Welding is one area of manufacturing where just having the right tools is not enough. Welding equipment must be well-maintained so that it can be used safely to complete jobs as efficiently as possible. Improper or incomplete maintenance can leave machines in a state of disrepair that could pose a serious safety hazard to both welders and others in the area.
Welding machine equipment failures are common causes of accidents in the industry. Unfortunately, these accidents can cause severe injuries or even mortalities. This article will take a look at why it’s so important to stay on top of maintenance schedules for all of a facility’s welding tools.
The Benefits of Regular Maintenance
Providing welding equipment with basic maintenance isn’t just about avoiding serious accidents. There are also other benefits to staying on top of routine maintenance.
1. Decreased Costs
Unexpected welding machine breakdowns are costly to fix. The need for emergency repairs can also put the shop behind schedule, further increasing costs. Regular maintenance helps to avoid these problems.
2. Product Quality
Caring for welding equipment properly is the only way to ensure performance. This, in turn, is how manufacturers can guarantee product quality. Welds must be both precise and strong, so even minor malfunctions in equipment that go unnoticed can cause problems with quality.
3. Longer Equipment Lifespan
Keeping equipment well-maintained is the best way to prolong its lifespan. Welding equipment is expensive, whereas routine oil changes and performing periodic inspections are very affordable.
Basic Maintenance Tips
Already understand the importance of routine maintenance but not sure how to get started? Find out about the basics below.
Maintaining Electrical Systems
With the exception of oxy-acetylene gas welding, all welding processes rely on electricity as a primary power source. As most people know somewhere in the back of their minds, electricity can be dangerous even when it’s not being supplied at levels high enough to run welding equipment.
Accidents in welding shops that result from electrical system issues can be avoided through routine maintenance of all electrical components in welding machines. Here’s what it requires:
- Disconnecting power units and vacuuming out machine interiors at least twice a year.
- Checking the wire feeder and cleaning it with a wire brush every three to four months.
- Checking the drive rolls and replacing them as necessary.
- Inspecting, cleaning, and replacing inlet and outlet guides once per season.
- Having welding guns and liner assemblies serviced by a trained technician once a year.
- Inspecting electrical cables for signs of wear at least once a month and replacing any of them that have cracks, breaks, or other signs of damage to the insulation.
- Inspecting electrical safety equipment such as circuit breaks and interlocks once a month.
Gas Cylinder Maintenance
All gas cylinders should be stored upright in cool, dry environments. However, welding shop owners shouldn’t just assume that they’re in serviceable shape. Instead, they should inspect and test the regulators and valves every six months to look for leaks and breaches that could cause incorrect pressure readings.
The Importance of Buying Quality Equipment
While ongoing maintenance for welding equipment is important, it doesn’t replace the need for investing in quality machines and tools, to begin with. If it seems like all the maintenance in the world isn’t keeping a shop’s current equipment running efficiently, it may be time to invest in better tools.