Knife die cotton sticking-what should be paid attention to in the use of intelligent cotton sticking machine?

Matters needing attention in the whole process of using knife die cotton sticking intelligent cotton sticking machine

The intelligent cotton sticking machine, which is suitable for automatically sticking foam (elastic rubber, EVA, rubber elastic pad) on the knife die, is divided into six sections: pre-start inspection, operation, shutdown and finishing, safety specification, daily maintenance and process quality control.

A, check before starting (daily class will be executed)

Environment and gas source and power supply

Confirm that the power supply voltage is stable, and the electrical cabinet and terminal are free of dust and burnt smell; Adjust the pressure of air source to the rated range of equipment (usually 0.4–0.6 MPa), check that there is no air leakage in the trachea and the filter drains water in time.

The equipment shall be placed horizontally, the workbench shall be stable, and the surrounding operation space shall be reserved. It is forbidden to pile up foam coils, knife molds and cartons to block the guide rails and heat vents.

Mechanical and protective components

Clean up the residual glue and foam chips on the workbench, moving beam, press roller and adsorption platform;

Confirm that the emergency stop button, safety grating/anti-collision sensor and protective cover are in good condition and effective; It is forbidden to short circuit or shield the safety protection device.

Check the lubrication state of lead screw and linear guide rail, and fill special grease in time when there is oil shortage.

Knife die and accessories preparation

Inspection of the tool die on the shelf: no tool collapse, deformation and weld protrusion; The bottom surface of the die is clean without welding slag burr, so as to prevent the table from being scratched and affect the positioning.

Check the thickness, hardness and release paper specifications of foam coil; The end face of the coiled material is flat, without wrinkles, moisture and adhesion.

System no-load self-test

Power on and wait for the completion of the system self-check to eliminate the historical alarm; Perform the operation of returning to the origin; Run for 2-3 cycles with no load, and observe whether there is abnormal sound, jamming and jitter when walking on the beam.

CCD vision model: clean the camera lens and light source, and make sure that the field of vision is unobstructed and the reference coordinates are not drifting.

Second, the operation of the production process matters needing attention

Clamping and positioning of cutter die

The cutter die shall be placed flat and the clamping force shall be moderate, and the cutter die shall not be deformed due to excessive pressure; The locating pin/datum plane fits in place.

For the first time, the new die must be put into trial operation in a single step, and the cotton sticking should be simulated at a low speed, and then the continuous automatic mode should be started after confirming that the motion trajectory does not hit the knife or wipe the blade.

Foam feeding and tension control

Coil limit baffle is adjusted to prevent left and right deviation; The tension should not be too large to avoid stretching deformation of foam and springback and warping after attachment; If the tension is too small, it is easy to wrinkle.

The peeling angle of the release paper remains stable, and the waste is peeled smoothly to prevent the waste from being involved in the roller shaft.

Process parameter adjustment (blind adjustment is strictly prohibited)

Attachment pressure, walking speed and hot pressing time (with heating machine) are adjusted according to foam thickness; Excessive pressure is easy to thin foam and the blade position is stuck with cotton depression; Degumming and virtual adhesion occur due to insufficient pressure.

Don't change the parameters greatly at one time; After the modification, try to paste a set of knife dies, and confirm the position and bonding effect before mass production.

Production process monitoring

Operators are not allowed to leave their posts, and continue to observe: cotton sticking position deviation, missing sticking, re-sticking, foam folding, broken material and abnormal sound.

Regular sampling inspection of finished products: check that the foam is centered, the distance from the blade is consistent, there is no bubble, and the edge is not warped; Stop the machine immediately in case of batch defects.

When the machine is moving, it is forbidden to put your hand into the beam, pressing area and above the die. For close observation, use single-step mode.

Abnormal emergency treatment

In case of impact, abnormal sound, alarm, paper jam and foam entanglement, press the emergency stop at the first time;

It is forbidden to stretch out your hand to clean up before stopping completely; Reset the alarm after the investigation is completed, and then start again after returning to the original point.

Three, stop and change, off-duty operation

Batch conversion

Stop the automatic operation first and wait for the mechanism to return to the original point; Clean up the residual glue on the table before replacing the die; Recalibrate the visual reference (CCD model).

Daily take-up specification

Return the moving beam to the safe origin; Turn off automatic operation;

Clean the foam crumbs and residual glue in the workbench, press roller and adsorption hole;

Turn off the main switch of gas source and equipment power supply in turn; Unplug the main power supply after long-term shutdown.

It is forbidden to directly and forcibly shut down the power supply, which is easy to lose parameters and damage the servo driver.

Four, the red line of safe operation (key)

Only trained personnel can operate; Non-operators are forbidden to touch the control panel.

It is forbidden to remove the protective cover and shield the safety sensor under the running state.

To clean up residual glue, maintain, debug and replace accessories, it is necessary to stop the machine → press the emergency stop → cut off the air supply and power supply, and hang a maintenance warning sign if necessary.

The blade of the die is sharp. Wear protective gloves when taking and transporting the die to prevent cutting.

It is forbidden to operate the electric control panel with wet hands; It is forbidden to splash water and cleaning agent in the electric cabinet.

It is forbidden to pile up tools, screws and sundries inside the equipment to prevent sports collision.

Five, regular maintenance points

daily

Clean the workbench, guide roller and camera lens; Drain the accumulated water from the air source filter; Clean up the waste.

weekly

Lubricating grease for guide rail and lead screw; Check the trachea joint for air leakage; Tighten loose screws; Calibrate the sensor position.

monthly

Check the tightness of servo motor, chain/synchronous belt; Clean the dust in the electric control cabinet; Test all emergency stops and safety gratings; Coordinate calibration of CCD machine.

Long-term discontinuation

Coat the guide rail with antirust grease; Relax the tension of the coil; Keep the workshop dry and dustproof.

Six, common process taboo (reduce bad, protect equipment)

Do not use wet, aging and sticky foam, which is prone to cotton removal and rework.

Don't superpose multiple foam parameters with excessive thickness difference at the same time, frequent and large-scale switching will easily lead to sticking drift.

Complex special-shaped cutter dies give priority to reducing the running speed to avoid positioning deviation caused by inertia.

Do not use strong corrosive solvent to spill residual glue directly on the countertop, and use cleaning agent recommended by the manufacturer to prevent corrosion of the countertop coating and sensor.

It is forbidden to force the super-size and super-thick foam onto the machine, increase the load and accelerate the wear of servo and guide rail.