What are the maintenance points of photovoltaic welding strip rolling mill

       We have sorted out the maintenance points of photovoltaic welding strip rolling mill from four dimensions: daily maintenance, regular maintenance, special maintenance, and fault prevention. The logic is clear and in line with production practice, and it is suitable for stable operation of equipment and welding strip accuracy requirements. The specific details are as follows:

1、 Daily maintenance (mandatory tasks before startup/during production/after shutdown)

       Core objective: To ensure that the equipment is ready for use upon startup, avoid sudden failures during production, and maintain the precision of welding strip rolling forming

Pre-start inspection

       Roll inspection: Check the surface of the work roll for scratches, aluminum adhesion, and rust. The surface should be smooth and free of impurities, and any defects should be cleaned in a timely manner (to avoid scratching the surface of the welding strip and uneven thickness)

       Lubrication inspection: Check the oil level at each lubrication point of the rolling mill (roller bearings, transmission gears, guide rollers) to ensure sufficient lubricating oil and no oil leakage or shortage

       Safety inspection: The protective devices are complete and firm, the emergency stop button is sensitive, there are no foreign objects blocking the transmission parts, and the electrical circuits are not damaged

       Accuracy check: Verify the benchmark value of the roll gap to ensure it matches the specifications of the welding strip to be rolled, and avoid damaging the equipment by rolling beyond the specifications

Inspection during production (every 1-2 hours)

       Operating status: Monitor the equipment's operating noise and there are no abnormal noises (bearing noises or gear jamming sounds require immediate shutdown); Observe that there is no severe vibration on the aircraft body

       Temperature monitoring: The temperature rise of the roller bearings and motors should not exceed 60 ℃. If the temperature is too high, stop the machine in time to cool down and avoid burning parts

       Welding strip quality linkage: If there is a thickness deviation, edge burrs, or surface scratches on the welding strip, priority should be given to checking whether the rolling mill is worn or dirty

       Cooling system: If it is a water-cooled rolling mill, check that the cooling water circulation is smooth, without blockage or leakage, to ensure uniform cooling of the rolling mill (to prevent thermal deformation of the rolling mill)

Cleaning after shutdown (end of daily production)

       Comprehensive cleaning: Use a brush and compressed air to clean the aluminum shavings and dust on the surface of the rolling mill, frame, and guide device (photovoltaic welding strips are mostly tin plated copper strips/aluminum strips, which are prone to sticking and need to be thoroughly cleaned)

       Surface protection: If the machine is stopped for more than 8 hours, apply anti rust oil to the surface of the rolling mill to avoid oxidation and corrosion

       Environmental organization: There is no accumulation of debris around the equipment, and ventilation and dryness are maintained to prevent dust from entering the interior of the equipment

2、 Regular maintenance (executed on a periodic basis, ensuring core accuracy and extending lifespan)

       Core objective: To solve the problem of wear and tear that cannot be covered by daily maintenance, ensure the long-term stable operation of the rolling mill, and avoid accuracy degradation

Weekly maintenance

       Lubrication and maintenance: Supplement lubricating grease/oil to various transmission parts (gears, chains, bearings), especially the roller bearings, which need sufficient lubrication to reduce wear and tear

       Gap calibration: Recheck the working gap of the rolling mill. Due to slight wear during long-term rolling, recalibration is required to ensure the thickness tolerance of the welding strip (photovoltaic welding strip tolerance is often ≤± 0.005mm)

       Guiding components: Check whether the guiding roller and positioning wheel are worn, whether the rotation is smooth, and if there is any jamming, replace the bearing in a timely manner

Monthly maintenance

       Roll maintenance: Polish the roll to remove fine scratches and oxide layers, restore surface smoothness (directly affecting the flatness of the weld strip surface)

       Transmission system: Check the gear mesh clearance and chain tension, and adjust any looseness in a timely manner; Severely worn and marked for replacement

       Cooling/Hydraulic System: Clean the water cooling pipeline filter screen to prevent scale blockage; Check the oil quality of the hydraulic system, there is no turbidity or deterioration, and replenish the hydraulic oil

       Electrical system: Clean the dust from the motor and control cabinet, check that the wiring terminals are not loose, and avoid poor contact

Quarterly maintenance

       Core component maintenance: Disassemble the roller bearings, check the degree of wear, measure the clearance, and replace immediately if it exceeds the tolerance; Check the bending degree of the rolling mill. If there is any deformation, it needs to be straightened or replaced

