Once the die-casting machine in the course of work failure warning, the operator should cause a high degree of attention, and calm observation, determine the location of the fault and the possible reasons to determine the feasible maintenance methods. Must remind the operator, should be developed according to the "working procedures" to work, do not violate the operation, so as to avoid a greater accident. Handling machine failure, whether cold chamber die casting machine or hot chamber die casting machine can be carried out according to the following steps:

1) by watching, listening, testing, to determine the symptoms and location of the fault.

2) Analyze the cause of the possible cause of the failure.

3) Check the equipment running records and fault files.

4) to determine the appropriate treatment methods and work steps.

5) hands-on maintenance.

First, the pump can not start

Inspection and analysis: press the pump start button to observe whether the motor relay pull.

1, if the relay does not pull is checked

1) Whether the motor thermal relay is moving or damaged.

2) whether the power supply circuit is normal (check with a multimeter).

3) start and stop button contact is normal, control the line is open.

4) Whether the relay coil is damaged (check with a multimeter).

2, if the pump after the start of the relay is a suction check

1) Whether the pump is damaged or stuck.

2) whether the relay to the motor line is normal.

3) whether the pump is damaged or the assembly is too tight. Hand to switch the coupling should be easy, axial movement coupling should be about 3 ~ 5mm gap for the appropriate.

Second, press the pump start button, thermal relay trip

Inspection and analysis: press the pump start button, thermal relay trip. This is related to the current, load and three-phase resistance is symmetrical and so on.

1) The motor thermal relay is damaged or the setting current is too small.

2) The voltage is too low to cause the current to increase or the three-phase voltage is not balanced.

3) motor three-phase winding resistance imbalance.

4) The total pressure or double pump pressure adjustment is too high, causing the machine to run overload and trip.

5) The pump is damaged or the assembly is too tight, so that the motor is overloaded and tripped.

Third, no total pressure

Inspection and analysis: After the pump starts, press the pressure button, first observe the pressure and flow indication whether the current meter shows the proportion of pressure valve (proportional relief valve) electromagnetic coil with or without current, distinguish between electrical or hydraulic failure.

1, if the current output is checked

1) whether the pump reversal (people face the direction of the pump shaft, clockwise rotation is forward).

2) Check the relief valve to see if it is improperly adjusted or stuck.

3) Check that the shut-off valve is closed.

4) Proportional relief valve throttle is lost or loose.

2, if no current output is checked

1) whether the rectifier plate is normal, the pressure proportional plate is improperly adjusted or damaged.

2) observe whether the computer is working properly, press the press button by hand, see the corresponding point on the computer whether the input, the total pressure point with or without output, if no input, check the pressure button to the computer line is normal, if input And the total pressure point without the output of the computer failure or the back door is not related conditions are not satisfied.

3) Check the electrical proportional plate output to the oil valve between the line is normal, the proportion of the motor is normal.

4) Check the pressure dial is normal.

Four, no automatic

If the manual action is normal, without automatic action, you should check the safety door limit switch is normal, whether the action back to the origin (according to the machine instructions). For example, the force of the horizontal cold chamber die casting machine, in the automatic action should meet the following conditions: safety door input signal is lit; automatic input signal is lit; lock mode input signal is lit; thimble back limit input signal is lit, hammer in place Lit.

If the manual action is not normal, you should first check and exclude.

Five, can not adjust the mold

Inspection and analysis: select the mode of operation, the machine can not achieve modal movement, should check the following:

1) Whether the condition of the modulating movement is achieved.

2) Whether the modulating pressure value is set too low.

3) whether the manual mode of operation is correct.

4) The above content check If there is no problem, check the following:

(1) Whether the motor is jammed or the motor is damaged.

② Check the hydraulic valve spool is stuck.

③ whether the transfer mechanism between the transmission pair wear or stuck.

Six, the whole machine no action

Inspection and analysis: After starting the pump, the whole machine manual, automatic no action, press the press button (pressure, flow has been set parameters) to see if there is pressure.

1, if no pressure is checked

1) whether the rectifier plate is damaged or the fuse is burned out.

2) P01 board input and output is normal.

3) Check that the proportional relief valve is adjusted properly or damaged and stuck.

4) whether the computer work properly.

5) Is the pressure dialing damaged, the line is normal, or the pressure flow setting is too small.

2, if the pressure is checked

1) 14 Road amplifier plate is normal.

2) All oil valve line 0V wiring is normal.

Seven, not locked mode

Check and analyze: close the security door, press the lock button (such as equipped with a mold should choose slow, so as not to crash the mold), observe the electrical box on the panel lock light is bright or the main computer with or without lock signal output The

1, if no signal output is checked

1) whether the signal input, no signal input check the external line.

2) thimble is back, thimble does not return can not be locked.

3) Check the mold in place to confirm whether the limit switch (Kyrgyzstan system) is damaged.

4) If the clamping conditions are met without the lock signal output is the computer is damaged.

2, the computer has a signal output, but still do not lock the mold is checked

1) Whether the clamping pressure is normal (press the clamping button to observe the pressure on the pressure gauge).

