How to maintain the PV Ribbon Rolling Mills in daily life

      The PV Ribbon Rolling Mills covers copper based strip rolling mills and photovoltaic welding strip two roll/four roll precision rolling mills. The core maintenance goals of the equipment are to stabilize thickness accuracy, prevent roll surface damage, eliminate welding strip indentation/scratches, reduce strip breakage, and extend the service life of the rolling rolls. The overall maintenance system is divided into five modules: pre startup inspection, in-process inspection, post shift maintenance, periodic maintenance, and contraindications.

1、 Pre start inspection for each shift (static+no-load 3-5 minutes jog)

1. Roller system (most importantly, directly determines the appearance of the welding strip)

      Clean the upper and lower work roll surfaces: wipe with a dust-free cloth and specialized cleaning agent to remove copper powder and rolling oil residue; Do not scratch the roller surface with hard objects.

      Visual inspection of the roller surface: scratches, pitting, and attachments; Once minor defects occur, immediately stop the machine for processing to avoid batch strip crushing.

      Check the roller bearing seat for any leakage or abnormal oil stains; Confirm that the cooling pipeline joints are not loose.

      The opening and closing action of the roller gap during the no-load inspection is smooth, without any impact or jamming; Confirm that there is no crawling of the oil cylinder under AGC pressure.

      Clean the copper chips of the guide, side limit, and entrance guide blocks, check the gaps, and prevent the strip from running off track, rubbing against the edges, and scratching the sides.

2. Rolling cooling/lubrication system (rolling oil system)

      The fuel tank level is normal, and there are no white, emulsified, or black impurities in the oil.

      Start the oil pump and check that the oil supply pressure is stable within the standard range of the equipment; The pressure difference of the filter is normal. If the pressure difference is too high, it indicates that the filter element is clogged.

      Check the spray nozzle: no blockage, spray direction aligned with the roller gap; Eliminate local overheating and copper sticking caused by unilateral oil shortage.

      The inlet and outlet water temperatures of the plate/shell cooler are normal, and the oil temperature is controlled within the process range (usually 30-42 ℃).

3. Hydraulic compression system (thickness control core)

      The oil level, oil temperature, and pressure of the hydraulic station are normal; If the oil temperature is greater than 45 ℃, it is necessary to check the cooling system.

      Whether there is leakage in the oil pipe and oil cylinder piston rod; Once the seal or dust ring leaks oil, it should be promptly registered and replaced.

      The wiring of solenoid valves and pressure sensors is firm; Test the effectiveness of emergency stop and overpressure interlock.

4. Tension and winding transmission system

      The unwinding, tension roller, and correction mechanism are clean and free of copper debris jamming; Clean the correction photoelectric/CCD lens.

      Check that each guide roller rotates flexibly and the bearings have no abnormal noise; The tension sensor cable has no compression wear.

      The tightness of the transmission belt/coupling is moderate, and the protective cover is intact.

5. Pneumatic, Electrical, and Safety

      The gas source pressure is 0.6-0.7MPa, and the water separator drains daily; The cylinder operates without any air leakage.

      Control cabinet cooling fan, filter screen dust removal; Emergency stop button and safety door interlock function test.

2、 Patrol inspection during production operation (once every 1-2 hours)

      Listen to the sound: there is no periodic abnormal noise or metal whistling from the rolling mill body, reducer, oil pump, and bearings; Immediately reduce speed and investigate if there is any abnormal noise.

      Temperature measurement: Infrared temperature measurement is used to monitor the temperature of the roller bearing seat, servo motor, and gearbox housing. Continuous heating is strictly prohibited.

Check the status of the strip

      Observe whether the entrance and exit belts are centered, without deviation, and without unilateral waves;

      Frequent running with emphasis on checking: asymmetric guide, uneven wear of roller surface, fluctuation of tension, and failure of correction;

      Random indentation appears on the surface, with a high probability of copper sticking to the roller surface or foreign objects on the guide roller.

      Monitor HMI data: rolling force, roll gap, front and rear tension, rolling speed, oil temperature. Stop the machine in a timely manner if the data fluctuates significantly.

      Rolling oil: observe whether there is a large amount of copper powder in the return oil; Regularly clean the oil return filter screen.

      Eliminate forced rolling under excessive pressure and tension; Prohibit the direct entry of raw materials with joints or severe warping into the rolling mill.

      Important: In case of belt breakage or stacking, stop the machine immediately, clean up the copper shavings caught in the roller gap, carefully inspect the roller surface for any scratches or damage, and confirm that it is intact before resuming production.

3、 Maintenance after each shift shutdown (closed loop 30 minutes after shift)

      Thoroughly clean the roller surface, frame, guide, tension roller, and machine, and blow copper powder; Copper powder belongs to abrasives, and long-term accumulation accelerates the wear of bearings and guide rails.

      Clean the rolling oil return filter and slag collection tank to prevent impurities from circulating and scratching the roll surface again.

      Check all grease fittings and replenish them according to specifications (roller bearings, lead screws, sliders); It is strictly prohibited for grease to splash onto the working surface of the rolling mill, causing oil stains and defects in the strip.

      Lift the gap between the rollers appropriately, and do not press and contact the rollers for a long time to prevent static indentation on the roller surface.

      Shut down the oil system, cooling system, and air source; Organize shift handover records, documenting abnormal noises, leaks, roller surface anomalies, and thickness fluctuations.