I. Welding equipment failure maintenance protocols
1. Understanding before acting
In the face of malfunctioning welding equipment, we should first remain calm and not act blindly. On the basis of a full understanding of the performance of the equipment, the background and specific performance of the malfunctions are understood by asking the operator. For unfamiliar and complex welding equipment, an in-depth study of its electrical principles and structural properties is required to ensure that the operation meets the requirements. Before being dismantled, it is important to have a clear picture of each component's function, location, connection and connection to the surrounding device. In the absence of a road map and assembly chart for welding equipment, it is recommended that drafts be drawn and marked along the lines of disassembly and that the objects removed be properly marked to ensure that the process is safe。
2. Progressive mapping from external to internal
In the face of welding equipment failure, we should normally first check the external condition of the equipment, including finding any visible physical damage or missing parts. At the same time, it is essential to understand the maintenance history, life and environment of the equipment. Next, welders are examined in depth. Before dismantling, however, it is important to ensure that potential perimeter failure factors, such as the correctness of the wire, the site, the distribution capacity and the welding process used, are eliminated. Dismantling operations should be carried out only if it is established that the fault is actually inside the welder. Otherwise, blind dismantling may cause further damage to welding equipment, such as welding arcs, welding, protection of the arcs by tungsten gases, plasma arc welding and melting the gas protection welders。
3. Mechanical and electrical
In the event of malfunctioning of the welding equipment, we should first focus on the mechanical parts and parts of the equipment, including the systems of lubrication, airways, waterways and oilways. Electrical inspections are initiated once it has been determined that none of these systems are malfunctioning. When circuit failure is checked, detection instruments should be used to locate the failure points and ensure that no problems of exposure are encountered before in-depth analysis of the link between the circuit and the mechanical operation is undertaken to avoid miscalculations. This step also applies to all types of welding equipment, including welding, welding, cams and welding。
Quiet before moving
In the event of malfunctioning of the welding equipment, we shall first perform static checks of key components such as buttons, contacts, heat-breaking electrical units and fuses, in the absence of electrical power in the equipment, in order to make a preliminary determination of the possible location of the malfunction by observation and judgement. Next, electrical experiments are carried out to further analyse and determine the specific causes of the malfunctions through dynamic means such as hearing sounds and measuring parameters. Where welder input is missing, if a simple measurement of triple-phase voltage cannot be clearly judged, we can use sound and individual measurements of the voltage at each relative location to identify precisely which is missing。
5. Cleaning and repairing
For more heavily contaminated welding equipment, we first need to clean up the buttons, the interface points and the points of contact thoroughly. At the same time, external control keys are checked for failure. In fact, many of the malfunctions stem from the accumulation of dirty and conductive dust, so that they can often be removed after cleaning. This step is particularly important in harsh environments such as the construction site。
6. Pre-chancellor-backer
The power input component tends to occupy a critical position during welding repairs, as it tends to account for a large proportion of overall failure. Thus, priority is given to overhauling the power input component, which tends to produce significant results. Next, other auxiliary parts of the welding equipment, such as walking, silk delivery and so forth, are checked in order to ensure full recovery。
7. Universal before exceptional
In the course of welding equipment repairs, common problems caused by failure of components and electrical components, the quality of assembly parts or other equipment account for about half of the overall failure. This type of failure usually manifests itself as a soft failure, and its diagnosis and repair requires extensive experience and sophisticated instrumentation. When on-site malfunctions are difficult to assess immediately, it is recommended that technical staff from the product production unit be contacted for assistance by reference to the product description. At the same time, internal procedures for welding, welding, cams and welding equipment should be avoided in case of unknown details, in order to prevent more complex malfunctions。
8. External control
In the course of welding, the electrical condition of the peripheral equipment should first be checked and its normality confirmed before replacing damaged electrical units or further checking the printed circuit boards. This would help to avoid unnecessary replacement and inspection work and increase the efficiency of inspections。
9. Straight flow after communication
The primary task in the overhaul of the printed circuit boards is to observe whether the circuit boards and their components show signs of abnormal heat or burning. At the same time, special attention should be paid to static measures for integrated circuit modules. Next, input signals, static work points of straight-flow circuits, and dynamic work points and output signals of traffic circuits should be successively checked to detect and remove potential malfunctions。
