1. Daily Maintenance (Performed by Operators)
Clean Dye Vats and Machine Body: After each operation, turn off the power and clean the dye vat of residual dye and fiber debris to prevent clumping and blockage of pipes; wipe away oil stains from valves, buttons, etc., to avoid corrosion or poor contact.
Check Key Components: Before starting the machine, confirm that there are no loose or leaking pipe connections, that the temperature controller and timer display are normal, and that the rotating devices run smoothly without abnormal noise.
Lubricate Rotating Parts: Add special lubricating oil to bearings, gears, etc., and run the machine idle for a few minutes after lubrication to ensure even oil distribution.
2. Weekly Maintenance (Assisted by Team Leaders)
Clean Filtration System: Disassemble and clean the inlet filter of the circulating pump and the dye liquor filter to prevent impurities from affecting the uniformity of dye liquor circulation.
Check Chain Tension: Adjust the tension of the drive chain to avoid excessive looseness causing skipped teeth or excessive tightness accelerating wear.
Verify Sealing Performance: Check the integrity of the cylinder door seals; replace any aged or damaged seals promptly.
3. Monthly Maintenance (Executed by Equipment Team)
Sensor Calibration: Calibrate temperature sensors, pressure gauges, and level gauges to ensure measurement accuracy.
Heating and Cooling System Inspection: Remove scale from heating elements and test the cooling valve response speed to ensure accurate temperature rise and fall curves.
Connection Tightening: Check bolts, keys, and pins for looseness to prevent parts from falling off or being damaged due to vibration.
4. Quarterly Maintenance (by Dedicated Maintenance Personnel)
Comprehensive Performance Testing: Perform repeatability testing on the robotic arm (applicable to automatic dyeing machines) and trajectory accuracy assessment to ensure dyeing uniformity.
Electrical System Inspection: Check motor insulation resistance and control cabinet terminals for oxidation to prevent short circuits or overload risks.
Deep Lubrication System Maintenance: Replace old lubricating oil and clean oil passages to prevent sludge blockage.
5. Annual Maintenance (Major Overhaul)
Pressure Test and Safety Valve Calibration: Conduct a pressure test on the entire machine to verify the reliability of the safety valve operation, ensuring safe operation under high pressure.
Core Component Replacement: Replace vulnerable parts such as seals, filters, and pump impellers to extend equipment life.
Control System Upgrade: Update PLC programs and touchscreen firmware to improve intelligence and self-diagnostic capabilities.
6. Establish Maintenance Records: Record the time, content, problems found, and handling measures for each maintenance session to facilitate tracing the cause of failures and optimizing maintenance cycles.
Regularly analyze maintenance data to predict component lifespan, achieving a shift from "passive maintenance" to "proactive prevention."
