We all know that machines will eventually break down, but with regular maintenance, repairs, and proper use, their lifespan can be maximized.
So what should we pay attention to in the maintenance, repair and use of machinery?
First, employ dedicated or part-time electrical maintenance personnel to regularly maintain and repair the electrical systems of woodworking machinery. Woodworking machinery requires a high level of expertise from maintenance personnel; even general electrical workers in furniture factories may find it challenging to repair complex machinery. However, under the guidance of the machine manufacturer, routine maintenance and periodic inspections can be performed to promptly eliminate potential safety hazards arising during the use of woodworking machinery and electrical systems.
Furthermore, during the use of machinery, it is essential to scientifically estimate the power consumption of the machine's electrical components and configure an appropriate electricity meter capacity. Furniture manufacturers must re-estimate the company's total power consumption capacity after adding new machinery and equipment. Any existing electrical capacity that is insufficient must be increased; do not wait until machine malfunctions before adding capacity. Simply adding equipment without increasing power consumption capacity is tantamount to creating a hidden danger of electrical malfunctions.
Electrical wiring must be inspected regularly, and old cables with insufficient cross-sectional area must be replaced to ensure the operation of machinery and electrical equipment. If the regional voltage is stable, but the voltage within the unit is unstable, consider replacing the cables; if the regional voltage is unstable, consider increasing capacity and replacing the cables.
Finally, it's essential to adjust the frequency of power usage and make rational use of electrical energy. Woodworking machinery consumes varying amounts of power; therefore, furniture production requires a reasonable combination of machines with different power ratings to maintain a relative balance in power consumption per unit time.
With the increase in furniture production, the demand for woodworking machinery is also growing. Paying attention to the maintenance, repair, and safe use of these machines can not only improve furniture processing efficiency but also effectively extend their lifespan.
It is important to perform regular maintenance on woodworking machinery. Maintenance includes the following three key points:
1. Minor repair work
(1) Partial disassembly of severely worn or damaged components;
(2) Clean the disassembled parts and components, and repair or replace them;
(3) Inspect the spindle, cutter shaft, or saw shaft, and repair it if necessary:
(4) Repair or replacement of vulnerable parts such as bearings, guide devices and other friction surfaces;
(5) Finishing of working surfaces such as worktable, tool holder, and guide ruler;
(6) Inspection and adjustment of operating mechanisms, electrical interlocking devices, switches, and positioners;
(7) Adjustment and repair of the hydraulic system and lubrication device, and replacement of hydraulic fluid:
(8) Inspection of the fit accuracy of transmission components, adjustment of spring tension, and adjustment of tool post uniformity and worktable movement:
(9) Inspection and adjustment of protective devices and dust collection devices;
(10) Test the machine tool under no-load conditions, check the noise and noise level, and inspect the workpiece accuracy.
2. Work content of intermediate repair
(1) Disassemble all parts and components for cleaning and wiping;
(2) Replace easily worn parts and repair the spindle, cutter shaft or saw shaft;
(3) Repair the workbench, guide device and friction surface;
(4) Repair hydraulic and lubrication equipment and replace the fluids;
(5) Replace the transmission components and assemble the machine tool;
(6) Repair the protective devices;
(7) Inspect the precision and surface finish of machine tools and products in accordance with technical requirements;
(8) Run the machine under no-load and check the noise and temperature rise;
(9) Spraying paint on the exterior of the machine tool;
(10) Restore markings, lines, scales and other signs.
3. Overhaul
Generally, the machine is disassembled from its foundation and repaired entirely in the machine repair workshop. Large band saws can be overhauled in the lumber mill.
(1) The machine tool was completely disassembled. It was cleaned, wiped dry, and all parts were inspected.
(2) Replace worn planer spindles and spindles of circular saws, milling machines, drilling machines, woodworking lathes, etc.
(3) Replace worn rolling bearings, bushings, and bearing shells;
(4) Replace worn gears, sprockets, and clutches, etc.;
(5) Replace worn drive shafts, lead screws, and couplings:
(6) Replace worn fasteners, such as bolts, key pins, etc.
(7) Replace worn belts, chains and other parts;
(8) Replace the damaged pressure plate and wedge;
(9) Repair the tool setting device. Adjust the scale indicating the cutting thickness;
(10) Plane or trim all guide rails, repair or replace working surfaces;
(11) Repair the hydraulic system and lubrication device, and replace the oil and lubricant;
(12) Repair protective devices and vacuum pipes;
(13) Assembly and adjustment of machine tools, smoothing of tool post and support stroke and correction of operating mechanism;
(14) Inspect and correct the foundation of the large blanket machine tool, such as the large band saw:
(15) Conduct idling and negative diffraction tests, and inspect the precision of the workpiece according to the technical requirements;
(16) Painting non-working surfaces:
(17) Restore markings, lines, scales and other signs.
