เข้าไปดำเนินการปรับแต่ง ซ่อมบำรุง เครื่องบีบสายไฮดรอลิค รุ่น P40 ( Cleaning / Tuning up of the P40 Swager and training on Interlock crimping system ) ดังนี้ :-
Phase 1 Hose Type
Phase 2 Cut Length/Interaxle Length
Phase 3 Out Side Skive
Phase 4 Inside Skive
Phase 5 Inside/Outside Skive Control
Phase 6 1st Fitting/2nd Fitting
Phase 7 Orientation
Phase 8 Crimping Diameter and Crimping Diameter Control
Phases 9 Manufacturing Date Marking
Phase 10 Proof Test (if requested)
Phase 11 Hose Flushing (if requested)
Phase 12 Capping (if requested)
SHEETS OF REFERENCE
MANUFACTURING AND CONTROL SHEET
INTERNAL ORDER
INTERAXLE LEGTH INERPRETATION
FITTING ORIENTATION
CRIMPING DIAMETER CHART
INSTRUCTIONS P32/FP110
HOSE FLUSHING – REGOLATION MACHINE CHART
PROOF TEST REPORT
1.0 GOAL
Hose Assembly Assurance Manual defines assembly process in order to garantee and assure that all operation of assembly productions are made following requirements requested by Customer Specifications e by Manuli Specifications. 2.0 APPLICATION FIELD
Work and control phases described in this Manual are applicable only to the activity of Hose Assembly production.
Each assembly phase is numbered with reference to Manufacturing and Control Sheet 3.0 ABBREVIATIONS
STOS : STORE SUPERVISOR
PROD : PRODUCTION
PRODS : PRODUCTIONE SUPERVISOR
QAS : QUALITY ASSURANCE SUPERVISOR
NC : NON CONFORM PRODUCT
MF/C : MANUFACTURING AND CONTROL SHEET 4.0 RESPONSABILITY PRODS
Issue MF/C with reference to internal order and give to production.
Operate swaging machine. At this operation, PRODS has to assure on every hose assembly that they are made following MF/C.
PROD
Has the responsibility to assembly and to control along the manufacturing process following what is written in SF/C.
QAS
Operate test pressure machine and report test result.
Issue NON CONFORM PRODUCT SHEET of NC
PHASE 1 HOSE TYPE
OPERATIONS
MACHINE
SHEET OF REFERENCE
Take from the storage the type of hose with the same code indicated on MF/C
Write the hose lot# on M/FC
Attention: to facilitate traceability of hose assembly, the type of hose used to manufacture a single lot of hose assembly must possibly be of the same lot
PHASE 2 CUT LENGTH / INTERAXLE LENGTH
OPERATIONS
MACHINE
SHEET OF REFERENCE
Cut length is indicated in MF/C. If it is not specified, operate as follow:
n consider interaxle length “L” of assembly indicated in MF/C;
n subtract from the measure of interaxle length “L” the sum of fittings length “x”, considering the measure from the abutting end of rubber hose to the fitting interaxle
n subtract to the result obtained the extension obtained during the crimping phase (5mm for braided hose and 8mm for spiralled hose)
L
x
Set the hose cut measure
steel ruler
Attention: cut must be perpendicular to the hose
cut section
YES
NO
Switch on the machine and wait until the number of cycles is stable.
cutting machine
Rule downward speed of blade (knife) depending on type of hose to be cut. A wrong regulation of downward speed can break the blade. For spiralled hose : minimum speed for all other types : normal speed.
cutting machine
Speed can be regulated with the handle on the left of cutting machine. Turning the handle anticlockwise speed increases and viceversa.
cutting machine
Front side
handle
Control cut rubber hose length and writ it on MF/C.
Steel ruler
PHASE 3 OUTSIDE SKIVE
OPERATION
MACHINE
SHEET OF REFERENCE
Take the pin guide of the same diameter of hose to be skived (see marking on the pin).
Set the pin as the skive length indicated on MF/C measuring with caliper the distance between the abutting of pin and the knife.
Skive machine
Set the phase inverter to wheel the mandrel to anticlockwise
Switch the skive machine with the foot -switcher
Insert the hose in the mandrel to skive.
Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
Be careful not to leave rubber dross, shavings on the hose.
Attention: skive has to be done just on hose with metallic reinforce.
PHASE 4 INSIDE SKIVE
OPERATIONS
MACHINE
SHEET OF REFERENCE
Spiralled hose must be skived inside.
Take the guide pin of the same diameter of the hose to be skived (see marking on the pin).
