SOP, Data Collection Checklist, and Fault Classification for Remote Diagnosis of Overseas Casting Mold Aftersales | Mold Overseas Aftersales System
Remote fault diagnosis of overseas molds lacks standardized information collection, resulting in 46% of repeated communication and misjudgment, leading to waste of after-sales resources.
The fault occurred only with photos, lacking pressure curves, mold temperature records, aluminum liquid spectra, vacuum degree, and spraying parameters, making it impossible to locate the root cause.
The fault description is not graded: air holes, shrinkage, strains, flying edges, and stuck molds are mixed together, and the priority order is disordered.
The recent number of mold cycles, maintenance records, and filter/seal replacement time have not been collected, making it impossible to distinguish between consumable failure and mold body damage.
The video only captures castings and lacks the parting surface, exhaust groove, liquid lifting pipe, water inlet and outlet temperature, and alarm screen.
There is no fixed data form, different customer feedback formats vary, diagnostic time is prolonged, and customer satisfaction decreases.
Low pressure die-casting molds (LPDC), reverse pressure casting molds (CPC), differential pressure casting molds for wheel hubs, low-pressure casting molds for wheel hubs, gravity casting molds, motorcycle wheel hub casting molds, structural component casting molds, aluminum alloy wheel hub molds, aluminum casting forming molds, low-pressure casting tooling molds, have extremely high overseas after-sales costs, and remote diagnosis is the key to cost reduction. Zhejiang Xinfeng Machinery Standardization Collection List: ① Defective X-ray/PT Photos; ② Pressure and vacuum timing curves; ③ Aluminum liquid temperature, spectral hydrogen content; ④ Temperature and flow rate of mold and cooling water inlet and outlet; ⑤ Spray parameters; ⑥ Accumulated module times and recent maintenance records; ⑦ Short video of the fault scene. Fault classification: Class A (mold collision, water leakage, insert displacement, high risk of shutdown); B-level (batch defects, seal leakage, and erosion of the liquid lifting tube); C-level (slight flying edge, sporadic strain, can continue production monitoring). Simultaneously sending the 'Fault Reporting Collection Form' to the customer when delivering the mold reduces back and forth communication and significantly improves the accuracy of remote diagnosis.
FAQ
1. Question: Is remote diagnosis primarily focused on collecting process documents?
Answer: Pressure curve, vacuum timing, mode temperature, and water circuit data.
2. Question: What is the definition of Class A faults?
Answer: If there is mold collision, water leakage, or component displacement, the machine must be stopped immediately.
3. Question: Typical examples of B-level faults?
Answer: Bulk porosity, seal leakage, and corrosion of the liquid lifting tube.
4. Question: What are the characteristics of C-level faults?
Answer: Occasional defects do not affect continuous production and will be monitored continuously.
5. Question: Is there any key information that is easily missing in customer reports?
Answer: Accumulated module times, spare parts replacement time, and aluminum liquid hydrogen content.
6. Question: What is the greatest value of remote diagnosis?
Answer: Distinguish between consumables consumption, process fluctuations, and mold body failures to avoid blind dispatching.