2) 14 Road Amplifier is normal (work its input, the output lights at the same time).

3) whether the slow slow valve is adjusted properly or damaged, unlock the mold valve is improperly adjusted or damaged.

4) Check the output of the electrical box to the oil valve line connection is normal, the mold clamping solenoid valve is normal.

5) Is the mold cylinder damaged?

Eight, no low-voltage mode

Inspection and Analysis: Observe whether the low voltage lock indicator on the panel of the electrical box is bright.

1) light does not light, then check the low-voltage mode-sensitive sensor switch to see if it can be induced or damaged.

2) If the light is on, check whether the low voltage code is adjusted or damaged.

Nine, no high voltage clamping

Check and analyze: If the clamping movement to high pressure sensor switch without high pressure, should check the high voltage sensor switch is damaged or sensitive to the total pressure setting is too low and no high voltage clamping.

Ten, no speed mode

Inspection and analysis: observe whether the computer speed input, output.

1) the computer without speed input, then check the external constant speed selection knob to the computer line is normal.

2) the computer has input, no output, then the computer failure.

3) the computer has input and output check: fourteen way to enlarge the board work is normal; fourteen to enlarge the plate to the oil valve line is normal; oil valve coil is damaged.

4) constant speed hydraulic valve spool is foreign body stuck or constant flow is too small.

Eleven, not open mode

Inspection and analysis: First of all, should observe the main electrical box panel on the open indicator light is bright, the main computer whether there is input, output.

1, no signal output check items

1) open mode in place sensor switch is normal.

2) Manual, the computer on the signal should be light, or should check the open button to the computer wiring is normal, if the computer is faulty.

3) When automatic, if the automatic selection of the knob line is bad (the vibration may cause the automatic signal to break), and can not complete an action cycle.

2, if the computer is working (with input, output) is checked

1) whether the four-way amplifier plate is working properly.

2) 14 Road Amplifier Board to the oil valve line is normal, the valve coil is damaged.

3) Whether the spool is jammed by foreign matter.

4) Is the mold opening pressure abnormal (observe the pressure gauge).

5) Whether the fixing nut of the piston rod and the crosshead is loose.

6) lock the module after a sudden power failure, a long time may also not open the mold, this time should be the total pressure to the maximum, choose a quick mold, press the pressure button, and then open the mold button for mold movement.

7) Check whether the lock cylinder is leaked.

12, no injection action (referred to as no charge material)

Inspection and analysis: manual operation punch movement is normal, but no automatic injection action, then check the following (hot chamber die casting machine should be removed hammer check):

1) Manual, automatic selection knob is normal.

2) The mode-locked termination sensor switch and the lock-in confirmation limit switch are not properly engaged, the mode-locked induction sensor is sensed, but the clamping is terminated to confirm that the limit switch is not pressed or the limit switch is damaged.

3) The shot is terminated and the sensor switch is damaged. (Hot chamber die casting machine does not have this)

4) injection of a speed, hammer oil valve whether there is electrical signal, spool is action.

5) The shot time is too short or the speed adjustment is too slow.

6) damage to the fuel tank.

7) Hydraulic system without pressure.

8) before the buckle is in place. (Cold room die casting machine does not have this)

Thirteen, no two speed injection movement

Inspection and analysis: manual operation of the punch action is normal, automatic operation without two speed injection movement. First, should observe whether the computer with two-speed injection signal input, automatic when there is no two-speed signal output (hot chamber die-casting machine should be removed hammer inspection).

1, no signal input check items

1) Check whether the two-speed sensor is normal.

2) Whether the shot time is set appropriately.

3) whether the speed movement is normal.

2, the computer has a signal input, the output check items

1) whether the four-way amplifier plate has input and output to the oil valve.

2) whether the valve coil is normal.

3) two-speed control valve is normal, two-speed cartridge valve is normal.

4) the speed of the trip is too long, two speed has no trip.

Fourteen, shot force weakness

Inspection and analysis: first to see whether the two-speed signal and the injection of two-speed, no two-speed see two-speed failure analysis, there are two speed check the following items:

1) one or two speed regulation is required, the two-speed flow regulation can normally open the two-speed flow valve.

2) Whether the fast pressure accumulator nitrogen pressure is within the required range.

3) Is the injection pressure setting too small?

Fifteen, pressure drop off pressure

Inspection and analysis: punch in the pressure when the pressure plunged, then check

1) injection cylinder, pressure reducing valve, cartridge valve is vent.

2) Is the stop valve tightened?

3) whether there is nitrogen, nitrogen pressure is insufficient or nitrogen pressure is too high.

4) The accumulator is faulty.

16, the furnace temperature can not be controlled

Inspection and analysis: Furnace heating for some time, the thermometer pointer does not move. The reasons are as follows:

1) The heat probe line is reversed, loose or the probe is damaged.

2) The thermometer is damaged.

