I. Focusing Only on "As Long as It Works," Neglecting Preventative Maintenance
Common Misconception: Waiting until the equipment makes abnormal noises, jams, or even stops before checking, equating "troubleshooting" with "routine maintenance."
Real Risk: Problems such as bearing dry friction, chain stretching, and seal aging may not have obvious symptoms in the early stages, but continuous operation will accelerate wear and tear, eventually leading to a chain reaction of failures.
Correct Practice: Establish a proactive maintenance mechanism, strictly adhering to the scheduled lubrication, cleaning, and calibration. Even if the equipment is running smoothly, regular "check-ups" are necessary.
II. Improper Lubrication: Using the wrong type of oil or over/under-lubricating
Common Misconception: Using ordinary grease to lubricate bearings indiscriminately, or believing that "the more oil, the better," leading to spillage and fabric contamination; some people neglect to lubricate for extended periods due to inconvenience.
Real Risk: Inferior grease is prone to emulsification and failure, accelerating wear; excessive lubrication leads to oil splatter, causing oil stains on the fabric; insufficient lubrication directly causes bearing burnout.
Correct Practice: Use compound calcium-based grease (dropping point 180℃). Lubricate the fabric roll bearings every 6 months and the transmission bearings quarterly, ensuring "appropriate amount, fixed location, and fixed time."
III. Superficial Cleaning, Neglecting Critical Dead Zones
Common Mistake: Only cleaning the visible areas of the dyeing tank, neglecting glue and fiber buildup in hidden areas such as under the chain, roller end faces, and inside the filter.
Real Risk: Accumulated residue can clog the circulation system, affect tension transmission, and even fall onto the fabric surface, causing color spots or abrasions.
Correct Practice: Clean glue buildup inside the machine weekly and check for yarn knots on the stainless steel rollers, ensuring a smooth and unobstructed fabric guide path.
IV. Neglecting Tension and Mechanical Precision Calibration
Common Mistake: Believing that "once the tension is adjusted, it's done," and neglecting to check roller parallelism, tensioner curvature, or sensor accuracy for extended periods.
Real Risk: Small deviations, accumulated over time, can lead to fabric problems such as wrinkles, weft skew, and edge-to-center discrepancies, which are difficult to remedy through process adjustments.
Correct Practice: Use a laser alignment instrument monthly to check the parallelism of the rollers; adjustments are required if the deviation exceeds 0.1mm. Check the fabric stretcher curvature quarterly to ensure it is suitable for the current fabric type (e.g., 4-8mm is recommended for silk).
V. Missing Maintenance Records, Unable to Trace and Provide Early Warning
Common Misconception: Maintenance is performed verbally or from memory, without written records, leading to omissions, duplication, or unclear responsibilities.
Real Risk: Inability to determine the last maintenance time and content makes it difficult to trace the source of malfunctions and hinders scientific maintenance cycle management.
Correct Practice: Establish a paper or electronic maintenance log, recording the specific items, time, and operator for each cleaning, lubrication, and calibration, creating a traceable maintenance record.
VI. Ignoring the Synergistic Effects of Environment and Operation
Common Misconception: Focusing only on equipment while ignoring the environment; drastic fluctuations in workshop temperature and humidity, or operators not following specifications for fabric handling and sewing. Real Risks: Environmental changes can cause fabric shrinkage and deformation; improper human operation can lead to problems such as overlapping marks and loose board marks, which may be misdiagnosed as equipment malfunctions.
Correct Practices: Maintain stable temperature and humidity in the workshop, while strengthening personnel training to ensure that pretreatment meets standards, seams are straight, and fabric feeding is neat, achieving collaborative protection of "people-machine-environment".