Dismantling before debugging
For welding equipment with simultaneous debugging and malfunctioning, the first task is to resolve the problem before commissioning. The debugging process must ensure that electrical lines are functional and correctly connected, including to the ground line. If conditions permit, welding equipment shall be subject to insulation resistance tests, confirmation of eligibility before debugging, or welding tests to ensure that the equipment is functional。
Detailed inspection and operational guidelines
When handling welding equipment, we need to follow a series of inspection methods and operational steps to ensure the smooth running of the work. First, the electrical circuits should be carefully checked to determine if there is a malfunction and to ensure that all connections are correct, particularly those connected to the ground line. Second, where conditions permit, insulation resistance tests should be conducted to safeguard the safety of the equipment. Finally, only after the above-mentioned checks have been completed and confirmed can the commissioning be carried out or the proper functioning of the equipment verified through welding tests。
1. Visual inspection
Intuitive means of judging external performance of electrical components through sensory means such as observation, smell and hearing. In the maintenance process, this method is often used to initially determine the location and cause of the failure。
1 survey: detailed enquiries are made to operators and those present at the time of the malfunction, regarding external performance of the malfunction, its approximate location and the state of the environment at the time of the malfunction. For example, whether there is an anomaly, whether the open fire or heat source is close to an electrical element, whether there is a corrosive gas intrusion, whether there is a leak, whether there has been repair or repair。
2 preliminary check: on the basis of the information obtained from the survey, check carefully whether there is external damage to the electrons, whether the connection is broken or loose, and whether the insulation is burning. At the same time, care is taken as to whether the smelting indicator of the spiral smelt is ejected, whether the electrons are fed with water and oil, the correct position of the switch, etc。
3 test welding: an electrical test may be performed after it has been determined that there is no risk of further failure and of causing human and equipment accidents. Observe the condition of welders during normal work, such as the absence of serious dives, unusual odor and sound. Once anomalies are detected, the power supply should be stopped and cut immediately. In addition, care needs to be taken to determine the location of the failure by checking the temperature rise of electrical units and the conformity of their actions with the principles of the welding equipment。
(2) maintenance inspection methods
1 observation welding equipment: electrical elements produce sparks when they close, break circuits or lead wires loose, so faults can be diagnosed by observing the presence and size of sparks. For example, if sparks or heat are found between a normal strong guidance line and a screw, the line may be loose or poorly exposed. When electrical units are closed and cut off from circuits, there is a fire, indicating that the circuit is open; if there is no fire, the circuit may not be connected。
For those who control electrically motivated contacts, if the primary point of contact is sparky and the other is missing, this may mean that the contact point without sparks is poorly exposed or circuits are broken. If two of the three are larger than normal and the other is smaller than normal, it may be preliminarily judged to be short circuits or grounding between the electric motors. If all three sparks are larger than normal, they may be electrically overloaded or partially mechanically contained. In the control circuits, electrical power is provided by checking the panel light or output signal of the welding equipment to determine possible cause of malfunction。
There are light sparks when the frequent contact closed position of the activated button indicates that the circuit is connected and the failure may be in the mechanical part of the contact point; if there is no spark between the contact points, the circuit may be broken。
Activation procedures for 2 welding devices: electrical motion processes must follow the specifications and rationales of the welding equipment. The discovery of premature, late or total non-action of an electrical device in a circuit often means that the circuit or electrical device is malfunctioning. In addition, we can further analyse and judge the causes of malfunctions by carefully listening to the sound of electrical devices, touching their temperature, feeling changes in stress and smelling. Using an intuitive approach, we can not only quickly identify simple failures, but also reduce complex failures to manageable levels。
2. Hydraulic measurements
The electro-voltage measure is a method of determining the location and cause of the failure by measuring the voltage and current values of electrical units and comparing them with normal values. It is implemented on the basis of the method of power supply to electrical units and the working performance of control circuit boards, which can be broken down into block measurements, segment measurements and spot measurements。
