锻压设备大修技术标准

锻造设备大修理技术标准锻造设备大修理技术标准 1 适用范围适用范围 本标准规定了锻造设备大修理时应达到的技术要求 本标准适用于东风汽车公司锻造设备的大修 2 一般要求一般要求 2 1 装配到设备上的零 部件 包括外购件 均应符合图纸 技术文件上规定的技术要求 并具有检验部门的质量检验合格证 不允许使用不合格的零 部件或未经质量检验部门验 收的零 部件 装配前对零件的主要配合 特别是过盈配合 尺寸和表面粗糙度应进行复检 确认无误后 方可装配 2 2 装配前应将所有零件清洗干净 清楚零 部件上的飞边 毛刺 锈斑 损伤等 油沟 的边缘应修成光滑的圆角 丝杠螺纹的起始端厚度应 1 mm 1 mm 的部分应修去 2 3 滑动轴承工作面 在装配轴之前应均匀涂抹润滑油 滚动轴承在装配前 应在滚道腔 内抹 2 3 的润滑油 2 4 部件在转配后应再经过清洗 装配好的部件内不允许有残留的棉丝 各种碎屑 机械 杂质和油泥等赃物 2 5 不在地面上操纵或维修的设备应有必要的阶梯和操作走台装置 如有损坏应予修复 2 6 设备的安全装置应修理完善 如原有安全装置有缺陷 修理时应加以改进 2 7 设备的附属装置应与设备同时维修和进行运转试验 并达到使用的性能要求 2 8 设备上的润滑 操纵和安全装置的各种标牌和标志应保持清晰 损坏和丢失的应予以 修复和更换 3 机械装配的质量要求机械装配的质量要求 Quality Requirements on Machine Assembling 3 1 重要的固定结合面应紧密结合 用 0 05 mm 的塞尺进行检验 只允许塞尺局部插入 插入深度一般不应超过厚度的 20 可插入部分累计不得超过可检长度的 10 Important fixation combined surface should be tight coupled When tested by 0 05 mm feeler gauge only part of gauge can insert and the insertion depth less than 20 of thickness should be guaranteed Sum of insert section cannot exceeding 10 of checked length 3 2 轴承外圈与轴承座之间不允许有间隙 更不允许加垫 轴承盖用螺栓均匀把紧后用塞 尺检查 压盖止口处应有间隙 Gap is not acceptable between bearing outer ring temperature of rolling bearing 40 maximum temperature 80 temperature rising of slide guide rail 15 maximum temperature 50 附表 9 单次行程试验时离合器制动器接合次数 Table 9 Times of Switching between Clutch Brake during Single Stroke Testing 工作机构行程次数 Times of Operating Mechanism Strokes 次 分 Times min 20 406080100 离合器和制动地接合次数 工作机构行程次数 Number of Switching between Clutch Brake Times of Operating Mechanism Strokes 100 70 60 50 40 35 注 1 当每分钟工作机构行程次数 100 时 每分钟接合次数均按 35 次进行试验 Notes 1 Times of switching should be tested by 35 times per minute when the times of operating mechanism strokes per minute large than 100 2 当每分钟工作机构行程次数介于表中两档之间时 可用插入法决定百分比 2 Interpolation method can be used to determine the percentage when times of operating mechanism strokes per minute is between two classes in the table 6 1 3摩擦离合器 制动器和电磁控制气阀在单次行程运转试验时 动作应平稳而协调 试验中摩擦片 块 不准有烧损现象 当采用耐高温摩擦材料时 摩擦片 块 的发热不 得影响其周围零件的正常工作 All movements should be smooth and harmonious for friction clutch brake and electromagnetic control valve under single stroke operating test Burning of friction disk block in test is forbidden Friction disk block cannot not affect normal operation of surrounding parts causing by heat generation of high temperature resistant friction material being applied 6 1 4整个设备工作机构 操作机构应相互协调 在所有工作范围内动作平稳可靠 All operating mechanism should work coordinately with each other Stable and reliable movements are required in all working distance 6 1 5电气 液压 空气 润滑和冷却系统及其它附属装置的工作情况应正常可靠 工 作系统内的液体和气体管路不应有阻滞和渗漏现象 Proper and reliable operating conditions must be guaranteed for all electrical hydraulic lubrication Cooling Systems and their other accessory devices Liquid and gas pipeline in working system cannot have phenomena of blockage or leakage 6 1 6安全保护装置和超负荷保险装置应准确可靠 在单次行程工作规范内 不得发生 连续行程现象 Safety protection devices overload protection devices are working in accurate and reliable condition Phenomenon of continuous stroke cannot happened under single stroke operating specification 设备的噪声级在空运转条件下按单次行程工作规范进行测定时 数值 100dB Equipment noise level measured in idling operation condition under single stroke operating specification should be less than 100dB 6 2 设备的负荷试验 工作试验 Load test operation test of equipment 设备的性能 结构 主要用途按下列要求进行试验 Test for performance structure main application of equipment can be proceeded referring to following requirements 6 2 1按照设备的性能 试验其最大作用力 打击能量 最大加工尺寸 生产率和其他 指标 According to performance of equipment testing its maximum force blow energy Max Outline productivity and other indexes 6 2 2锻造设备应做工作试验 检验其所加工典型零件质量 应符合设计工艺文件的规 定 并进行加工零件质量的稳定试验 Operation test for forging equipment is required which quality of typical product should be tested All products should comply with regulations from design process documents After that stability test of processing parts quality should be proceeded 6 2 3设备的所有机构 工作系统 在负荷试验下动作应协调 可靠 设备的超负荷保 险装置动作应灵敏可靠 All mechanisms operating system of equipment must work coordinately and reliably in load test And overload protector should be ensured operating sensitively and reliably 6 2 4设备应进行满负荷试验 试验次数 3 次 Full load test of equipment is required test times should be larger than 3 times 6 2 5设备交付使用后 应进行为期一周的跑合 跑合期内设备负荷 80 One week running in is required after equipment delivered Equipment load 80 during running in period 6 3 设备的精度检验 设备大修后应进行精度检验 精度检验前 设备的安装水平在纵 横向上应 0 3 1000mm 在精度检验过程中 不允许对影响精度的机构和零件进行调整 以负荷试验合格后的精度检验实测数据记入精度检验单 作为验收依据之一 并存入档案 Accuracy testing of equipment Accuracy test should be proceeded for after overhaul equipment Installation level of equipment in both horizontal and vertical direction should be ensured by 0 3 1000mm before accuracy test Adjustments of mechanisms or parts which may affecting