Routine Maintenance (per shift or daily)
Clean the mixing head and pouring port.
Remove any residual material promptly after shutdown.
Check the mixing chamber for lumps or solidified residue.
Prevent cross-contamination that could lead to abnormal mixing ratios.
Check the raw material system.
Check the TDI tank level.
Check for moisture absorption.
Confirm the raw material temperature meets process requirements.
Check the metering pump.
Observe if the flow rate is stable.
Check the pump for leaks or abnormal noises.
Monitor pressure fluctuations.
Check the temperature control system.
Verify the set temperature against the actual temperature.
Check the heater, heat transfer oil system, or electric heating system for proper functioning.
Excessive temperature deviation can lead to unstable product performance.
Check the vacuum system.
Confirm the vacuum level meets standards.
Release condensate and impurities.
Check for leaks in the vacuum lines.
Weekly Maintenance
Filter Cleaning.
Clean the raw material filter.
Check for filter blockage.
Lubrication Maintenance.
Add grease to the guide rails and transmission mechanism according to the equipment manual.
Check the automatic lubrication system for proper functioning.
Inspect the piping. Check for aging, cracks, and leaks in the hoses.
Tighten the joints.
Verify metering accuracy. Perform weighing tests on components A and B.
Verify that the mixing ratio error is within the equipment's allowable range. High-precision casting machines typically require mixing ratio errors to be controlled within a small range.
Monthly maintenance.
Electrical system inspection. Clean dust from the control cabinet.
Check for loose wiring terminals.
Test emergency stop and safety interlocks.
Heating system inspection. Check the accuracy of the temperature sensor.
Inspect the heating elements, heating rods, or heat transfer oil circulation system.
Vacuum pump maintenance. Replace or replenish the vacuum pump oil.
Clean the oil mist filter.
Agitator inspection. Check the agitator motor, current, and bearing condition.
Remove sediment from the bottom of the tank.
Quarterly or semi-annual maintenance.
Complete overhaul of the metering pump. Check for wear on gears, plungers, and seals.
Replace seals if necessary.
Hydraulic system maintenance (if the equipment is hydraulically driven).
Change the hydraulic oil.
Replace the filter element.
Check the pressure valve and oil pump status.
Perform overall machine calibration.
Temperature calibration.
Flow rate calibration.
Pressure calibration.
PLC parameter backup.
Special Precautions for TDI Equipment
Because TDI (toluene diisocyanate) readily reacts with moisture in the air:
Raw material drums and storage tanks should be kept sealed.
The dry air or nitrogen protection system must be operating normally.
For extended downtime, raw materials should be emptied or circulated according to process requirements.
Prevent materials from solidifying and clogging due to prolonged residence in the mixing head and pipelines.
Operators should wear protective eyewear, chemical-resistant gloves, and respiratory protective equipment.