The daily maintenance and repair work of induction furnace is very important. It can detect various hidden dangers in time, avoid major accidents and ensure long-term safe production, and promote the improvement of casting output and quality. See table (1, 2, 3, 4) for the maintenance and overhaul of induction furnace lining, induction coil, windable wire (water-cooled cable), furnace cover, hydraulic system, cooling system, electrical system, etc.
Table 1
Maintenance item | Maintenance and repair content | Maintenance time and frequency | Prepare Note | |
furnace lining | Whether the furnace lining is cracked | Check for cracks in the crucible | Before each start of the cold furnace | If the width of the crack is less than 2mm, and if there is no deep cutting chip and other objects will not be embedded in the crack, it is not necessary to repair, and it can still be used. Otherwise, it needs to be repaired before it can be used |
Repair of liquid outlet | Observe whether there are cracks at the junction of the side fireplace lining and the liquid outlet | When bleeding | Repair cracks if they occur | |
Repair of furnace lining at furnace bottom and slag line | Observe whether the furnace lining at the bottom of the furnace and the slag line is partially corroded | After discharge | If there is obvious corrosion, it needs to be repaired | |
sense answer Wire lock up | Visual inspection | aIs there any foreign matter attached to the surface of the coil? b Are the assembly bolts of the top tightening coil loose? | 1 time/day 1 time/day | Blow with workshop compressed air Tighten the bolts |
Rubber tube | aIs there any looseness at the rubber pipe joint? b Visually inspect the rubber tube for damage | 1 time/day 1 time/week | ||
Cooling water temperature at the coil outlet | Under the condition of rated molten metal volume and rated power, record the maximum and minimum temperature of cooling water in each branch of the coil | 1 time/day | ||
dust | Use workshop compressed air to blow away dust and melt spatter from the coil surface | 1 time/day | ||
Pickling | Pickling of sensor water pipes | 1 time/1-2 years | with 5% dilute hydrochloric acid | |
can be wound Sexual guidance Wire | water cooling cable | aWhether there is water leakage or seepage b check whether the cable touches the furnace pit c Record the cable outlet water temperature at rated power d Whether the water-cooled cable tube is aging and cracked | 1 time/day 1 time/day 1 time/week 1 time/month | |
Table 2
Windable wire | Dry Cable | aRemove the dust on the insulating glued wooden busbar splint b Check whether the suspension bus bar is broken | 1 time/day 1 time/week | |
furnace cover | refractory castable | Visual inspection of the thickness of the refractory filling layer in the furnace cover | 1 time/day | When the thickness of the refractory castable layer remains 1/2, the furnace cover lining should be rebuilt |
add lubricating oil | Furnace cover pivot part | 1 time/week | ||
pour verb: move Oil cylinder | Upper and lower bearing and high pressure pipe of oil cylinder | aIs there any traces of metal melt scald on the bearing part and the high-pressure pipe? b oil leakage | 1 time/week
1 time/day | Observe whether the support under the cylinder is oily or not, and remove the gland for inspection |
Oil Cylinder | a Whether there is leakage in the sealing part b abnormal sound | 1 time/day 1 time/day | When the furnace is tilted, when the oil cylinder block makes a sound such as tapping the oil cylinder, it is mostly due to the lack of oil in the bearing. | |
Tilting furnace limit switch | a movement check Press the limit switch by hand, the oil pump should stop loading b Is there any molten metal splashed on the limit switch? | 1 time/week 1 time/week | ||
add lubricating oil | All fuel fillers | 1 time/week | ||
Low pressure open close cabinet | Knife switch contactor | a Roughness and wear of main contacts b Check whether the auxiliary contacts are in good contact and whether they are worn c Is the arc chute carbonized? d dust eCheck if the screws are loose |
1 time / half a year 1 time / half a year 1 time / half a year 1 time/month 1 time/week | When the roughness is serious, use a file, sandpaper, etc. to level it When the contact is worn by 2/3, replace the contact The carbonized part is polished with fine sandpaper Sweep with workshop compressed air, wipe off dust with a cloth |
