Vacuum Furnace Troubleshooting and Troubleshooting: The Secret to Rapid Return to Production

In the modern industrial production process, vacuum furnace with its unique, in aerospace, electronic information, machinery manufacturing and many other fields play an indispensable role. However, prolonged high-load operation or interference from external factors can lead to failures in vacuum furnaces. Once the failure occurs, not only will interrupt the production process, resulting in production delays and economic losses, but also may affect product quality. Therefore, to master the vacuum furnace fault diagnosis and troubleshooting methods, become the key to quickly restore production. Ltd. with years of technical accumulation and practical experience in the field of vacuum furnace, summed up a set of effective troubleshooting and troubleshooting strategies to help enterprises solve problems efficiently, to ensure the smooth progress of production.

First, the impact of vacuum furnace failure on production

The impact of vacuum furnace failure is multifaceted. At the level of production efficiency, the failure occurred, the production line was forced to interrupt the original orderly production rhythm is disrupted, the product delivery cycle is extended, may lead to corporate default, damage to the credibility of the enterprise and customer relations. In terms of product quality, if the failure occurs in the production process, it may lead to quality defects in the product being processed, such as vacuum welding furnace failure may make the welded joints appear pores, cracks, vacuum heat treatment furnace failure will affect the organization of the material transformation and performance indicators, resulting in a large number of substandard products, scrap, and increase production costs. In addition, frequent failures will accelerate the aging of equipment, shorten the service life of equipment, increase the cost of equipment maintenance and replacement, the long-term development of enterprises have a negative impact.

Second, the vacuum furnace common failure types and diagnostic methods

(A) the vacuum degree of abnormal failure

Failure phenomenon: the vacuum furnace can not reach the set vacuum, or in the operation of the vacuum degree suddenly dropped.

Diagnosis: First of all, use professional leak detection equipment, such as helium mass spectrometry leak detector, a comprehensive test of the vacuum system. Focus on checking the furnace door sealing place, vacuum pipe interface, valves and other parts, which are common leakage points. If a helium leakage signal is detected, the location of the leak can be determined. At the same time, check the working condition of the vacuum pump to see whether the vacuum pump oil needs to be replaced and whether the rotor, rotary vane and other parts in the pump are worn out. The vacuum furnace produced by Principal Vacuum Technology (Jiangsu) Co., Ltd. is equipped with a high-precision vacuum monitoring device, which can display the vacuum value in real time and alarm automatically when the vacuum level is abnormal, so that it is convenient for the operator to find out the problem in time.

Troubleshooting strategy: if the seals are aging, broken and lead to leakage, timely replacement of the same specification of the sealing tape or gasket; if the pipe interface is loose, re-tighten the connection bolts; for the vacuum pump failure, in accordance with the requirements of the equipment manual to replace the vacuum pump oil, repair or replacement of worn parts.

(ii) Temperature anomaly fault

Failure phenomenon: the temperature can not be raised to the set value, or the temperature fluctuation is too large, more than the range of process requirements; furnace temperature is not uniform, the temperature difference between different areas is large.

Diagnostic methods: check whether the heating element is damaged, observe the appearance of the heating element whether there is fracture, deformation, oxidation, etc., use a multimeter to measure the resistance value of the heating element to determine whether it is working properly. At the same time, test the temperature control system, including the temperature sensor, temperature control meter and control circuit. Check whether the temperature sensor probe is clean, whether it is covered by materials or dust to affect the accuracy of temperature measurement; check whether the temperature control instrument display is normal, whether the parameter settings are correct; test the control circuit wiring connection is loose, aging. Ltd. vacuum furnace with intelligent temperature control system, through the system comes with the fault diagnosis function, the initial judgment of the temperature abnormality is caused by the heating element or temperature control system.

Troubleshooting strategies: If the heating element is damaged, promptly replace the heating element of the same type, and ensure that the installation position is accurate and wiring is firm; for temperature sensor failure, clean the probe or replace the new sensor; if the temperature control instrument meter or control circuit problems, contact professional and technical personnel for repair or replacement parts.

(C) control system failure

Failure phenomenon: the vacuum furnace can not start normally, or start some of the functions can not be achieved; the operator interface display abnormalities, such as black screen, garbled code, etc.; the operation of the equipment in the process of a sudden stop running, no obvious reasons.

Diagnostic method: Check the working status of the programmable logic controller (PLC), see whether the indicator light on the PLC module is normally lit, and determine whether there is a module failure. Check whether the communication line connection between the human-machine interface (HMI) and PLC is normal, which can be tested by replacing the communication line or interface. At the same time, check whether there is any error in the PLC program, whether there is any program loss or tampering. The vacuum furnace control system of Xinan Vacuum Technology (Jiangsu) Co., Ltd. has perfect self-diagnostic function, which can display the error code when the fault occurs, and the operator can quickly locate the fault point according to the code prompts.

