What should be paid attention to in the installation and debugging of high-speed die-cutting machine?

The installation and debugging of high-speed die-cutting machine directly affects the precision, productivity and safety of the equipment, and it needs to be strictly controlled from multiple dimensions such as environmental preparation, mechanical installation, electrical debugging and functional testing. The following are the points for attention and operation in the whole process:

First, the environment and preparation before installation

1. Site planning and environmental requirements

Spatial layout:

An operation channel ≥ 1.5m shall be reserved around the equipment, and coil loading and unloading space (length ≥ 3m) shall be reserved at the front and rear;

Avoid being adjacent to high-frequency vibration equipment (such as punch and large fan) to avoid affecting cutting accuracy (vibration value ≤50μm/s).

Ground bearing:

The dead weight of high-speed die-cutting machine is usually ≥5 tons, and the ground bearing capacity should be ≥1.5 tons/㎡. It is recommended to lay 10-15mm thick steel plate or concrete for reinforcement.

Temperature and humidity control:

Electronic die-cutting needs constant temperature and humidity environment (temperature 23 2℃, humidity 45%-60%) to avoid the influence of material thermal expansion and cold contraction on accuracy;

The laser die-cutting machine needs to be equipped with an air conditioner separately (the temperature of the laser head should be ≤35℃).

2. Unpacking of equipment and inventory of accessories

Unpacking inspection:

Check the packing list (main engine, control cabinet, cutter, instruction manual, warranty card, etc.), and focus on checking whether there is any bump damage to precision parts such as motor, guide rail and cutter roller;

Record the equipment serial number and factory parameters (such as motor model and system version) for subsequent maintenance.

Second, mechanical installation: the core link of precision calibration

1. Horizontal adjustment and fixation

Horizontal calibration:

Use 0.02mm/m precision level to measure at the four corners and center of the workbench, and the flatness error is ≤ 0.1 mm/m;

Adjust the foot cup at the bottom of the equipment for fine adjustment, and tighten the anchor bolt for fixation (to prevent displacement during operation).

Transmission system installation:

The parallelism (gap difference ≤0.03mm) between the cutter roller and the press roller should be calibrated for the circular cutter die cutting machine, which can be detected by a feeler gauge or a special gauge.

For the flat knife model, it is necessary to confirm the verticality between the die-cutting platform and the tool rest (the error is ≤0.05mm) to avoid offset cutting.

2. Installation of feeding and winding system

Tension control:

Magnetic powder brake or servo tension controller should be installed at the coil unwinding end, and the tension value should be set according to the material thickness (for example, the tension of 0.1mm adhesive tape is 5-8n);

The winding end shall ensure that the reel is parallel to the guide rail to avoid winding deviation (deviation ≤1mm).

Guide roller calibration:

All guide rollers should be perpendicular to the center line of the equipment (error ≤ 0.1), which can be calibrated by laser marking instrument to prevent material deviation.

Three, electrical and control system debugging

1. Circuit connection and safety inspection

Power configuration:

The equipment needs an independent three-phase five-wire power supply (380 V 10%, 50Hz), and the grounding resistance is ≤4Ω. It is recommended to configure a voltage regulator (when the voltage fluctuation is > 10%).

The laser die-cutting machine needs a separate loop power supply (power ≥20kW) to avoid sharing wires with other equipment.

Security protection:

The emergency stop button, safety grating and overload protection device need to be connected to the PLC control system. When the emergency stop button is pressed during the test, the equipment should stop completely within 0.5 seconds.

The motor overload protection current is set to 1.2 times the rated current to prevent open-phase operation.

2. System initialization and parameter setting

Servo motor debugging:

Calibration of X/Y/Z axis servo parameters (position loop gain, speed loop gain) in turn, the motor noise is less than or equal to 65 dB during no-load operation, and there is no abnormal vibration;

Set the soft limit of each axis (for example, reserve a safety distance of 50mm at the cutting width boundary).

Man-machine interface configuration:

Input the basic parameters of the equipment (such as workbench size and tool specification), and test the response speed of each function button (such as tool change and zero return operation ≤1 second feedback);

Import at least 3 sets of processing parameters (such as die-cutting pressure and feeding length) of different products, and verify the function of program storage and call.

