How to debug and check the installed automatic sandblasting machine?

Debugging and acceptance of automatic sandblasting machine is the key link to ensure the equipment performance reaches the standard and the production is stable, which needs to be verified in combination with equipment parameters, process requirements, safety specifications and other dimensions. The following are detailed debugging and acceptance processes and key points:

1. Debugging process: Verify the function and performance of the equipment by stages.

(1) No-load debugging: check the running status of equipment foundation.

Electrical system debugging

After turning on the power supply, test whether the control system (PLC, touch screen) starts normally, whether the buttons (start, stop and emergency stop) respond sensitively, and whether the indicator light display is consistent with the operating state (such as "in operation" and "failure").

Test whether the motors (sand blasting motor, conveying motor and dust removal motor) turn correctly (consistent with the equipment identification), and whether there is abnormal sound or overheating during operation (no-load operation for 30 minutes, motor surface temperature ≤60℃).

Verify the safety interlock function: whether the equipment stops immediately when the sandblasting door is opened and the protective device is removed; After the emergency stop button is pressed, whether all motors are powered off instantly and need to be restarted after reset.

Pneumatic and conveying system debugging

Turn on compressed air, check whether there is air leakage in the pipeline (the interface is coated with soapy water without bubbles), and the pressure gauge shows whether it is stable within the equipment requirements (usually 0.4-0.8MPa).

Test whether the spray gun switch and sand valve are open and closed smoothly, and whether the pressure gauge value changes linearly (no jamming or jumping) when adjusting the sand blasting pressure knob.

Debugging the conveying system (conveyor belt, turntable, fixture): test the speed adjustment function (continuously adjustable from low speed to high speed), whether there is deviation or jamming during operation, and whether the conveying accuracy meets the requirements (for example, the workpiece positioning deviation is ≤±2mm for pass-through equipment).

Debugging of dust removal system

Start the dust removal fan, and check whether the air volume is sufficient (it can be measured by hand feel or anemometer, and the wind speed at the outlet is ≥10m/s), and whether the dust in the cabin can be effectively sucked away (there is no obvious dust overflow in the cabin during no-load sandblasting simulation).

Test the dust cleaning function of the filter bag (such as pulse back blowing), whether the back blowing time and interval meet the set value, and whether the dust removal effect is restored after dust cleaning (which can be judged by observing the visibility in the cabin).

(II) Load debugging: verify the process effect and stability.

Adjustment of abrasive and parameters

According to the workpiece material and processing requirements (such as rust removal, deburring and matte), corresponding abrasives (such as steel grit, glass beads and alumina) should be added, and the first filling amount should cover 1/3 of the bottom of the sandblasting chamber.

Trial injection debugging:

Test with a standard workpiece (consistent with the material and size of the production part), and adjust the spray gun angle (30-60), distance (100-200mm), sandblasting pressure (gradually increased from 0.4MPa) and conveying speed (such as conveyor belt speed of 5-15m/min).

After adjusting a set of parameters, record the surface effect of the workpiece (such as roughness Ra value and cleanliness level) until it reaches the preset standard (for example, rust removal should reach Sa2.5 level, and there is no visible scale and rust).

Cyclic system verification

Check whether the abrasive recovery is smooth: whether the screw conveyor and hoist are stuck when running, and whether the abrasive separation device (such as screen) can filter impurities (such as workpiece chips) to avoid blocking the spray gun.

Run continuously for 30 minutes, and observe the abrasive loss (normal loss ≤5%/ hour). If the loss is too fast, check whether the pipeline leaks sand and the spray gun nozzle is worn.

Ii. acceptance criteria: confirmed from three aspects: function, performance and safety.

(I) Functional acceptance: all systems of the equipment are operating normally.

Inspection method of qualified standard for acceptance project

The touch screen of the control system operates smoothly, the parameter settings can be saved, the fault alarm is accurate (such as lack of sand and overload), the simulation operation is simulated, and the fault is intentionally triggered (such as gas failure).

The spray gun of the sandblasting system is not blocked, the sandblasting range is uniform, and there is no leakage or overspray phenomenon. Three groups of workpieces are sprayed continuously, and the surface consistency is checked.

The workpiece in the conveying system is conveyed smoothly, without deviation or falling, and the speed adjustment is accurate. Measure the conveying speed with a stopwatch and compare it with the set value.

The dust concentration in the cabin of the dust removal system is ≤ 2 mg/m (measured by a dust detector). When there is no overflow, open the observation window and there is no obvious dust overflow.

The abrasive recycling pipeline is not blocked, and the abrasive purity is ≥95% (no obvious impurities). Stop the machine and check the pipeline and abrasive bin.

(II) Performance acceptance: the process effect and efficiency are up to standard.

Surface treatment quality

Inspect the workpiece surface according to the product requirements:

Roughness: measured with a roughness meter, it must meet the preset Ra value (for example, hardware usually requires Ra1.6-6.3μm).

Cleanliness: the derusting parts shall meet the Sa2.5 level and above in Rust Grade and Derusting Grade of Steel Surface before Painting (GB/T 8923); Deburring parts need to be touched without sharp edges, and there is no residual burr under the microscope.

Consistency: 50 pieces shall be produced continuously, and 10 pieces shall be randomly selected for testing, and the qualified rate shall be ≥98%.

production efficiency

To calculate the throughput per unit time (e.g. the number of workpieces processed per hour by pass-through equipment), it is necessary to reach the design capacity of the equipment (error ≤5%). For example, the design capacity is 100 pieces/hour, and the actual test needs to be ≥95 pieces/hour.

(3) Safety and compliance acceptance: meeting the requirements of specifications.

Safety protection

The safety interlock and emergency stop device function normally, and the grounding resistance of the equipment is ≤4Ω (measured by grounding resistance tester).

The noise in the operation area is ≤85dB (measured by sound level meter), which conforms to the Code for Design of Noise Control in Industrial Enterprises.

Environmental protection standard

The dust concentration at the exhaust port of the dust removal system is ≤ 10 mg/m (measured by a third party or an instrument approved by the environmental protection department), which meets the local air pollutant emission standards (for example, Kunshan area implements the Integrated Air Pollutant Emission Standard GB 16297).

The dust concentration in the working area of the workshop is ≤ 8 mg/m (in line with occupational exposure limits on Hazardous Factors in the Workplace).

Iii. Post-acceptance documents and training

Document delivery: the supplier is required to provide equipment instructions, electrical schematic diagrams, operating procedures, list of vulnerable parts, and qualification certificates (such as equipment nameplates and material reports) and other materials, and file them for future reference.

Operation training: The supplier needs to train the operators, including parameter debugging, routine maintenance (such as cleaning the filter bag and replacing the nozzle) and troubleshooting (such as gun blocking) to ensure that the workers can operate independently.

summary

The core of debugging is to verify the equipment function step by step through "no-load → load" and find the suitable process parameters; Acceptance should be strictly controlled from three aspects: "normal function, up-to-standard performance and safety compliance", and third-party testing institutions can be invited to participate if necessary (such as environmental protection and safety acceptance). Only through complete debugging and acceptance can the automatic sandblasting machine run stably for a long time and meet the production requirements.