For the repair cycle structure of general woodworking machine tools, the ratio of major, medium, and minor repairs can be 1:9:6, with 18 regular inspections during the medium stage. Of course, the repair cycle structure should be continuously adjusted in practice to achieve the best results.
Complete Guide to Safe Operation of Woodworking Machinery
1. Machinery without safety protection devices or that is malfunctioning must not be used.
2. Gloves are strictly prohibited when operating woodworking machinery. Cuffs should be tightened, clothing corners straightened, and buttons fastened. Female employees must wear work caps, and long hair must not be exposed.
3. The wood to be processed must be free of nails, wires, hinges, stones, sand and other debris; otherwise, they should be thoroughly removed beforehand.
4. For materials with cracks (sloping layers) and knots, do not feed too quickly, and keep your hands as far away from the cutting tool as possible.
5. When moving timber, pay attention to whether there are people or obstacles in front, behind, left, and right; when stacking timber at a height, it must be nailed securely to prevent accidents.
6. When using iron hooks to lift timber, the hooks should be inserted into the timber, not hooked on the surface, to prevent the timber from falling and causing an accident.
7. Smoking and open flames are strictly prohibited in the workplace, and necessary fire-fighting equipment shall be provided. Smoking and glue boiling shall be carried out in designated areas. After the glue is boiled, any remaining fire shall be completely extinguished. Otherwise, no one shall leave the glue boiling area unattended.
8. After the work is completed, the power should be turned off, and the wood shavings and sawdust should be swept up with a broom. Do not wipe them directly with your hands.
Hand planer
1. When planing material, spread your legs apart to maintain body stability, and hold the material with both hands. When planing large surfaces, your hands should only be placed on the top of the material; when planing small surfaces, you can place your hands on the upper half of the material. Your fingers must be at least 3cm away from the planing edge; when your hands pass over the planing edge, apply light pressure.
2. For large planers, the thickness of the wood to be planed must not be less than 1.5cm, and the length must not be less than 20cm (for planks); 30cm (for die heads). For small planers, the thickness of the wood to be planed must not be less than 1cm, and the length must not be less than 15cm (for planks); 20cm (for die heads). When planing wood that is less than 1.5cm thick, less than 80cm long, or less than 30cm wide, a pusher or push stick must be used; pushing by hand is prohibited.
3. Each planing operation must not exceed 1.5mm, and the planed wood must be kept close to the back of the machine. Small and thin pieces must be pushed forward using a safety pry bar or pressure plate. When planing upright surfaces, prevent them from tipping over and cutting your hands.
4. When planing old materials, nails, dirt, ice, snow, etc. must be removed from the materials first.
5. The planer must maintain a uniform speed and must not push or pull suddenly. If the wood has knots or rough edges, the speed must be reduced and it is strictly forbidden to press your fingers on the knots while operating.
6. When the wood is about to be planed to the end, your hand must be moved in front of the planer blade. It is forbidden to push or pull the wood back from the front. The wood must be lifted and pulled back to prevent the blade from cutting your hand or the wood from flying out and injuring you.
7. When two people are operating, they must work in unison. Only after the wood has moved 20cm past the planer's kerf can you take it. After taking the wood, do not pull it violently.
8. When adjusting the cutting amount on a movable table, the power must be turned off and the machine stopped before adjustment can be made; it is strictly forbidden to make adjustments while the table is rotating to prevent the table from contacting the planer blade and causing a flying knife accident.
9. The gap between the planer blade and the planer kerf should not be too large (generally no more than 3mm is appropriate). The planer blade must be kept sharp to prevent it from being pushed back by the planer blade when there are knots or gnarled wood, which could cause an accident.
Drilling machine
1. Before operation, the machine bed and clamps must be adjusted to ensure the table is stable, the clamps are flexible, and the drill bit is straight.
2. The material must be clamped tightly and aligned, and the holes must not be skewed.
3. When drilling, start steadily, then accelerate evenly. When you are about to penetrate, press down lightly on the handle. If you encounter knots, press down slowly and never press down hard.
4. During operation, if the chisel core is clogged with wood chips or the machine rotates slowly or smoke comes out of the eye due to sudden pressure, the handle should be lifted immediately.
