The common problems, precautions and maintenance knowledge during the use of glass washing machines
A glass washing machine is special equipment for cleaning and drying the glass surface before glass deep processing such as mirror making, vacuum coating, tempering, hot bending, and insulating glass lamination. Generally speaking, cleaning equipment is divided into vertical glass washing machines and horizontal glass washing machines according to the processing method. The glass washing machine is mainly composed of the transmission system, brushing, clear water rinsing, pure water rinsing, cold and hot air drying, electric control system, etc. According to user demands, medium and large glass washing machines are also equipped with manual (pneumatic) glass turning trolleys and inspection light sources, and other systems.
The principle of glass washing and glass drying
Generally speaking, the cleaning principle of the glass washing machine is that after the transducer converts high-frequency electrical energy into mechanical energy, high-frequency vibration with extremely small amplitude will be generated and transmitted to the cleaning water in the cleaning tank. Under high temperature, a large number of tiny bubbles will be continuously generated inside the cleaning water and burst instantly. The rupture of each bubble will generate a shock wave with a high temperature of hundreds of degrees and a pressure of nearly a thousand atmospheres, so that the glass to be cleaned is washed clean.
The common glass washing methods of automatic glass washing machine are divided into two types:
First, after the flat glass is placed on the glass washing machine, the glass is carried by the drive roller into the brushing room, washed by the brush sprayed with water, and then enters the washing room, rinsed with pure water, and then enters the air-drying room with a special high-pressure fan thoroughly peel off the water film to achieve a dry and clean cleaning effect. This type of vertical glass washing machine is characterized by power saving, but noise.
Second, after passing through the scrubbing room and the rinsing room, only the air knife is used to blow the breeze, coupled with the electric heating drying system, to achieve a dry and clean cleaning effect. This type of horizontal glass washing machine is characterized by more power consumption and less noise.
Common problems and solutions during use:
①Unable to turn on or appear overloaded
A. Check whether the emergency stop is fully turned on;
B. If the machine cannot be turned on, check whether the fuse in the electric box is damaged;
C. If it is overloaded, open the electric box and press the red button on the calorimeter. If the red light goes out, adjust the current button of the calorimeter appropriately;
②Couldn't washing clean
A. Check whether the brush has been opened;
B. Whether the water inlet switch has been turned on;
C. Whether the brush can brush the glass;
D. Whether the brush is worn;
③The water on the glass does not dry
A. Check whether the absorbent sponge is adjusted and pressed well;
B. Whether the red ball valve is turned off;
C. Whether the fan is turned on and rotating forward;
D. Whether the heating is turned on;
E. Whether the absorbent sponge is damaged;
F. Whether there is oil pollution in the water tank;
④ leakage phenomenon
A. Check whether the ground wire;
B. Open each motor cover to see if there is any pressure on the wire;
C. Check whether the wire inside the rack tube is broken;
⑤The water pressure is not good
A. See if there is enough water in the water tank;
B. See if the pump is evacuated;
C. Whether the water outlet of the water tank is blocked;
⑥ Transmission glue stick does not turn
A. If it does not rotate at all, check whether the motor is turned on, and check whether the chain is disconnected;
B. If one does not turn, check whether the sprocket screw is locked, or the top bar of the top chain below may be loosened;
The lubrication of glass washing machine
To prevent gear necrosis caused by excessive wear of the wear machine, the washing machine must be properly lubricated. In particular, the glass coating process requires very high cleanliness of the glass, and a small amount of lubricating oil is not allowed to enter the washing and drying area, so grease with good mechanical stability and adhesion should be selected. Focus on lubrication of drive chains, helical gears, and drive shafts.
①Isolate the parts that need to be lubricated from the cleaning area with a plastic sheet to avoid grease contamination.
② Lubricate the joint surface of the chain, gear, drive shaft chain roller, and chain plate.
③ The transmission chain and roller table should be lubricated evenly.
④ Wipe off excess grease with a clean cotton cloth.
Figure 1 The lubrication of drive chains from glass washing machine
Calibration of conveying roller table
The glass washing machine adopts the method of pinch glass, the lower roller table is fixed, and the height of the upper roller table can be adjusted to ensure the uniform force of the glass and smooth transmission. The lower roller table is driven by the drive shaft and gear system, and the bearings and the horizontal and vertical levels need to be checked regularly. The upper roller table is fixed by two water-lubricated plastic bearings at both ends and can rotate freely. Because the plastic bearing is easy to wear and increases the gap after a period of use, the two ends of the upper roller table are unbalanced, and the original glass sheet is easy to be skewed in the glass washing machine. For the upper roller table, we add fixed end block clamps and regularly measure the height change, correspondingly calibrating or replacing the bearing to adjust the pressing force of the roller.
Figure 2 The conveying roller of glass washing machine
Adjustment of the height of the disc brush
The inlet glass washing and drying machine mainly cleans the surface of the original glass sheet through a disc brush, and at the same time adds a liquid polishing agent to ensure that the glass surface can be effectively polished and remove stubborn stains. To make the disk brush effectively roll on the glass surface, the height of the disk brush bristle tip is generally set at 1.5 mm below the surface of the glass sheet. As the bristles of the disc are worn, the height of the disc brush needs to be lowered regularly to ensure the quality of glass washing.