Insulation resistance | Use a 1KV megger to measure the insulation resistance between the main circuit and the ground should be greater than 1MW | 1 time/6 months | ||
G | Check if the ground wire is good | 1 time/month |
Table 3
IF power cabinet | Cabinet appearance inspection | a Whether the components are damaged or burnt b Whether the terminals are loose or falling off | 1 time/week | If loose, it may burn out components |
Action test | a Check whether the indicator light indicates whether the overcurrent and overvoltage actions are sensitive. c Whether the furnace leakage, phase loss, lack of water pressure, water temperature alarm, etc. are reliable | 1 time/day | ||
Dust removal in the cabinet | Clean with workshop compressed air | 1 time/week | ||
relay | a Check the roughness of the contacts, and polish them with fine sandpaper if the roughness is serious. b Replace the contacts: if the contacts are severely worn, replace them. | 1 time/3 months | ||
Change pressure device | Check the appearance | a Whether there is seepage and oil leakage b Whether the cooling insulating oil is added to the specified position | 1 time/week | If the oil level drops, it should be replenished in time |
Sensitivity | a Check the daily temperature indication, it should be lower than the specified value | 1 time/day 1 time/month | ||
sound and vibration | ausually check by listening and touching | 1 time/week | ||
Capacitor Banks | Check the appearance | a Check for oil and water leakage b Check for looseness of each terminal screw | 1 time/day | If loosening occurs, the terminal part may change color due to overheating |
Temperature around the capacitor bank | Measured with a mercury thermometer | 1 time/day | Ventilate so that the ambient temperature does not exceed 40°C | |
Hydraulic device | Hydraulic oil | a The oil level displayed by the oil level gauge, whether the color of the oil has changed b Check the amount of dust in the hydraulic oil and the quality of the oil c Measure the temperature | 1 time/week | If the oil level drops, there is leakage in the circuit. When the quality is poor, the oil should be replaced. |
Table 4
Hydraulic | pressure gauge | Whether the tilting pressure is different from usual | 1 time/week | |
Pump | Check if the noise of the pump is different than usual | 1 time/week | When the pump is noisy, there are the following reasons: a. The air is sucked by the suction filter. b. The suction side of the pump sucks the air. c. | |
Pressure regulating valve | a When there is a time lag from the start of the pump to the pressure rise and when the noise of the pressure regulating valve becomes large, disassemble the pressure regulating valve for cleaning b When the furnace tilting speed is too slow, increase the pressure regulating valve within the maximum operating pressure range of the device the set pressure, the set pressure does not rise, remove it for cleaning | |||
filter | Disassemble the filter for cleaning | The first time is half a month, | ||
Piping | Visually inspect the piping for oil leaks | 1 time/month | ||
Cooling water circuit | Soft water cooling device
| a Whether there is water leakage in each part of the device b Whether the noise and vibration of the motor and pump are different from usual c When the operation is stopped for a long time, or when the operation is stopped in winter or at night, the remaining water should be drained (refer to When the water temperature is lower than +5°C) d Wear and replacement of the gland gasket | 1 time/day 2 years | |
Cooling tower backup waterway | Is the backup water supply normal? | 1 time/month | (Party A's own equipment is for Party A's reference only) | |
cooling water circuit | cooling water distribution rack | aWhether the alarm value of the water pressure gauge is issued normally, and whether the pressure indication is different from usual bbWhether the thermometer indication is normal, and whether the alarm contact is abnormal | 1 time/month 1 time/week 1 time/day | |
emergency equipment | Is the backup water pump normal? | 1 time/week | ||
Leakage furnace alarm device | Electrode lead wire inspection | a Whether the connection of the electrode lead wire is normal b Whether the electrode lead wire is grounded | 1 time/day | This device is optional |
Coil inspection | When dismantling the furnace: |
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