The geogrid production line equipment is the core equipment for producing high-strength geosynthetic materials, and its stable operation directly determines product quality (such as tensile strength, dimensional accuracy) and production efficiency. Equipment failure not only leads to downtime losses, but may also result in product scrapping and safety hazards. Therefore, establishing a preventive and full process maintenance system is the key to reducing the occurrence rate of failures. The following elaborates on specific maintenance strategies from the dimensions of daily maintenance, regular inspections, specialized maintenance of key components, seasonal protection, and personnel management.

1、 Daily Basic Maintenance: A Must Do 'Health Check' Every Day

Daily maintenance is the first line of defense for stable operation of equipment, which needs to run through three stages: before startup, during operation, and after shutdown:

Pre startup inspection:

Lubrication system: Confirm that the oil level at each lubrication point (such as extruder gearbox, traction roller bearings) is within the specified range and there is no oil leakage;

Fasteners: Check whether the bolts of key parts such as screws, traction rollers, and cutting tables are loose;

Electrical and safety: Check for damaged wires, good grounding, and sensitive emergency stop buttons;

Materials and tools: Clean the impurities in the hopper and prepare commonly used tools (such as wrenches and thermometers).

Monitoring during operation:

Real time observation parameters: barrel temperature, screw speed, and melt pressure of the extruder; The speed and tension of the tractor; The cooling water temperature of the shaping device; If the cutting accuracy of the cutting equipment deviates from the threshold (such as temperature fluctuation ± 5 ℃), it needs to be adjusted immediately;

Listen, look, and touch: Check for any abnormal noises from the monitoring device (such as the "clicking sound" of gear wear); Observe whether there are bubbles or burrs on the surface of the product; Touch the temperature of the motor casing (not exceeding 60 ℃) to prevent overheating.

Cleaning and recording after shutdown:

Thoroughly clean up residues: The extruder barrel needs to be emptied of residual materials with cleaning materials (such as PE material) to avoid solidification and adhesion; The traction roller and shaping plate need to be wiped clean;

Cut off power: Turn off the main switch and unplug the plug (extra attention should be paid in humid environments);

Fill in the log: Record the daily running time, parameter fluctuations, abnormal situations, and handling measures to provide a basis for subsequent maintenance.

2、 Regular in-depth maintenance: eliminate potential hazards on a periodic basis

Regular maintenance should be planned on a weekly, monthly, and quarterly basis, targeting key areas such as vulnerable parts, transmission systems, and hydraulic systems

Weekly inspection: Check the tension of the transmission belt (if the traction belt is not loose), whether there are blockages in the cooling system pipes, and whether there are gaps in the cutting blades; Clean the surface dust of the equipment to prevent it from entering the electrical cabinet.

Monthly inspection: replace the hydraulic system filter element (to avoid oil contamination); Check the wear of the extruder screw and barrel (measure the gap with a micrometer, repair if it exceeds 0.5mm); Calibrate the tension sensor of the coiler to ensure neat coiling.

Quarterly inspection: Thoroughly disassemble the extruder screw and clean up carbonization residue; Replace the gearbox lubricating oil (select the model according to the instructions, such as hydraulic oil No. 46); Clean the scale in the cooling water tank (rinse with citric acid solution in circulation); Polish or replace cutting blades (replace when blade wear is ≥ 0.2mm).

Attention: Lubricating oil should not be mixed. When replacing, the old oil should be drained and the oil tank should be cleaned to avoid chemical reactions between different oil qualities.

3、 Special maintenance of key components: focus on extending the lifespan of core equipment

The core components of the geogrid production line, such as extruders, tractors, and shaping devices, require targeted maintenance

Extruder screw and barrel:

Avoid material degradation: Before shutdown, it is necessary to clean with low melting point materials (such as PP material to clean PVC residue) to prevent material carbonization at high temperatures;

Reduce wear: Do not add metal impurities, regularly check the degree of wear on the screw edges, and repair if there is a "chamfer".

Traction system:

Roller maintenance: Keep the surface of the traction roller clean (without adhesive materials), adjust the parallelism of the roller (error ≤ 0.1mm/m), and prevent product deviation;

Belt maintenance: If belt traction is used, the tension should be adjusted regularly to avoid slipping and uneven product stretching.

Fixed cooling device:

Cooling effect guarantee: Regularly clean the scale in the cooling water pipe to ensure stable water temperature (such as controlling the water temperature at 20-30 ℃ for PVC geogrid shaping);

Cleaning of shaping board: Wipe the surface of shaping board daily to prevent material adhesion from affecting the flatness of the product.

Cutting and coiling equipment:

Cutting blade: Polish once a week to maintain sharpness and reduce burrs;

Winding tension: Calibrate the tension controller monthly to avoid excessive tension causing product breakage or insufficient tension causing loose winding.

4、 Seasonal protection: special maintenance to adapt to environmental changes

Seasonal changes can easily cause equipment failures, and targeted protection is needed:

Winter: The cooling system needs to drain accumulated water (or replace antifreeze) to prevent pipeline freezing and cracking; Add low-temperature lubricating grease to the motor bearings to prevent grease from solidifying at low temperatures;

Summer: Clean the dust from the motor cooling fan and ensure that the ventilation openings are unobstructed; Check the cooling fan of the electrical cabinet to prevent components from overheating and burning out;

Rainy season: Regularly check the insulation resistance of electrical equipment (≥ 1M Ω) to prevent short circuits; Install dehumidifiers in the workshop to reduce equipment corrosion.

5、 Personnel and system: the core support for ensuring the implementation of maintenance

Operator training:

Skill training: Familiarize employees with equipment structure (such as screw types of extruders, transmission methods of tractors), and master common fault handling (such as abnormal noise shutdown, parameter adjustment);

Safety training: Emphasize the need for power-off and hanging tags during maintenance, and prohibit live operation; Tools should be used in a standardized manner to avoid accidental injury to equipment or personnel.

Establish a maintenance responsibility system:

Develop an Equipment Maintenance Manual to clarify the maintenance responsibilities of each position (such as operators responsible for daily cleaning and maintenance workers responsible for quarterly maintenance);

Establish a maintenance ledger to record the time, content, and responsible person for each maintenance, for easy traceability and assessment.

The maintenance of the geogrid production line should adhere to the principle of "prevention first, full participation of all staff", and organically combine daily maintenance, regular inspection, and special maintenance. Through systematic maintenance measures, not only can equipment failures be reduced (according to statistics, standardized maintenance can reduce more than 70% of sudden failures), but equipment life can also be extended (such as screw life can be extended by 2-3 years), ultimately improving production efficiency and product quality, and creating greater value for enterprises.