3. Barrier measurement
The resistance measurement method is equally important and consists mainly of both block and segment measurements. These two methods apply in particular to welding devices that are distributed more distantly between internal switches and electrical metreware (e. G., printed circuit boards)。
4. Contrast, replacement device, step-by-step (or access) method
(1) comparative method
By comparing the detection data with the sample data and normal parameters recorded in normal times, it is possible to determine the failure of the electrical metaware. In the case of electrical metaware that lack information or are normally recorded, a manual or product description can be consulted, or a comparison made with the same type of fine electrical metaware。
Other similar or identical power element actions and data can be used to assist in the determination of faults when electrical element units in circuits have the same purpose or components to control the same equipment together。
(2) conversion component method
The conversion element method may be used in cases where the cause of failure of certain circuits is difficult to identify or check for long periods of time, subject to guaranteed uslding equipment utilization. The method is experimented with the same elemental devices with the same convertible performance on the same welding equipment to confirm whether the failure was caused by a particular electrical element。
It is important to note that after removing the original electrical unit, it should be carefully checked whether it has been damaged. New electrons may be replaced only if it is established that the damage was caused by the factor of the electrical element itself in order to avoid further damage to the new element。
(3) step-by-step (or access) approach
Where welding equipment combines multiple roads and controls more complex circuit short circuits or grounding problems can be detected directly if there are visible external manifestations such as smoke, burnt marks, etc. However, short circuits and off-sites within the electric welder or with a shield may not be easily detectable except for the melting of the melter. At this point, a step-by-step (or access) approach could be used to inspect。
1 step-by-step approach: in the face of short circuits or ground failure that are difficult to detect, attempts can be made to replace the melter. Subsequently, multiple circuits were cut off or given priority for electrical testing. If the breaker repeatedly melts, the malfunction is on the recently broken secondary road。
The main road is then broken down into paragraphs and connected to the circuits. The failure is determined to be on the circuit and on the electrical element(s) it connects to the circuit whenever the breaker melts again. While this method is simple, it is important to note that there is a risk of complete damage to electrical components that were not otherwise serious as a result of improper operations。
A step-by-step approach to access: in case of short circuits or ground failure of the circuits, a new breaker is first replaced. It is then planned or targeted to access the power supply and conduct electrical testing. If the breaker again melts upon access to a certain section of the circuit, the failure is on the newly connected circuit and the electrical unit it contains. This method also requires careful operation to avoid unnecessary damage to electrical components。
5. Legal forced confinement
In the event of failure of electrical components, a visual inspection that does not detect a failure point and does not include an appropriate instrument to measure it, an insulation bar may be used to force components such as relay components, contacts and electromagnets to close their contact points. Subsequently, careful observation is made of changes in electrical element parts or mechanical components, such as electrical motors from stationary to rotation, and related parts of equipment from non-action to normal work. This method is designed to reveal potential malfunctions by forcing the components into working condition by external force。
Direct short-linking
In the event of failure of electrical circuits or electrons, we often encounter short circuits, overloads, break-ups, grounding, wiring errors, partial electromagnetic and mechanical malfunctions of electrical appliances, as well as the ageing of metaware. Among them, circuit break-ups are more common and may involve particulars such as circuit break-ups, cascading, looseness, poor contact, welding, welding and melters。
In addition to the use of electrical resistance and voltage for detection of such failures, there is a simpler and more reliable method - short-linking. It requires us to use a well-insulated guide to link directly to the parts suspected to be cut off. For example, when we are short on a position, if the circuit begins to work normally, it is clear that there is a problem with the location。
In practice, we can use a local short- or long-duration method for short-linking. At the same time, some operational details need to be noted. For example, in the case of continuously burned metaware, the cause should be identified prior to replacement; in the measurement of voltage, consideration should be given to the steering line pressure down; in the restoration of the welding equipment, the first operation should ensure that the steps of air, water and refuelling have been properly completed; in addition, during the electrical operation, the hand must not leave the power switch or stop button to ensure safety; and finally, caution must also be exercised in the selection of the stoppage of the meter。
