regular maintenance measures such as replacing hydraulic oil, inspecting motors, and cleaning transmission systems can not only extend the service life of the flattening machine, but also improve production efficiency, reduce downtime due to malfunctions, and ensure smooth and safe production processes.