       Accuracy verification: Use professional measuring tools to calibrate the overall accuracy of the rolling mill (roll parallelism, perpendicularity), and any deviation needs to be corrected by adjusting bolts (accuracy directly determines the welding strip qualification rate)

       Sealing components: Replace each sealing component (bearing seal, hydraulic seal) to prevent oil leakage and dust ingress

Annual maintenance (major overhaul, shutdown execution)

       Comprehensive disassembly: Conduct a comprehensive disassembly and inspection of the rolling mill mainframe, transmission system, hydraulic system, and electrical system

       Component replacement: Replace core components such as rollers, gears, bearings, motors, etc. that are severely worn out; Replace all aging circuits and sealing rings with new ones

       Precision reset: The overall precision of the machine is recalibrated to ensure compliance with the high-precision requirements of photovoltaic welding strip rolling

       Performance testing: no-load trial run+load trial run, to verify the stability of equipment operation and the accuracy of welding strip rolling. Production can only resume after meeting the standards

3、 Special maintenance (targeted treatment, adapted to the special requirements of photovoltaic ribbon)

       Photovoltaic ribbon has extremely high requirements for dimensional accuracy and surface quality, and requires targeted maintenance in three areas

Special maintenance of rolling mill (core key)

       The rolling of photovoltaic welding strips requires strict requirements for the hardness and smoothness of the rolling rolls. The surface hardness of the rolling rolls must be ≥ HRC60, and the hardness should be regularly tested. If it is insufficient, it needs to be re quenched

       Do not use hard objects to scratch the surface of the rolling mill. Only use a soft bristled brush or specialized cleaning agent for cleaning to avoid damaging the surface coating

       If the rolling mill has local dents or severe scratches that cannot be polished and repaired, it must be replaced immediately, otherwise it will result in batch scrap of welding strips

Precision specialized maintenance

       After changing the specifications of the welding strip (width, thickness) each time, the gap between the rollers must be recalibrated, and a trial run of 5-10 meters of welding strip must be conducted. Only after passing the inspection can mass production be carried out

       Long term production of welding strips of the same specifications requires random inspection of roll accuracy every 3 days to prevent the accumulation of trace wear and tear that may lead to accuracy exceeding the standard

Tin plating/coating welding tape adaptation and maintenance

       When rolling tin plated welding strips, it is necessary to clean the residual tin chips on the surface of the rolling mill in a timely manner after stopping the machine to avoid the tin layer sticking to the rolling mill at high temperatures

When rolling coated welding strips, it is necessary to regularly clean the residual coating on the surface of the guide roller to prevent affecting the flatness of the welding strip

4、 Maintain core taboos and prevent faults (key to avoiding pitfalls)

Core taboos (strictly prohibited operation)

       It is strictly prohibited to start the machine without lubrication: Rolling in a state of oil shortage can cause bearing burnout, roll locking, and serious equipment damage

       Strictly prohibit excessive rolling: Forcefully rolling welding strips beyond the rated thickness/width of the rolling mill can cause bending of the rolling mill and breakage of the transmission system

       It is strictly prohibited to operate with faults: in case of abnormal noise, high temperature, or accuracy exceeding the standard, the machine must be stopped immediately, and it is forbidden to "mix and match" to cause the fault to expand

       It is strictly prohibited to rinse the electrical control cabinet directly with water: to prevent short circuits, only dry compressed air should be used for cleaning

Common fault prevention

       Uneven welding strip thickness: Regularly calibrate the gap between the rolling rolls, check the parallelism of the rolling rolls, and promptly clean up the sticking dirt on the rolling rolls

       Scratches on the surface of the welding strip: Keep the rolling mill smooth, clean impurities in the guide components, and prevent foreign objects from entering the rolling area

       Equipment vibration and abnormal noise: Regularly tighten bolts, adjust gear clearances, and replace worn bearings

       Motor overheating: Clean the dust on the motor cooling fan, check if the load exceeds the standard, and avoid overloading operation

5、 Key points for maintenance assistance (extending equipment lifespan)

       Oil adaptation: Special rolling mill lubricating oil for lubrication (viscosity adapted to equipment operating conditions), hydraulic oil needs to be filtered regularly to prevent impurities from wearing parts

       Environmental control: Equipment should be placed in a dry and dust-free workshop to avoid electrical failures and component corrosion caused by humid environments; The workshop temperature is controlled at 15-30 ℃ to prevent the rolling mill from expanding and shrinking, which may affect the accuracy

       Personnel regulations: Operators must receive training before taking up their posts, and it is strictly prohibited to adjust parameters in violation of regulations. Maintenance records must be kept and archived (for the purpose of tracing the cause of faults)