Cleaning of the water storage tank and drip tray
The inlet cleaning machine adopts the method of step-by-step cleaning and recycling with three-level water quality. There are 5 water tanks and corresponding water receiving trays at the lower part of the conveying platform, which is used to store cleaning water. Since the water itself is polluted while cleaning the glass, some dirt such as a polishing agent is usually deposited in the water storage tank, which needs to be washed regularly to ensure the cleanliness of the water quality.
The smoothness of the polishing agent and spray pipe
The inlet glass washing machine uses an aluminum or cerium oxide aqueous solution as a polishing agent, which is added to the rubbing process of the disc brush through the water spray pipe between the upper roller tables. Since the solid aqueous polishing agent is used, when the concentration is too large, it is easy to cause the nozzle to be blocked. When it is observed that the polishing agent nozzle is blocked during use, it should be cleared in time and the concentration of the diluted polishing agent should be adjusted. Follow the steps below to clean the polish and spray the hose.
①Remove the baffle plate of the washing machine, raise the upper roller table of the washing machine and turn off the power supply and the water supply valve.
② Loosen the fixing bolts at both ends of the nozzle and remove the nozzle.
③Use a high-pressure water gun to drive pure water from the inlet of the nozzle into the nozzle to form water pressure, observe the water outlet of each nozzle, and use a paper clip to dredge.
④Clean the nozzle, install it back to the original place, fasten the bolts, and pay attention to keeping the nozzle direction unchanged before dismantling and washing.
Figure 3 The smoothness of spray pipe of glass washing machine
The washing and adjustment of air knife drying area
The last water tank of the washing machine is filled with high-purity water that has been heated (the temperature is about 45°C), so the water stains attached to the surface of the original glass sheet can be blown away and evaporated by the high-strength wind of the air knife after entering the drying area. . The blade of the air knife and the plane of the original glass form a certain acute angle. Every time the air knife is disassembled or installed or its position is changed, the angle should be measured and kept unchanged.
①Clean up the glass debris, labels, paper clips, and other dirt in the dry area, and wipe the air knife, roller table, and other components with a clean cotton cloth to ensure cleanliness.
②Remove the primary filter plate and secondary filter bag for the fan, blow out the dust inside with compressed air in reverse, check for damage or blockage, and replace it regularly.
③Use a saw blade to probe into the air knife edge to check whether there is debris such as filter bag fibers that block the knife edge.
As long as the inlet glass washing machine is regularly and carefully maintained and maintained according to the above procedures, under normal conditions, the cleaning effect of the original glass sheet can be guaranteed to a greater extent, and the quality of the coated glass products can be guaranteed.
Figure 4 The cleaning of air knife drying area from glass washing machine
Easy to ignore pre-spray
Regardless of whether horizontal or vertical cleaning is used, the pre-spraying device is a very important and easily overlooked place. Most of the pre-spraying devices set up by some washing machine manufacturers are drilling holes on stainless steel pipes. The spray pressure and water volume of this method are not enough. The function of pre-spray is mainly used to remove the floating dust and dirt on the glass surface. If the required water spray pressure and amount of water cannot be achieved, the glass surface cannot be cleaned effectively, so the dirt on the glass surface will not be cleaned. It enters the washing machine with the glass, causing pollution to the roller brush and the water tank.
Regular brush maintenance
The key part of glass cleaning is the roller brush part of the cleaning machine, which is very important for the regular maintenance of the roller brush. The dust, oil stains on the glass surface, and the paper glue of the glass backing paper are easily attached to the bristles of the roller brush, and some are also hidden at the roots of the bristles. If it is not cleaned in time, it will contaminate the glass surface being cleaned. Especially for glass washing machines that clean off-line Low-E glass, more attention should be paid to the regular maintenance of the roller brushes. A high-pressure water gun can be used for cleaning during maintenance. In addition, after long-term use of some vertical cleaning machines, the lower part of the roller brush wears faster than the upper part, and it also needs to be trimmed.
Re-understand the washing water
The quality of washing water is directly related to the cleaning results. It is not acceptable to use tap water, well water, or ordinary purified water to clean glass, because tap water, especially well water, contains a lot of calcium, magnesium, chlorine, and other ions. The cleaning water should be deionized water with a conductivity of less than 20 g/cm after being treated by water treatment equipment with a deionization function. When processing off-line tempered Low-E insulating glass, the requirements for cleaning water are more stringent. The water in the washer tank needs to be changed frequently to keep it clean. Remove deposits from the tank during water changes to prevent the tank supply pump from carrying these deposits to the roller brushes.
Notable air knife design and maintenance
After many glass washing machines wash the glass, the air knife cannot completely blow the water on the glass surface, especially when the speed of the washing machine is fast. This is mainly the design, manufacture, and installation adjustment of the glass washer air knife. The structure of the air knife of the washing machine, the angle between the air knife and the glass, and the wind force of the air knife are the key factors. In addition, the filter screen of the air inlet of the fan should be cleaned in time. Once the dust enters the fan, it will be difficult to clean up completely. After the air knife blows the glass surface with water, it will cause water marks on the glass surface.
Figure 5 The air knife design and maintenance of glass washing machine
During the production process, the cleaning effect of the glass should be checked frequently. The recommended simple method is to use the Hack method, which can intuitively see the cleanliness of the glass surface.
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