Troubleshooting strategy: if the PLC module failure, replace the corresponding fault module, and re-download the program; if the communication line problems, repair or replace the communication line; for program errors, restore the backup program or contact professional programmers for program debugging and repair.

(D) cooling system failure

Failure phenomenon: abnormal cooling system pressure, too high or too low; cooling water flow is insufficient to meet the cooling needs of the equipment; during the operation of the equipment, the temperature of the key components is too high, beyond the allowable range.

Diagnostic method: Check whether the cooling water pump is running normally, see whether the water pump motor is energized and whether the water pump impeller is rotating. Check whether there is blockage and leakage in the cooling water pipeline, observe whether there is obvious water stains on the surface of the pipeline, and use a pressure gauge to detect whether the pipeline pressure is normal. At the same time, check whether the radiator fins are piled up with dust or sundries, which affects the heat dissipation effect. The vacuum furnace cooling system of Principal Vacuum Technology (Jiangsu) Co., Ltd. is equipped with flow and pressure monitoring devices, which can provide real-time feedback on the operating status of the cooling system.

Elimination strategy: if the cooling water pump failure, repair or replace the pump; for pipe clogging, use detergent to clean the pipeline, or disassemble the pipeline to remove internal impurities; clean up the radiator fins to ensure that the heat dissipation is good; if found in the pipeline leakage, timely repair or replacement of damaged pipelines and seals.

Third, XVACUUM TECHNOLOGY (JIANGSU) CO., LTD. professional support and service

XVACUUM Technology (Jiangsu) Co., Ltd. always adheres to the customer-oriented, to provide users with a full range of professional support and services. In terms of troubleshooting, the company has a professional technical team, which can assist users in troubleshooting and diagnosis through telephone and network remote guidance. For complex fault problems, the company can quickly arrange for technical personnel to visit the service, with rich experience and professional testing equipment, quickly locate the cause of the fault. In the troubleshooting section, the company provides users with original high-quality parts to ensure that the replacement parts are perfectly matched with the equipment to ensure the performance of the equipment after repair. At the same time, the technicians will operate in strict accordance with the maintenance standards and procedures, comprehensive repair and debugging of faulty equipment to ensure that the equipment back to normal operation. In addition, the company also provides users with equipment maintenance training services to help user operators and maintenance personnel to master the diagnosis of common failures of vacuum furnaces and troubleshooting techniques to improve the user's ability to solve problems on their own, reducing the frequency of failures and downtime.

Fourth, the measures to prevent failure

In addition to mastering the fault diagnosis and elimination methods, prevention of failure is equally important. Enterprises should develop strict operating procedures for the equipment, the operator must be professionally trained, familiar with the equipment operating procedures and precautions to avoid failure caused by improper operation. Regular maintenance of the vacuum furnace, in accordance with the requirements of the equipment manual, the vacuum pump, heating elements, temperature control system and other key components for inspection, cleaning, lubrication and calibration. Establish the equipment operation file, record in detail the equipment operation time, maintenance, fault occurrence and treatment and other information, through the analysis of the data, find out the potential problems of the equipment in advance, and take preventive maintenance measures. xvacuum technology (jiangsu) co., ltd. provides the users with the equipment regular inspection service, the technicians carry out a comprehensive inspection of the equipment in accordance with the predetermined period, find out and deal with the hidden danger of the equipment, and eliminate the fault. The technicians carry out a comprehensive inspection of the equipment according to a predetermined cycle, discover and deal with the hidden problems of the equipment in a timely manner, and nip failures in the bud. At the same time, the company will also provide users with equipment upgrading and remodeling suggestions according to the use of equipment and the development of industry technology to improve the performance and reliability of equipment and reduce the probability of failure.

Vacuum furnace troubleshooting and diagnosis is an important part of the production of enterprises to ensure smooth progress. By understanding the common types of vacuum furnace failure, mastering the scientific diagnosis method and effective troubleshooting strategy, enterprises can respond quickly in the event of failure, rapid recovery of production and reduce losses. xvacuum technology (jiangsu) co., ltd. with professional technology and perfect service system, to provide users with strong support to help users solve the problem of vacuum furnace failure. At the same time, enterprises should pay attention to the daily maintenance and prevention of equipment to reduce the possibility of failure from the source. In the future, with the continuous development of industrial technology, vacuum furnace equipment will be more intelligent, fault diagnosis and troubleshooting technology will be constantly upgraded, XVACUUM Technology (Jiangsu) Co., Ltd. will continue to innovate, to provide users with more efficient and convenient fault solution, help enterprises to enhance productivity and competitiveness.