How to do daily maintenance of PV Ribbon Rolling Mills

      The PV Ribbon Rolling Mills belongs to the micrometer level high-precision cold rolling equipment, with core guarantees of thickness/width tolerance, roll mirror accuracy, AGC hydraulic closed-loop, tension system, cooling and lubrication, pre shift inspection (before each shift starts), in shift inspection, post shift cleaning and maintenance, weekly maintenance, and monthly deep maintenance. All modules are in line with the practical operation of the photovoltaic welding strip production site, without fabricating parameters.

1、 Pre shift inspection (required by operators 10 minutes before starting up)

1. Inspection of Rolls and Rolling Channels (Precision Core)

Visual inspection of tungsten carbide rolling mill surface: no copper powder indentation, scratches, pitting, or oxidation spots; Wipe the slight copper shavings with a dust-free soft cloth and specialized rolling cleaning solution. Do not use a hard scraper to scrape the roller surface.

Check the feeding and discharging guide wheels, straightening wheels, and material dividing blocks: the rotation is smooth without any jamming, the surface is free of copper slag accumulation, the guide gap is not offset, and prevent the welding belt from bending and burrs on the side.

Check the seam benchmark: Confirm that there are no hard impact marks on the upper and lower rollers, and that the records of the last roller change and seam adjustment are complete; Manual turning without load, the rolling mill rotates without abnormal noise or scratches.

Wire laying and winding I-shaped wheel fixture: The fixture is locked tightly without looseness, the blocking plate is flat, and the wire is prevented from running off track and stacking.

2. Inspection of cooling and lubrication system (anti roll surface damage, defense material oxidation)

The liquid level of the rolling fluid tank is within the standard scale range, and there are no white emulsification or black impurities; The filter screen is unobstructed and the spray pipeline is unobstructed.

Start the lubrication pump and observe that the oil from the spray nozzles of the upper and lower rollers is evenly distributed without interruption or unilateral liquid shortage; Immediately clear the clogged nozzle to prevent local dry friction from scratching the rolling mill and welding strip.

Confirm that the cooling circulation fan and heat exchanger are normal, and the oil temperature is controlled at 30-45 ℃. Overheating will accelerate the deterioration of the rolling fluid and the thermal wear of the roll surface.

3. Hydraulic AGC pressing system (determining thickness with accuracy of ± 0.002mm)

Confirmation of hydraulic station oil level, oil temperature, and pressure gauge: The system pressure is stable at the rated value of the equipment, without continuous pressure drop or pressure fluctuation.

Check that there is no oil leakage in the oil cylinder, oil pipe joint, and servo valve; The dustproof sealing ring of the piston rod is intact, and there is no copper powder entering the interior of the oil cylinder, causing the valve core to be stuck.

Lift and lower the roller with no load 2-3 times, observe the synchronous response of the pressing, no jamming or crawling, and no alarm on the AGC automatic compensation interface.

4. Transmission and tension system

The oil level of the main reducer and gearbox is at 1/2 of the oil window, and there is no emulsification or foaming of the oil; The coupling protective cover is intact, and the elastic buffer block is not cracked.

The traction and winding tension controller is powered on for self inspection, the tension sensor value is reset to zero, and there is no abnormal noise from the tension roller bearings.

The tension of the chain and synchronous belt is moderate, without looseness or jumping teeth, and the lubricating grease is not dry.

5. Electrical, online detection, safety interlocking

The cooling fan of the electrical control box is normal, and there is no accumulation of copper powder or oil stains inside the box; Compressed air triple component drainage, with a stable air pressure of 0.5-0.6MPa.

Clean the lens and sensing probe of the online thickness gauge, there is no splashing or obstruction of rolling fluid, and the zeroing calibration is normal.

The safety door, emergency stop, wire breakage protection, and ultra thick and ultra-thin alarm have all been tested to be effective, and the interlock cannot be short circuited.

2、 Dynamic inspection during class (once every 2 hours, production process)

Monitor the whole machine for abnormal noise: If there is abnormal noise or excessive vibration in the roller bearings, reducer, hydraulic pump, and traction motor, stop the machine immediately for troubleshooting; The temperature rise of the rolling mill bearing is ≤ 65 ℃. If it exceeds the temperature limit, stop the machine and replenish the lubricating grease.

Real time monitoring of product dimensions: Every 30 minutes, take samples and retest the thickness and width with a micrometer. If the tolerance drifts, check for roller wear, hydraulic pressure fluctuations, and unstable tension.

