The maintenance and upkeep of metal pipe benders are the key to ensuring their efficient, stable operation and extending their service life. The following are some detailed maintenance and upkeep steps:
First, daily inspection and maintenance
Check and refill the fuel level in the fuel tank
Frequency: The oil level in the fuel tank should be checked regularly every week.
Operation: Ensure that the oil level is not lower than the mark on the oil window. After the maintenance of the hydraulic system, it is also necessary to check the oil level and add hydraulic oil in a timely manner. The hydraulic oil used in pipe benders is usually ISO HM46 or MOBIL DTE25. These hydraulic oils have good anti-wear, anti-oxidation and anti-rust properties.
Inspection of electrical circuits and grounding
Frequency: Before each operation.
Operation: Check whether the oil pipes and electrical circuits between the power control box and the main unit are properly connected and confirm their correctness. The pipe bender must be well grounded to prevent equipment damage or personal injury caused by electrical faults. When cleaning and inspecting the pipe bender, the power supply must be disconnected to ensure safety.
Fan cleaning
Frequency: Clean regularly based on usage.
Operation: When the suction power of the fan is insufficient and the smoke exhaust is not smooth, the fan should be cleaned to remove the accumulated dust.
Circulating water replacement and water tank cleaning
Frequency: Once a week.
Operation: Ensure that the laser tube is filled with circulating water before the pipe bender starts working. The water quality and temperature of the circulating water directly affect the service life of the laser tube. Therefore, it is necessary to replace the circulating water regularly and clean the water tank.
Lens cleaning
Frequency: Every day.
Operation: Gently wipe the reflector and focusing lens to prevent dust or contaminants from causing laser loss or lens damage. When cleaning, be careful to protect the coating on the lens surface. Handle it gently to prevent dropping.
Second, regular maintenance
Oil change and cleaning of the hydraulic system
Frequency: The hydraulic oil of a new bending machine should be replaced after it has been in operation for 2,000 hours. Thereafter, it should be changed again every 4,000 to 6,000 hours of operation.
Operation: Each time the oil is changed, the oil tank should be thoroughly cleaned to remove deposits and impurities to ensure the cleanliness of the hydraulic oil. The oil temperature of the system should be controlled between 35℃ and 60℃, and must not exceed 70℃. Excessively high oil temperature can lead to deterioration and damage of the oil quality and components.
Replacement and cleaning of filters
Frequency: Each time the oil is changed, the filter should be replaced or cleaned simultaneously. If the pipe bender shows relevant alarms or abnormal phenomena such as unclean oil quality in the filter, the filter should be replaced immediately.
Operation: The air filter on the oil tank should be inspected and cleaned every three months, and a new air filter should be replaced annually to ensure the normal operation of the hydraulic system.
Cleaning and tightening of hydraulic components
Frequency: Clean the hydraulic components monthly and tighten the connections of all accessories every two months.
Operation: Clean the hydraulic components (such as the base plate, valves, motors, pumps, oil pipes, etc.) to prevent dirt from entering the system. When cleaning, do not use cleaning agents to avoid corrosion or damage to hydraulic components. Meanwhile, check whether there is any deformation at the bends of each oil pipe. If any abnormality is found, they should be replaced. When fastening the accessories, it should be ensured that the system is pressure-free.
Guide rail cleaning
Frequency: Clean once every two weeks.
Operation: Clean the guide rails and linear shafts of the pipe bender, remove accumulated dust and smoke to ensure the processing accuracy and smooth movement of the equipment. The pipe bender should be turned off before cleaning.
Tightening of screws and couplings
Frequency: Regularly check based on usage conditions.
Operation: During the operation of the pipe bender, observe whether there are any abnormal sounds or phenomena in the transmission components. If any problems are found, they should be promptly repaired and maintained. At the same time, the pipe bender should be tightened with tools one by one after a period of time. The first tightening should be done about one month after the equipment is used.
Third, long-term maintenance and upkeep plans
Formulate a maintenance plan
Operation: Enterprises should formulate detailed maintenance plans based on the usage frequency and working intensity of the pipe bender. The maintenance plan should include daily inspection, regular maintenance, troubleshooting, spare parts replacement and other contents.
Reserve of spare parts and tools
Operation: Stock up on an appropriate amount of spare parts and tools, such as hydraulic oil, filters, sealing rings, solenoid valves, wrenches, screwdrivers, cleaning agents, etc., so that they can be replaced or repaired in time when the equipment malfunctions.
Training of operators
Operation: Operators should receive professional training to understand the structure, performance, operation methods and maintenance knowledge of the pipe bender. Through training, operators can master the operation skills of the equipment proficiently and improve the utilization efficiency of the equipment. Meanwhile, the operators should also have the ability to troubleshoot and handle emergencies.
Fourth, safety precautions
Safety check before operation
Operation: Before each operation, check whether the power supply, oil level, air pressure, etc. of the equipment are normal. Only after confirming that everything is correct can the machine be started. At the same time, check whether the safety protection devices are in good condition and effective to prevent safety accidents caused by improper operation.
Safety requirements during the operation process
Operation: Operators should strictly abide by the operating procedures and are prohibited from overloading the equipment. When the equipment malfunctions or shows abnormal conditions, it should be stopped immediately for inspection and the relevant personnel should be informed for handling. It is strictly prohibited for non-designated personnel to operate this equipment.
Safety measures during maintenance and servicing
Operation: During maintenance and servicing, the power supply and gas source should be disconnected to ensure that the equipment is in a safe state.
Through the above steps, the metal pipe bender can be effectively maintained and serviced to ensure its efficient and stable operation, extend its service life, and improve production efficiency and product quality.