Set the ghiera as the skive length indicated on MF/C measuring the distance between the ghiera abutting and the knife.
Skive machine
Set the phase inverter to wheel the mandrel to clockwise
Switch the skive machine with the foot -switcher
Insert the hose in the mandrel to skive.
Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
Be careful not to leave rubber droll, shavings inside the hose.
PHASE 5 INSIDE/OUTSIDE SKIVE CONTROL
OPERATIONS
MACHINE
SHEET OF REFERENCE
Control the skive length with caliper as indicated in MF/C.
Caliper
Operator must also consult with skiving chart for the skive length in order to prevent too long/to short skive.
Skiving Chart
If skive is out of the range, put the assembly hose in a NC area, QAS to fill the Non Conformity product sheet.
Non Conformity Product Sheet
PHASES 6 1ST FITTING / 2ND FITTING
OPERATIONS
MACHINE
SHEET OF REFERENCE
Fittings are stored boxes identified with the product code which recorded in stock cards and/or computer.
Take fittings indicated on MF/C of the same box.
Put in the fittings to the hoses as indicated on MF/C.
PHASE 7 ORIENTATION
OPERATIONS
MACHINE
SHEET OF REFERENCE
Block fittings in the vice.
Vice
Turn manually the other fitting, following the chart enclosed, till the value indicated on MF/C is visible on goniometer
Goniometer
PHASES 8 MANUFACTURING DATE MARKING
OPERATIONS
MACHINE
SHEET OF REFERENCE
Use electric pen to mark
date-month-year on the ferrule of the assembly hose.
Example : 30/12/43
Electric Pen
PHASES 9 CRIMPING DIAMETER AND CRIMPING DIAMETER CONTROL
OPERATIONS
MACHINE
SHEET OF REFERENCE
The crimping diameter is indicated on MF/C.
Consult crimping diameter chart to choose the set of dies required for the crimping diameter requested.
P32/FP 110
Crimping Diameter Chart
Be sure the machine is turned off.
Put in the correct dies. Make sure that all dies are completely sit on the master dies.
Operator must also consult with the crimping diameter chart in order to prevent the out of range of crimping diameter.
Crimping Diameter Chart
Switch the machine on.
P32/FP 110
Instructions P32/FP110
Set the right crimping diameter with the diameter setting device.
“
Instructions P32/FP110
Push the press button to crimp the hose.
“
Instructions P32/FP110
Control the crimping diameter with caliper. Operator must measure the crimping diameter in every change of diameter setting
If crimping diameter is out of range, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet.
Non Conformity Product Sheet
PHASE 10 PROOF TEST (IF REQUESTED)
OPERATIONS
MACHINE
SHEET OF REFERENCE
Supply the bench with connections conform to hose to be tested.
Pressure bench
Customer Specifications
Switch on the bench and the computer.
Select or create the recipe. Remember that the proof pressure is double the working pressure written on the rubber hose.
Close the door and start the bench.
When cycle is finished write results on MF/C.
Print the report if requested by the Customer.
If there is leakage along the rubber or on the fittings, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet.
Non Conformity Product Sheet
PHASE 11 HOSE FLUSHING (IF REQUESTED)
OPERATIONS
MACHINE
SHEET OF REFERENCE
THE USE OF GLOVES IN THIS PHASE IS COMPULSORY
Control oil level with dipstick. If oil is under the half fill it up with oil.
Dipstick
Prepare the machine according to the hoses diameter, following the machine chart for the time and number of pumps
FMX 150
MOD. MOT06
Screw hoses on the rack in the correct way, being careful with long hoses, with wide bend radius (it is sufficient to screw two turns)
Push the two buttons on the sides of the bench. Door closes and automatically cycle works.
Front side
buttons
Door opens automatically, unscrew the hoses and put them on the rack to drip.
Attention: fluid used in this phase is oil for spark erosion (BP/HP-0 FINA IT/11-004 FINA PARAPUR/1013) and pollution grade to specifics NAS 1638 is checked monthly in an outside laboratory.
According to the analysis results: if the value of fluid is less or equal to 8 NAS can be used till the following month; if it is more or equal to 9 NAS must be changed by TEQ.
PHASE 12 CAPPING (IF REQUESTED)
OPERATIONS
MACHINE
SHEET OF REFERENCE
Take caps according to hose type and diameter.
Cap fittings when hoses are completely dry (if flushed).
NOTE The handling of hoses from the cutting phase to the fitting assembly/crimping one and from the latter and the flushing phase, has to be done by racks which can garantee outside hose cleanliness and prevent abrasions due to trailing along the floor.
