In the context of modern industrial development, science and technology are recognized as the primary productive forces. The effective utilization of advanced foreign technology and equipment in production not only enhances product output and quality but also accelerates enterprise growth and contributes significantly to China’s modernization. Imported equipment plays a crucial role in manufacturing due to its advanced technological features, particularly in numerical control (NC) systems. With the rapid advancement of computer technology, evolving production structures, and increasing demands for precision and complexity in industrial products, NC technology has become widely adopted across various industries.
In the 1980s, our company introduced the Austrian Sierle diesel engine project, which involved large-scale use of imported equipment for closed-process production. In recent years, we have focused on the maintenance, technical upgrades, and localization of spare parts for these imported machines, gaining valuable experience that has led to significant economic and social benefits.
**First, Equipment Maintenance**
To align with the needs of modern enterprises and enhance both the performance of imported equipment and the brand reputation of our products, we follow the principle of "three-place" in maintenance: fault analysis, corrective measures, and record-keeping.
1. **Fault Analysis in Place**: Traditionally, maintenance focused on identifying and fixing faults. However, for imported equipment, it is more critical to deeply analyze the root cause of failures to prevent recurrence. Due to limited documentation and lack of prior experience, thorough analysis is essential to avoid unnecessary downtime and wasted effort. For instance, after introducing an Austrian K4960 twin-shaft hole boring machine, issues such as uneven cross-cutting and non-crossing holes arose. Through expert analysis, we discovered that the problem stemmed from poor lubrication and incorrect cutting fluid ratios. By addressing these underlying causes, we prevented further damage and improved machine performance.
2. **Measures in Place**: Effective solutions must be reliable and based on existing technologies. For example, instead of using expensive imported cutting fluids, we opted for high-quality domestic alternatives, along with improved sealing and lubrication systems. This approach proved cost-effective and eliminated recurring issues.
3. **Maintenance Records in Place**: We maintain detailed records of all equipment maintenance activities, including fault locations, causes, solutions, and replacement parts. These records help streamline future repairs and improve overall efficiency.
4. **Preventive Inspection and Repair**: Given the high cost of downtime for CNC machines, predictive maintenance is essential. Regular inspections and pre-repair actions help identify potential problems early, reducing costs and improving operational reliability.
**Second, Equipment Transformation**
Imported equipment in the 1980s was highly advanced in terms of machining accuracy, efficiency, and automation, contributing significantly to our ability to produce high-quality, high-volume diesel engines. However, over time, some machines lost their precision, and parts became worn or damaged. Based on extensive maintenance experience, we developed strategies for equipment transformation.
1. **Correct Planning Is Half the Battle**: Before any transformation, a comprehensive study of the target equipment is conducted. For example, when upgrading Japanese grinders used for finishing crankshaft necks, we redesigned key components and replaced diamond grinding wheels with multi-point particle ones, improving both accuracy and efficiency.
2. **Reasonable Implementation and Verification**: After planning, the implementation phase must be precise and thorough. All parts must meet national standards, and installation and testing should ensure safety and reliability. Successful transformations are verified through practical testing, often exceeding original performance levels.
3. **Updating Equipment Data**: After any modification, technical documents and drawings must be updated to reflect changes. Failure to do so can lead to inconsistencies that hinder future maintenance.
**Third, Research and Application of Localized Spare Parts**
Imported equipment components are designed with high precision and often rely on standardized, systematized configurations. However, maintaining these machines presents challenges, such as limited access to spare parts, high costs, and long procurement cycles. Localizing spare parts is therefore essential.
For example, the K4950 machine tool from Austria uses high-precision bearings that are expensive and difficult to source. By replacing them with domestically produced high-precision alternatives, we achieved the required accuracy while significantly reducing maintenance costs.
Through years of hands-on experience, our maintenance team has grown in expertise, mastering both the technology and the processes involved in maintaining imported equipment. As technology continues to evolve, we remain committed to improving our capabilities and building a skilled, professional maintenance team.
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