5. Wood shavings from drilling should be cleaned up with tools; never use your hands.
Opening the reel
1. Do not face the planer blade or planer disc directly during operation to prevent the blade from flying out and injuring people.
2. When operating, the pressure bar must be pressed firmly against the wood, and it can only be loosened after processing is completed; when unloading, do not let your fingers get close to the planer.
3. When feeding, the material should be pushed in slowly, and then the speed should be increased. Do not push or bump it violently. When there are knots or burrs, the feeding speed should be reduced appropriately.
4. When changing tools, the bolts must be tightened, and the protective cover and protective plate should also be in place.
Cutting machine
In addition to complying with the relevant provisions in the safety and technical operating procedures of the hand planer, the following should also be observed.
1. When operating a push-type cutting machine, you must press firmly with your left hand and push with your right hand, keeping both hands away from the cutting blade; this is especially important when processing narrow plates.
2. When feeding, push slowly and do not push forcefully. When encountering large knots, the feeding speed should be reduced appropriately.
3. When the wood is about to be planed or sawed to its end, the hand should be moved to the front of the planer or saw blade, and it should not be dragged from front to back; short pieces of wood should not be pushed by hand, but should be fed using a pressure plate tool.
4. When making cuts with a saw blade, hold the cut piece of wood firmly to prevent it from slipping out and injuring someone.
5. The screws on the planer blade holder must be tightened to prevent the blade from flying out and injuring people.
Circular saw
1. Operators should wear protective glasses to prevent sawdust from flying into their eyes.
2. Before sawing, check the saw blade for broken teeth and cracks. If a crack is found on the saw blade, drill a small hole at the end of the crack to prevent the crack from continuing to develop.
3. When sawing wood, stand slightly to the left of the saw blade. Never stand in a straight line with the saw blade to prevent the wood from flying out and injuring you.
4. Do not swing or lift the wood when sawing, and do not feed it with excessive force.
5. When the saw is about to end, do not push or press it with your hands; when the wood is exposed but not yet out of the saw cut, the person receiving the wood should not pull it with their hands to prevent their hand from being caught in the saw.
6. If there are knots in the timber, the knots should be sawed first to prevent the saw blade from jumping or bouncing back and injuring people when the timber is almost finished being sawed.
7. When processing short pieces of wood, use a wood-jointing hand to push the material; when cutting long pieces, two people should operate the machine and their movements should be synchronized.
8. Wood exceeding the radius of the saw blade must not be cut on a circular saw or a hanging saw. When using a hanging saw, the operator should stand to the side and never stand in the same straight line as the saw blade to avoid the saw blade breaking off and flying out and injuring people. At the same time, the hand holding the material should be at least 25cm away from the saw cut to ensure safe production.
9. If the wood gets stuck on the saw blade, stop the machine immediately; do not touch it before the saw blade has come to a complete stop.
10. After the machine stops, if the saw blade is still rotating, do not use wood to block the saw teeth or use wood to push against the side of the saw blade to force it to stop.
11. Do not clean wood chips and sawdust from the saw table by hand; use a wooden stick or other tools instead.
file saw
1. When removing bundles of saw blades, step on the blade head firmly with your foot and place it gently to prevent the blade from curling back and injuring people.
2. The saw blade rack should be higher than the average person's height and placed in a location where no one walks or operates.
3. When placing the saw blade into the rack, the saw teeth should face upwards; when taking, placing, or turning the saw blade, pay attention to the front and back to avoid injury.
4. The grinding wheel of the grinding machine should be kept smooth and level at all times, and should be equipped with a reliable protective cover. When working, the operator should stand to the side of the grinding wheel.
5. When lowering the grinding wheel of a file or saw, do not stand directly in front of the grinding wheel. Find a safe distance and lower it gently. Wear protective goggles to prevent injury from the grinding wheel.
6. When pressing the saw blade, press it evenly and check for any cracks.
7. When joining saw blades, the joint should be tight. If it is not up to standard, it should be rejoined immediately to prevent the saw blade from breaking when it rotates on the saw.
8. After the saw blade is filed, it should be strictly checked for cracks, slanted teeth, etc. If the saw blade is cracked, it should not exceed 1/10 of the saw surface; otherwise, it should be cut off and rejoined.
9. No more than three teeth should be missing from the saw blade, and no teeth should be missing from the joint. The joint should be smooth, uniform, and of consistent thickness.
10. Damaged saw blades and saw pieces should be stacked in a designated area and should not be left lying around.
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