J. สายน้ำหล่อเย็น Water Cooling Hoses 4″ –> ( Water Cooling Tower / Water Cooled Air Conditioning System type ) Water Chilling Unit + Fan Coil Unit ( FCU ) , Air Handling Unit ( AHU )
We make a trial for lance hose assy. combine with our Spin Rotary Spray Nozzle in our loboratory by gradually increasing the pressure.
We found that :-
ทางบริษัทฯได้ทำการทดสอบ Lance + Nozzle ในห้องปฏิบัติการแล้ว โดยค่อยๆ เพิ่มแรงดัน ขึ้นเรื่อยๆ เราพบว่า :-
1) The water flows out form the 4 opertures of rotary spray nozzle very well. The size for each operture in the nozzle is 500 microns.
1) น้ำพ่นออกทั้ง 4 รู ตามแบบตัวอย่างสมบรูณ์ แต่ยังไม่หมุนอาจเพราะต้องใช้ปั๊มตัวใหญ่ ที่มีอัตราการไหล Flow Rate Capacity สูงๆ และ หัวฉีดก็พร้อมที่จะหมุนฟรีไปตามคราบตะกรัน ( Scale ) ที่เกาะอยู่ภายในผนังท่อ
2) The developed ratating pipe cleaning nozzles, always have a spiral labyrinth for the better cleaning results.The labyrinth give the rotor a braking effect and as such creates perfect water lubrication between shaft and rotor.
2) มีการทำร่องแอ่งน้ำที่ทำให้น้ำหมุนวน Spiral Labyrinth หัวฉีดจึงจะหมุนเหมือน Springer ร่องแอ่งน้ำที่ทำให้น้ำหมุนวน Spiral Labyrinth หัวฉีดจะหมุนเหมือน Springer และพร้อมที่จะหมุนตามลักษณะคราบตะกรัน ( Scale ) ที่เกาะอยู่ภายในผนังท่อ
3) The nozzle also have a weep hole. This ensures a perfect seal between nozzle and hose or lance.
3) รูล็อคหัวเจาะ Weep hole ขนาด M 1.5 mm เป็นน็อตตัวหนอนหัวจม ทำหน้าที่เป็น Pin-lock ขันเพื่อกันหัวเจาะรูปจรวดแหลม คลายเกลียวออก
After the Polyflex 2204 D + nozzle trial, we took off the Nozzle. Keep them dry or soaking in the oil.
หลังการทดสอบ หรือ เวลาใช้งานเสร็จแล้วเก็บไม่ใช้งาน ถอดเคลียวเกลียวออก ทิ้งไว้ให้แห้ง หรือ แช่น้ำมันไว้
For your infromation and reference.
Your Lance could work with our Spin Rotary Spray Nozzle quite well. เวลาใช้งานเสร็จแล้วเก็บไม่ใช้งาน ให้ถอดเคลียวเกลียวออก ทิ้งไว้ให้แห้ง หรือ แช่น้ำมันไว้
สายแส้ สีฟ้า PolyFlex เส้นเล็ก ขนาด 1/8″ หัวสาย ใส่ประกอบดูกับ หัวสปิน Rotary Spin Nozzle 1/8″ [ Part Number 6012.218 : หัวสปินฉีดน้ำแรงดันสูง Spin Jet Nozzle สำหรับสายแส้ I.D 4 mm. เกลียว G1/8″ ตัวเมีย Female Fitting ( Spin Jet Max Working Pressure 1000 Bar 1/8″ NPTF SI.12BRFF ) : Side Spraying Only พ่นออก ด้านข้างอย่างเดียว , วัสดุ: แสตนเลส เกรด SUS440C หรือ เหล็ก STARVEX ] ตรวจสอบก่อนส่งให้ทดลองใช้งานจริง
Subject: Lubricant Gel Soap เจลหล่อลื่นป้องกันผิวนอกสายแส้ ลดความเสียดทานผนังด้านในท่อแป็ป
Lubricant Gel Soap ใช้งานหล่อลื่นผิวนอกสายแส้ ลดความเสียดทานผนังภายในท่อแป็ป ป้องกันผิวนอกของสายแส้เสียหาย
มี 2 เบอร์ คือ :-
Lubricant Gel Soap B 907
Lubricant Gel Soap B 1039
ตอนนี้ที่มีของอยู่เป็น Gel Soap B 907
ใบรับรองการใช้งานสายแส้ จากผู้ผลิตสายแส้ โดยตรง
