Regular Inspections to Extend Service Life
Regular inspections involve performing maintenance centered on lubrication oil, air-related components, coolant, and the control box with the aim of extending the service life of machine tools. Here's a closer look at how to perform these inspections.
Lubrication Oil Inspections
With use, the oil used in various parts of the machine will degrade or decrease in volume. If the degrading or decreasing oil is left alone, it may cause a machine failure. Check the oil condition and amount regularly, replacing or refilling as necessary.
Areas which use oil include coolant oil, bearings, screws, and gearboxes. When checking the oil for these areas, make sure that the rate of oil degradation is normal and that oil is not significantly lower than usual.
If the oil has degraded or is drastically lower than normal, it may be signaling a component failure or oil leak. In such cases, in addition to the oil, also check for failures in the surrounding area.
Air-Related Inspections
Many machine tools have components that operate with an air supply. As these components are important parts of production, regular inspections are essential to prevent failures.
A clogged filter can cause a malfunction or failure. To prevent this, remove any dust or iron powder adhering to the machine. The filter itself must also be replaced regularly.
A compressor compresses the air along with airborne moisture content. Take caution when using compressed air with moisture content, as this may cause problems with equipment operation.
An air dryer is the proper means for removing moisture from the air. Doing so prolongs the life of the equipment and will reduce maintenance costs.
It is also important to check air pressure. Check the air pressure using a pressure gauge, and if the pressure does not reach the reference value after adjusting the valve, inspect the supply circuit.
Coolant Inspections
If coolant is not functioning properly to cool the machine, the heat can cause the tool to deteriorate or workpieces to warp. When inspecting the coolant unit, make sure that the coolant level sensor is working properly, that the tank and filter are clean, and that there are no clogs.
Switches around the coolant area are prone to failure due to dirt. Make sure these switches are functioning properly. Along with the inspection, also clean up and replace the filter.
It is also important to check whether the coolant fluid has degraded or changed in concentration. Degradation of the coolant fluid may cause poor quality or bad odors, so be sure to check it during maintenance and replace if there is an issue.
Control Box Inspection
The control box, cooling fans, and exhaust fans are also to be routinely inspected. The control box is sensitive to heat and must be checked frequently in summer. Dirty cooling fans or exhaust fans could result in a heat failure, so check them regularly.
The control box itself is inspected by checking whether any wiring is loose or disconnected, whether the servo motor is operating correctly, and whether the power switch is functioning.
Machine Cleaning
Cleaning should be done frequently to prevent part failure due to a build-up of chips. Chip build-up can lead to ball screw or bearing failure. Regularly inspect and clean the cover to prevent chips from building up on the cover.
Clean any dirt on the machine with a dry cloth, brush, or compressed air. Clean not only the machine, but also the surrounding floor.
Inspection of Various Parts
First, visually inspect the various parts for deformation or scratches. Check for loose screws and surrounding dirt, and re-tighten if loose.
After each area has been inspected, turn on the power to confirm that the machine is working properly. At this time, also check the spindle speed and listen for any abnormal noises.
