1、 Deviation of arc accuracy in sector segments

Fault manifestation:

Cracks or indentations appear on the surface of the cast billet

The internal quality of the cast billet is unstable

Abnormal measurement value of fan-shaped roller gap

Root cause analysis:

Deformation or settlement of the basic framework

Wear of roller bearings leads to inaccurate positioning

Unstable hydraulic system pressure

Error or improper operation of the arc calibration tool

resolvent:

Regular testing and adjustment:

Conduct a comprehensive arc detection every quarter using a high-precision laser tracker

Establish a fan-shaped arc database to track historical trends

Mechanical adjustment shall be made for sections with a deviation exceeding 0.1mm/m

Strengthen basic maintenance:

Check and tighten all foundation connection bolts

Replace or professionally correct severely deformed frames

Add insulation protection in high-temperature areas

Optimize the operational process:

Develop standardized arc operation specifications

Provide professional training and assessment for operators

Implement a dual person review system to ensure calibration accuracy

2、 Fan segment roller system malfunction

Fault manifestation:

The roller rotates poorly or gets stuck

Abnormal increase in bearing temperature

Leakage of cooling water at the sealing area

Severe wear on the roller surface

Root cause analysis:

Poor lubrication of bearings or water ingress

Blockage or angle deviation of cooling water nozzle

Excessive casting temperature leads to thermal deformation

Improper roller material or heat treatment process

resolvent:

Lubrication system improvement:

Switch to high-temperature long-lasting lubricating grease to extend the grease replenishment cycle

Install an automatic lubrication system to ensure accurate oil supply

Upgrade the sealing structure to prevent the intrusion of cooling water

Cooling system optimization:

Clean the nozzle monthly to ensure the angle and coverage of spray

Add water temperature monitoring and flow alarm devices

Adopting zone controlled cooling and matching the temperature curve of the casting billet

Roller maintenance strategy:

Establish a roller life prediction model and arrange replacement in advance

Stock spare rollers to shorten downtime due to malfunctions

On site repair or factory treatment of severely worn roller surfaces

3、 Hydraulic system malfunction

Fault manifestation:

Unstable control of sector opening degree

Slow or asynchronous action of hydraulic cylinder

Large fluctuations in system pressure

Frequent oil contamination alarms

Root cause analysis:

Hydraulic oil cleanliness does not meet the standard

Seal aging and leakage

Servo valve stuck or delayed response

Insufficient system design traffic

resolvent:

Oil management:

Strictly implement the regular inspection and replacement system for oil products

Install a multi-stage filtration system to maintain NAS level 7 cleanliness

Seal the fuel tank with nitrogen to prevent oxidation

Component maintenance:

Establish a preventive replacement plan for key valve groups

Adopting intelligent hydraulic components with status monitoring

Add shock-absorbing devices to the vibrating parts of the pipeline

System upgrade:

Add an accumulator to stabilize the pressure in the high-pressure section

Optimize control algorithms to improve multi cylinder synchronization accuracy

Consider using electric cylinders to replace some hydraulic functions

4、 Electrical control system malfunction

Fault manifestation:

Position sensor signal drift

Frequent alarms in PLC module

Communication interruption or data loss

Drive device overload tripping

Root cause analysis:

High temperature environment affects the lifespan of electronic components

Electromagnetic interference causes signal distortion

Software version incompatible

Poor grounding system

resolvent:

Environmental control:

Add a forced cooling system to the electrical cabinet

Use high-temperature grade components

Regularly clean the heat dissipation channel

Anti interference measures:

Use shielded twisted pair cables instead of signal lines

Add signal isolation amplifier

Optimize cable laying path to avoid strong electrical interference

System maintenance:

Establish a control program version management system

Regularly backup parameters and programs

Upgrade and renovate the old control system

5、 Overall maintenance strategy for sector segments

Establish a status monitoring system:

Install vibration and temperature online monitoring devices

Develop intelligent diagnostic algorithms to provide early warning of faults

Integrate with production management system to optimize maintenance plan

Improve maintenance methods:

Adopting modular design to shorten replacement time

Develop standard maintenance work packages to improve efficiency

Cultivate a professional maintenance team and reduce reliance on outsourcing

Optimization of spare parts management:

Determine the list of key spare parts based on fault statistical analysis

Implement graded inventory management

Establish a rapid response mechanism with suppliers

Through the above systematic solutions, the operational reliability of the anisotropic steel sector can be improved, unplanned downtime can be reduced, and strong guarantees can be provided for the stable and smooth operation of continuous casting production. In practical applications, adjustments and optimizations need to be made based on specific equipment models and production conditions.