Fourth, functional testing and accuracy verification

1. Empty machine operation test

Low speed operation:

Run the equipment at the rated speed of 20% for 1 hour, and observe whether the shafts run smoothly and the transmission parts (belts and gears) have no abnormal noise;

Check the lubrication system (the automatic yellow oil pump supplies oil every 15 minutes, and the oil level should be kept above 1/2 of the window).

High speed idling:

Raise it to rated speed (e.g. 100m/min) and run for 30min. Check the motor temperature rise (≤70℃) and the control cabinet temperature ≤40℃.

2. Material trial cutting and precision calibration

The first test:

Use the actual production materials for 3-5 times of trial cutting, focusing on testing:

Dimensional accuracy: the key dimensional error is ≤±0.05mm (precision parts ≤ 0.03 mm) when measured by projector or secondary element;

Edge quality: observe whether there is burr, indentation or hot melt residue (laser die-cutting needs to control the focal spot offset ≤ 0.1 mm);

Repeated positioning: cut continuously for 10 times, and measure the position deviation of the same point ≤ 0.1 mm.

Capacity test:

Continuous production at 80% rated speed for 2 hours, statistics of productivity stability (such as target production capacity of 5000 pieces/hour, fluctuation range ≤5%), and inspection of winding uniformity (edge dislocation ≤2mm).

Five, safety regulations and operator training

1. Commissioning of safety protection device

Grating protection: when the safety grating is blocked, the equipment should be stopped immediately, and it can only be restarted after being reset by manual confirmation;

Tool protection: the protective cover of the round knife roller should be installed in place, and the equipment should be automatically powered off when the protective cover is opened (the response time of the interlocking device is ≤0.3 seconds).

2. Key points of operator training

Basic operation:

Demonstrate the tool changing process (for example, a torque wrench is needed to change the blade of a flat knife model, and the torque value is usually 8-12 nm according to the requirements of the manual);

Train the skills of material tension adjustment (for example, it is necessary to reduce the unwinding tension when the material is wrinkled and increase the winding tension when it slips).

Fault emergency:

Handling of common problems: press the "material return" button to run slowly in reverse when the paper jam occurs, so as to avoid forcibly pulling and damaging the tool;

Record the meaning of the fault code (for example, "E007" means servo overload, so it is necessary to check the load or motor wiring).

Vi. Suggestions for debugging special scenes in the industry

Application scenario debugging key risk avoidance measures

Anti-static treatment of electro-optical film by die cutting, laying anti-static rubber (resistance of 10-10Ω) on CCD vision calibration workbench, and matching the color of the film with the visual recognition light source (such as blue light source for transparent film).

Die-cutting pressure cutting and dust removal system for automobile interior parts shall set the die-cutting pressure ≥ 15t (thick EVA material) and be equipped with cyclone dust collector (dust concentration ≤ 2mg/m).

Control the cleanliness of dust-free production of medical consumables, spray food-grade coating on the surface of equipment without oil pollution contact, wipe the workbench with alcohol before debugging, and use dust-free grease for motors.

VII. Acceptance and Document Filing

1. Acceptance criteria

Sign the commissioning report, including: empty machine operation parameters, test data of trial cutting samples and productivity test records;

The supplier is required to provide technical documents such as Equipment Operation Manual, Maintenance Guide and Electrical Schematic Diagram.

2. Later maintenance plan

Make daily maintenance table (such as daily check of guide rail oil level and weekly cleaning of servo motor encoder);

Regularly calibrate the accuracy (check the flatness of the workbench with a standard block every three months, and invite the manufacturer to make a comprehensive accuracy calibration every year).

Summary: Debugging the Core Logic

The installation and debugging of high-speed die-cutting machine should follow the principle of "from mechanical accuracy to functional verification, from single machine testing to production adaptation", focusing on four core links: horizontal calibration, servo parameters, tension control and visual alignment. By testing in stages (empty machine → low speed → high speed → material loading) and recording the whole process, the failure rate of equipment can be effectively reduced and the expected production capacity can be ensured.