If you are operating CTL’s, Folders, Rollformers or any other forms of sheetmetal machinery, then they are likely a critical part of your manufacturing operation, and have required a substantial initial investment. The reliability and performance of these machines directly impacts production efficiency, product quality, and overall operational costs. We believe that preventative maintenance is essential to ensuring that these machines run optimally and have a long service life – maximising your ROI. This practice involves regular detailed inspections, cleaning, adjustment, and testing of safety features that is aimed at preventing the majority of breakdowns and costly downtime. Among the many aspects of preventative maintenance, we focus on mechanical inspections, oil testing, and electrical checks which we believe are crucial in detecting problems early and prolonging equipment life.
The Importance of Preventative Maintenance
Preventative maintenance involves a structured, proactive approach to maintaining machinery. Unlike reactive maintenance, or the run to fail approach — where problems are fixed only after they occur — preventative maintenance seeks to prevent these issues from arising in the first place. Regularly scheduled maintenance tasks, such as oil testing and filtering, electrical inspections, and mechanical testing, help keep machines running smoothly and reduce the risk of unexpected failures.
A robust maintenance plan extends the life of your machinery, reduces the total cost of ownership, and increases productivity. When problems are caught early, they are typically cheaper and easier to repair. Additionally, well-maintained machines perform more efficiently, which can lead to higher quality output and less energy consumption. Here are three key aspects of preventative maintenance that are especially beneficial for sheet metal machinery: oil testing, electrical checks, and mechanical inspections.
Mechanical Inspections: Catching Wear and Tear
Mechanical wear is an inevitable part of operating machinery. Components such as bearings, gears, pumps, chains, belts, and other moving parts experience stress over time, which can lead to failures if not addressed early. Regular mechanical inspections help identify wear before it leads to severe damage, allowing for timely repairs or replacements.
Benefits of Mechanical Inspections
- Detecting Misalignment: Misaligned components can cause excessive wear, vibration, and machine inefficiency. Regular inspections help catch misalignment issues early, allowing adjustments that prevent further damage and prolong machine life.
- Monitoring Bearings and Gears: Bearings and gears endure high levels of stress and are prone to wear. Signs such as noise, vibration, or increased heat can indicate the need for maintenance. Regular checks ensure these components are functioning properly and can prevent major breakdowns.
- Maintaining Proper Belt and Chain Tension: Belts and chains that are either too loose or too tight can damage the machine’s drive system. Regular inspections ensure that belts and chains are properly tensioned, minimising the risk of failure.
- Ensuring Adequate Lubrication: Proper lubrication reduces friction between moving parts, which is essential for minimising wear and extending the life of components. Mechanical inspections often include checking lubrication levels to ensure all moving parts are adequately lubricated.
Best Practices for Mechanical Maintenance
Mechanical inspections should be conducted routinely – we recommend every three or four months focusing on high-stress areas like bearings, gears, and drive systems. Mechanical checks of all safety controls on the machine is also critical during these checks. Proper lubrication practices should also be followed to ensure smooth operation of the machine.
The Role of Oil Testing in Machinery Maintenance
Oil is a critical part of many sheet metal machines, often playing a crucial role in operating uncoilers, folding beams, knife positioning systems, guillotines and dropstackers. Over time, oil degrades and can become contaminated with particles, moisture, or other substances. Contaminated or degraded oil can cause significant wear on machine components, leading to premature failure or costly repairs. Regular oil testing is one of the most effective ways to monitor the condition of both the oil and the machine.
Benefits of Oil Testing
- Early Detection of Wear: Oil testing can reveal early signs of component wear by identifying metal particles in the oil. For instance, elevated levels of iron or copper can indicate wear in bearings, gears, or other components. Detecting this early allows maintenance teams to filter the oil, replace or repair parts before a catastrophic failure occurs.
- Monitoring Oil Condition: Over time, oil can lose its viscosity or become contaminated with water, dirt, or other materials. By regularly testing the oil and comparing it against a previous sample from the same machine, maintenance teams can determine whether the oil needs to be changed or if the system needs to be flushed and cleaned.
- Improved Machine Performance: Clean, well-maintained oil helps machines run more smoothly and efficiently. It reduces friction between moving parts, minimises heat build-up, and protects against corrosion. This, in turn, helps to prolong the life of the machine.
- Cost Savings: Regular oil testing and maintenance can lead to significant cost savings by preventing unexpected breakdowns and prolonging the intervals between major overhauls. It also reduces the risk of secondary damage that can occur when worn components fail.
Best Practices for Oil Testing
To maximise the benefits of oil testing, we recommend six monthly checks as part of the machine’s maintenance schedule. Oil samples should be taken in a clean, controlled manner to avoid contamination. The samples are then sent to a lab that specialises in oil analysis, where they will be tested for viscosity, contamination, and metal particles and compared against the last sample from that same piece of equipment. Based on the results, maintenance teams can decide whether to change the oil or take corrective actions to prevent further damage.
Electrical Checks to Prevent Failures
Most modern machinery incorporates advanced electronics for control systems, sensors, and hydraulic or servo movements. Electrical failures can lead to costly downtime, particularly as they can be hard to pinpoint, damaged components, or even safety hazards. Regular electrical checks are an essential part of a preventative maintenance program and can catch potential issues before they escalate.
Benefits of Electrical Checks
- Identifying Loose Connections: Electrical systems are prone to loose or corroded connections over time. This can lead to arcing, intermittent operation, or complete failure of electrical components. Regular inspections can identify and correct these issues before they cause a breakdown.
- Testing for Voltage and Current Fluctuations: Voltage and current imbalances can indicate problems with the machine’s electrical system or its power supply. These fluctuations can lead to overheating, increased wear on components, or electrical failures. By regularly testing electrical systems, maintenance teams can identify and correct these issues early.
- Preventing Sensor Failures: Many modern machines rely on sensors to monitor temperature, pressure, position, and other critical parameters. If a sensor fails, it can cause the machine to operate incorrectly or shut down unexpectedly. Regular sensor checks can help ensure that these devices are functioning properly.
- Ensuring Safety: Electrical problems can pose serious safety risks, particularly if sensors are not working as required. Regular electrical inspections should ensure that the machine’s safety systems—such as emergency stops and grounding—are functioning correctly.
Best Practices for Electrical Maintenance
To conduct effective electrical checks, maintenance teams should regularly inspect all wiring, connections, and electrical components aswell as testing all safety switches / devices. Additionally, the machine’s control system and any variable speed drives should be checked for any error codes or abnormal readings, which can indicate developing problems.
Insights
Preventative maintenance is essential for prolonging the life of all machinery, including those in sheetmetal and rollforming operations, in order to promote optimal performance. Regular oil testing, electrical checks, and mechanical inspections can catch problems early, prevent costly breakdowns, and improve overall efficiency. By tailoring our preventative maintenance program offerings to your specific need, companies can significantly reduce downtime, extend the life of their equipment, and enhance their bottom line. In the competitive world of sheetmetal manufacturing, the benefits of preventative maintenance cannot be overstated—it’s a critical practice that keeps operations running smoothly and efficiently for the long term.