Rolling fluid status: Observe whether there is a large amount of copper powder suspension in the circulating liquid. If the filtration pressure difference increases, it indicates that the filter element is blocked. Switch to the backup filter in a timely manner.

Pipeline sealing inspection: Check for leaks in hydraulic oil pipes, lubrication pipes, and cooling water pipes. If there is a small amount of oil leakage, tighten the joints in a timely manner to prevent surface defects caused by oil contamination of the welding strip.

Observation of tension stability: The wire does not shake, tighten or loosen intermittently; The winding and wiring are neat, without folded edges or collapsed coils, and the wiring motor screw is regularly lubricated.

Environmental dust control: Timely blow the copper powder around the rolling mill, and prohibit large amounts of dust from floating into the thickness gauge, servo valve, and bearing seat.

3、 Post shift cleaning and maintenance (15-30 minutes after shutdown, daily end)

1. Whole machine cleaning (high copper dust on photovoltaic ribbon, key)

Stop the machine and turn off the power. Use low-pressure dry compressed air (≤ 0.3MPa) to blow and clean the roller frame, guide wheel, winding mechanism, and heat dissipation port of the electrical control box, and remove the attached copper powder.

Wipe the roller surface, thickness gauge lens, tension roller, and straightening roller with a dust-free cloth to thoroughly remove residual copper shavings from rolling and avoid scratches on the wire during the next day's rolling.

Clean the slag return tank and filter barrel of the rolling fluid, discard the deposited copper mud, and prevent blockage of the circulation pipeline.

Wipe the outer surface of the equipment and the operating platform, clean the copper powder on the ground, classify and recycle copper shavings to prevent dust from entering the bearings and guide rails.

2. System Closing Maintenance

Lubrication system: Keep the circulating pump running for a short period of time for 3 minutes, empty the residual impurities in the pipeline, and close the spray valve; Clean the dust on the external cooling fins of the cooler.

Hydraulic system: observe for leaks, record oil temperature and pressure operation data; Release the accumulated water in the three piece air storage tank.

Roll protection: During long-term shutdowns (night shifts/weekends), apply a small amount of rust proof rolling oil to the roll surface to prevent oxidation and rust from producing pitting.

Return the tooling to its original position: Clean the I-shaped wheels, spare rolling rolls, and adjusting shims before storing them in a rust proof tooling rack to prevent damage to the roller surface from collision.

3. Record ledger

Fill in equipment operation records: rolling output, gap adjustment, roller surface wear, hydraulic abnormalities, alarm faults, filter element replacement, lubrication and filling situation, ensuring traceability of one machine and one file.

4、 Regular in-depth maintenance every week (4 hours of downtime, fixed shifts per week)

Roll and bearing maintenance

Remove the end cover of the roller bearing seat, clean the internal copper powder, and add high-temperature and extreme pressure resistant lubricating grease; Check the bearing clearance, whether there is pitting or abnormal noise, and replace the bearing if the wear exceeds the tolerance; Check the sealing water blocking ring of the rolling mill, replace it directly if it ages and becomes hard, to prevent the rolling fluid from infiltrating the bearing and corroding.

Deep cleaning of lubrication and cooling system

Clean all filters of the rolling fluid (primary coarse filter, secondary precision filter) and replace clogged filter elements; Check for copper mud accumulation in the circulation pipeline and clear the spray main pipe; Take samples to observe the turbidity of the rolling fluid, and replace all impurities that exceed the standard with new fluid.

Maintenance of transmission system

Check the color of the gearbox gear oil, replace it in advance if it turns black or contains metal abrasive particles; Tighten the coupling, anchor bolts, and frame tie rods (diagonal torque tightening to prevent frame deformation from affecting rolling coaxiality); Clean the dust and lubricate the synchronous belt and chain.

AGC hydraulic system maintenance

Clean the air permeable filter element of the hydraulic station; Check the servo valve plug and circuit for oil stains; Check the pressure of the accumulator, if it is insufficient to replenish nitrogen gas; Check the dust prevention and sealing ring of the oil cylinder, replace any minor damages in advance to avoid a large amount of oil leakage.

Online detection and tension system calibration

Calibration of the zero point and standard block of the online thickness gauge; Zero the tension sensor and clean the adhesion of the sensing roller; Wipe and lubricate the wiring screw and linear guide to ensure even wiring.

Electrical dust removal fastening

Open the low-voltage blowing and dust removal of the electrical control box, and tighten the screw torque of the terminal block; Clean the copper powder on the surface of contactors and relays to prevent poor contact of contacts from causing tension and thickness measurement signal drift.