Seventeen, alarm

Inspection and analysis: If the machine in the manual or automatic operation when the alarm situation, that is, the electric box alarm light flashes, while the speaker on the electrical box buzzing, may be caused by the following factors (when the machine has a fault display, Directly according to the fault location displayed on the display):

1) unlock the mold limit alarm: open mold termination, the end of the mold, the sensor switch or die to terminate, to confirm whether the limit switch at the same time foreign body block.

2) lock-in protection alarm: automatic production, low-voltage mode to protect the time to lock, and the clamping action is not completed.

3) the battery battery voltage is too low: PLC CPU program battery voltage is too low, you must replace the battery as soon as possible to avoid loss of procedures.

4) elbow lubrication alarm: elbow lubrication oil pressure can not reach the set pressure.

5) thimble limit alarm: thimble limit and thimble back limit at the same time by foreign body induction to.

6) Core release limit alarm: before and after the core stroke limit switch at the same time ON; or not selected core, core into the limit is ON.

7) Motor overload alarm: motor overload, while the motor stops rotating.

8) Modulation limit alarm: die, die limit switch is OFF.

Eighteen, no thimble

Inspection and analysis: the top of the cylinder can not achieve thimble action, you should first observe the electrical box on the panel thimble work indicator light or whether the computer signal output.

1, if the indicator does not light or the computer no signal output is checked

1) whether the mold in place.

2) If the core is loaded, whether the core is in place.

3) Whether the thimble limit switch is damaged.

2, if the computer has a signal output is checked

1) whether the thimble pressure is normal (observe the pressure gauge).

2) 14 Road Amplifier board is normal (observe the fourteen way to enlarge the plate on the thimble output indicator light is bright).

3) fourteen way to the hydraulic valve plate is open circuit, oil valve coil is normal.

4) thimble valve is normal, thimble cylinder is the phenomenon of internal discharge.

5) mold thimble was stuck, thimble top no.

Nineteen, computer failure

Inspection and analysis: observe the computer PLC on the lights, the following analysis:

1) POW power indicator does not light, that no power supply; green light that normal.

2) ALM light red, that the CPU is not working properly; light does not indicate that normal.

3) BAT light red, computer battery failure; bright yellow light, computer battery power is not enough; light does not indicate that normal.

4) RUN light green, indicating that the CPU is working properly; light does not light, that CPU is not working properly.

Twenty, hydraulic system oil temperature is too high

Inspection and analysis: the machine for a period of continuous work, the hydraulic system oil temperature is too high (normal oil temperature 15 ~ 55 ℃), should check the following items:

1) cooling water is not enough water, requiring water to meet the requirements.

2) too much fouling in the cooler failed to clean up as required.

3) Fuel tank oil storage is below the minimum oil level.

4) hydraulic system has the phenomenon of internal leakage.

5) cooler into and out of water, cooling effect is poor.

Twenty one, the cylinder leak

Cylinder leakage is one of the causes of the failure of the cylinder.

Cylinder leakage includes both external leakage and internal leakage. External leakage refers to the cylinder cylinder and cylinder head, cylinder bottom, port, exhaust valve, buffer valve, cylinder head and piston rod and other external leakage, it can be directly observed from the outside. Internal leakage refers to the internal pressure of the high pressure chamber pressure oil to the low pressure chamber leakage, it occurs in the piston and cylinder wall, piston hole and piston rod connection. Internal leakage can not be directly observed, the need for unilateral access to pressure oil, the piston stopped at a certain point or after the terminal to observe whether the other oil spill to determine whether there is internal leakage.

Whether it is outside the leak or internal leakage, the main reason for the leakage is bad, the connection caused by poor bonding; followed by the cylinder pressure expansion caused by internal leakage, welding structure of the cylinder welding failure caused by external leakage.

Twenty two, goose neck leakage material

1) The tank taper is damaged and needs to be repaired.

2) Shear body taper is not correct, should be replaced to meet the requirements of the nozzle body.

3) Install the ejector body is not correct, clean the hole and the nozzle body and re-install it in the correct way.

Twenty-three, mouth mouth

Plug mouth refers to the solidification of the material in the nozzle head or nozzle body can not be continuous shot production, mainly due to lack of temperature caused. In case of such problems generally need to raise the nozzle temperature or directly with gas heating.

Twenty four, the card hammer

1) check the feed piston rod and the material pot center is correct, fitted with a hammer to see whether the hand rotation, can be rotated is correct.

2) the furnace temperature is normal, see the furnace temperature meter shows whether the temperature is in the range of 400 ~ 430 ℃.

3) due to a long time to clear the material slag, resulting in slag in the furnace in the accumulation of more or too much furnace alloy material, the general normal liquid surface from the crucible about 3cm.

4) mold sprue sets with the barrel with the poor.

Twenty-five, not before the buckle

First observe the front panel button on the front panel is bright or whether the main computer signal output.

1, no signal output check items

Should check whether the front button signal input.

2, a signal output check items

1) the computer before the output point to the oil signal line connection is normal.

2) whether the charge pressure adjustment is normal.

3) button mouth valve and cylinder is normal.

Note: If there is mold