The debugging of automatic high-speed die-cutting machine needs the following steps:

First, the preparation work before debugging

1. Equipment inspection

-First, conduct a comprehensive appearance inspection of the die-cutting machine to see if there are any damages caused by the transportation of various components, such as deformation and scratches on the shell, looseness of components, etc. Pay special attention to check whether the electrical circuit is damaged or has poor contact.

-Check the installation of the die-cutting machine to ensure that the equipment has been correctly installed on a solid foundation according to the installation instructions, and the levelness and verticality meet the requirements. Generally, a level meter is used to measure the levelness of equipment, and the deviation should be controlled within ±0.5mm/m/m..

-Check whether the model, specifications and attached accessories of the die-cutting machine are consistent with the contract and packing list, and check whether the technical data and operation manual of the equipment are complete.

2. Material preparation

-Prepare suitable die-cutting materials according to debugging needs, such as paper and plastic film. The specifications and quality of materials should meet the requirements of die-cutting process, such as the thickness and stiffness of paper within a certain range to ensure the accuracy of debugging results.

-Prepare the die-cutting tool, and check whether the size and shape of the tool meet the design requirements, and whether the blade is sharp and without notch. At the same time, prepare corresponding auxiliary materials such as pads.

3. Tool preparation

-Prepare all kinds of tools needed for debugging, such as wrenches, screwdrivers, calipers, micrometers and other measuring tools, as well as tools and materials for cleaning and lubrication.

Second, the mechanical part debugging

1. Transmission system debugging

-Check the tension of the drive belt. Improper tension will lead to belt slippage or excessive wear, which will affect the transmission efficiency. Generally, the tension is adjusted by adjusting the position of the pulley. When the belt is pressed with your fingers, it should have a certain elastic deformation, and the deformation amount is within a suitable range (for example, 10-15mm).

-Check the rotation of each transmission shaft. If you rotate the transmission shaft manually, you should feel that the rotation is flexible and there is no sticking phenomenon. At the same time, check the axial and radial runout of the transmission shaft, and the runout should be controlled within a small range (for example, the axial runout should not exceed 0.05mm and the radial runout should not exceed 0.03mm). If the runout is too large, it is necessary to check the installation of bearings and other components and make adjustments.

-Debug the gear transmission part to ensure good gear engagement and no abnormal noise. Red lead powder can be applied to check the meshing marks of gears, which should be evenly distributed on the tooth surface and the contact area should meet the requirements (generally not less than 70%). If the meshing is poor, it is necessary to adjust the installation position or center distance of the gear.

2. Debugging of die cutting mechanism

-Install the die-cutting tool and backing plate to ensure that the tool is firmly installed and the blade direction is correct. The clearance between the cutter and the backing plate should be even, and generally the clearance should be controlled between 0.05 and 0.1 mm, which can be measured and adjusted by tools such as feeler gauge.

-Adjust the die-cutting pressure, which directly affects the quality of die-cutting. The pressure is too small to completely cut off the material; Excessive pressure may damage tools and equipment. Generally, it is realized by adjusting the pressure regulating device of die-cutting machine (such as hydraulic system or pneumatic system). During initial debugging, the pressure can be gradually increased from small pressure, and the appropriate pressure value can be determined through trial cutting.

-Check the movement accuracy of the die-cutting mechanism. The up-and-down movement of the die-cutting tool should be vertical and smooth, and the movement stroke should meet the design requirements. Use a dial indicator and other tools to measure the movement accuracy of the tool, and the deviation should be controlled within 0.05 mm.. At the same time, check the return speed and pause time of the die cutting mechanism to ensure that it meets the production process requirements.

3. Commissioning of feeding system

-Adjust the pressure and gap of the feeding roller. The pressure of the feeding roller should be moderate, which can not only ensure the smooth transportation of materials, but also cause excessive extrusion deformation of materials. The gap should be adjusted according to the thickness of the material, which is generally 0.1-0.2mm larger than the thickness of the material. The pressure and gap can be adjusted by adjusting the pressure adjusting devices (such as spring pressure devices) at both ends of the feed roller.

-Check the synchronization of feeding, and keep good synchronization between feeding system and die cutting mechanism to ensure the accuracy of die cutting position. By adjusting the parameters such as the speed and phase of the feeding motor, the feeding speed is matched with the die cutting speed. You can use marking materials for trial cutting, observe whether the die-cutting position is accurate, and adjust it in time if there is any deviation.

-Debug the feeding tension control system. Different materials have different feeding tension requirements, which should be adjusted according to the material characteristics and process requirements. Generally, the tension is adjusted by the tension controller. During the initial debugging, the tension can be started from a small one and gradually increased. Observe the conveying situation of the material to ensure that the material does not relax or stretch during the conveying process. The fluctuation range of tension should be controlled within 5% of the set value.

Third, the electrical system debugging

1. Control system inspection

-Check whether the wiring of the electrical control system is correct and firm, and whether all electrical components (such as sensors, contactors, relays, etc.) are in place and working normally. Check the connection of wires one by one according to the electrical schematic diagram to ensure that there is no wrong connection or missing connection.

-Start the control system and check whether the display and operation functions of the display screen and operation panel are normal. The display screen should clearly show the running status and parameters of the equipment, and the buttons and knobs on the operation panel should be sensitive, reliable and easy to operate. The parameters of the control system are initially set, such as die cutting speed, feeding length, counting and other parameters, according to the process requirements.

2. Motor debugging

-Debug the operation of each motor, including main motor, feeding motor and receiving motor, etc. First, carry out no-load operation, and observe whether the rotation direction of the motor is correct, whether the motor runs smoothly, and whether there is abnormal noise and vibration. The rotation direction of the motor should be consistent with the direction required by the equipment. If there is any error, it can be changed by adjusting the wiring phase sequence of the motor. During no-load operation, the vibration amplitude of the motor should not exceed the specified value (for example, the effective value of vibration speed should not exceed 1.8mm/s), and the noise should be lower than the specified decibel value (for example, it should not exceed 85dB).

-Run the motor with load, gradually increase the load, and check whether the current, speed and other parameters of the motor are within the normal range. The current of the motor should not exceed its rated current, and the rotation speed should be consistent with the set value, with the deviation within 2%. At the same time, observing the response of the motor when the load changes, we should be able to adjust the speed and torque quickly and smoothly.

3. Sensor debugging

-Debugging various position sensors, such as feeding position sensor and die cutting position sensor. Ensure that the sensor can accurately detect the corresponding position signal and transmit the signal to the control system correctly. By moving the sensor to detect the target, observe the feedback of the control system, adjust the installation position and sensitivity of the sensor, so that the sensor can trigger the corresponding action at the right position and time. The detection accuracy of the sensor should be controlled within 0.1 mm..

-Debugging photoelectric sensors and other sensors used to detect materials, and adjusting the transmitting and receiving angles, sensitivity and other parameters of the sensors, so that they can accurately detect the presence, color, thickness and other characteristics of materials. For example, when photoelectric sensor detects transparent materials, it may be necessary to adjust its sensitivity and background suppression function to avoid false detection.

Fourth, the whole machine debugging and optimization