What matters should be paid attention to when high-speed die cutting machine processes products?

When processing products, high-speed die-cutting machine should be strictly managed from many dimensions, such as material characteristics, equipment parameters, process control and safe operation, to ensure product accuracy, equipment stability and production safety. The following are the matters needing attention in the whole process and the key points of industry practice:

A, material pretreatment and computer specification

1. Matching of material properties

Thickness and tension control:

Adjust the tension according to the thickness of the material (for example, the tension of 0.05mmPET film is 3-5N, and the tension of 0.5mm foam is 8-12N). Insufficient tension will easily lead to material deviation, while excessive tension will lead to tensile deformation;

The eccentricity of coil should be ≤1mm (detected by dial indicator), and serious eccentricity will lead to feeding fluctuation and affect die-cutting accuracy.

Anti-static treatment:

Electronic materials (such as optical films and FPC) need to be produced in an anti-static workshop (electrostatic voltage ≤100V). Anti-static rubber covers should be laid on the equipment table, and operators should wear anti-static bracelets (grounding resistance ≤1MΩ).

2. Material installation and calibration

Coil installation sequence:

Fix the coil at the unwinding end to ensure that the end face is perpendicular to the guide roller (the deviation is less than or equal to 0.5 mm);

Sequentially passing through a tension roller, a deviation rectifying device and a die cutting station, and clamping a reel by a chuck at the winding end;

Start the "automatic deviation correction" function, so that the deviation between the material edge and the center line of the guide roller is less than or equal to 0.3 mm.

Second, process parameter setting and real-time monitoring

1. Debugging of core parameters

Die cutting pressure:

Flat knife die cutting: set the pressure according to the hardness of the material (for example, 10-15 tons of PVC sheet and 20-25 tons of aluminum foil). If the pressure is insufficient, it is easy to cause half-cutting failure, and if it is too large, it will damage the blade (the blade wear is ≤ 0.02 mm per month);

Circular knife die cutting: the gap between the knife roller and the pressure roller is set according to the material thickness+0.01mm (for example, the gap of 0.1mm adhesive tape is 0.11mm), and the position is locked after calibration with a feeler gauge.

Cutting speed:

The speed of ordinary materials (paper and adhesive tape) is 80-120m/min, and the speed of high-precision materials (optical film and lithium battery pole piece) is reduced to 30-50m/min;

When the speed changes suddenly (for example, from 100 m/min to 50 m/min), the tension should be adjusted synchronously to avoid material stacking.

2. Real-time parameter monitoring

Equipment dashboard:

Monitor the current (≤ 80% of rated current) and temperature (≤70℃) of the servo motor, and immediately stop the machine for inspection when it exceeds the threshold;

Observe the barometer (the pressure of the pneumatic system should be stabilized at 0.6-0.8MPa), and insufficient air pressure will lead to the lag of the feeding cylinder.

Intelligent system early warning:

Equipment connected to MES system can set parameter fluctuation warning (such as automatic alarm when die-cutting pressure fluctuates more than 5%), and record abnormal production data (batch, speed and material batch).

Third, product quality control and process inspection

1. The first three inspection system

Size detection:

Measure key dimensions (such as the length and width of mobile phone adhesive ±0.03mm and the aperture ±0.02mm) with a secondary imager, and detect 5-10 points for the first piece in each batch;

Compared with CAD drawings, if the error exceeds ±0.05mm, it is necessary to recalibrate the tool or adjust the parameters.

Visual inspection:

Edge quality: no burr, flash (burr height ≤0.01mm), laser die-cutting needs to control the focal edge width ≤ 0.05 mm;

Surface defects: no indentation or scratch (observed with a magnifying glass of 30 times), and hot melt adhesive die-cutting needs no overflow (the overflow range is ≤0.1mm).

2. Process inspection and dynamic adjustment

Sampling frequency:

Sampling 5-10 tablets every hour, focusing on the products after 30 minutes of continuous production (the accuracy of the equipment may change after warm-up);

When the material batch is changed, it is necessary to increase the sampling quantity to 20 pieces to confirm the suitability of the new batch of materials.

Exception handling:

In case of batch offset (offset > ＞0.1mm), immediately check:

Whether the feeding servo encoder is loose (calibration is required when the error is ≥0.01mm/turn);

Clearance of knife roller bearing (detected by dial indicator, axial movement ≤0.02mm).

Fourth, equipment maintenance and fault emergency

1. Preventive maintenance in processing

Tool maintenance:

Wipe the blade with alcohol for every 5000 pieces produced, and remove the glue residue (glue accumulation will make the blade dull, and the blade needs to be replaced when the cutting force increases by 10%);

The circular cutter die-cutting machine fills the cutter roller bearing with high-temperature grease (model: KLUBER NBU 15, the filling amount is 1/3 of the bearing cavity) every 8 hours.

Transmission system inspection:

Monitor whether there is abnormal noise (normal noise ≤75 dB) in gears and belts during operation, and the belt tension shall be based on the press sag of ≤10mm;

The slide block of the guide rail is lubricated automatically every 2 hours (through the oil pump provided by the equipment), and it needs to be stopped for manual oil replenishment (to avoid oil mist polluting materials).

2. Sudden fault handling

Paper jam emergency:

Press the "Emergency Stop" button to disconnect the servo power supply;

Loosen the winding tension, and manually rotate the feed roller reversely (speed ≤ 5m/min) to take out the waste;

Check the surface of the guide roller for bumps (smooth with sandpaper, roughness Ra≤1.6μm).

Motor overload:

Check whether the load is too large (for example, the material is wound around the guide roller), and reset the servo parameters after cleaning (the position loop gain is reduced by 10%-20%).

V. Safe operation and special requirements of the industry

1. General safety specifications

Use of protective devices:

It is forbidden to dismantle the safety grating and the tool guard (the equipment shall be forced to stop when operating illegally), and the grating response time shall be ≤0.1 second;

When replacing the blade, special tools (such as torque wrench, torque value according to the instruction, for example: M6 screw 8-10 nm) must be used, and it is forbidden to operate by hand.

Emergency stop process:

In case of equipment smoke, abnormal vibration (amplitude > ＞0.5mm) or personal injury, immediately press the red emergency stop button, cut off the main power supply and report to the supervisor.

2. Matters needing attention in special scenes of the industry

Risk control measures for processing points in application fields

Die-cutting explosion-proof design of lithium battery pole piece, grounding resistance of equipment without metal debris residue ≤1Ω, installation of spark detector, and ceramic coating for cutting tools (to avoid metal friction and ignition).

Medical dressings die-cutting dust-free level, chemical pollution-free workshop reaches ISO 8 level cleanliness, knives need to be lubricated by FDA-certified lubricant, and each batch of products is tested for microorganisms.

The die-cutting strength of automobile airbag fabric is consistent, the pressure fluctuation of waste collection die-cutting is less than or equal to 3%, and an automatic waste recycling system is equipped (to prevent explosion caused by fiber dust accumulation).

Six, data recording and process optimization

1. Production data ledger

Record the processing parameters of each batch:

Material information: model, thickness and batch number;

Equipment parameters: speed, pressure, tension and temperature;

Quality data: qualified rate of first piece, defective rate of process, reasons for waste products (such as offset cutting and raw edge ratio).

2. Process iterative optimization

Parameter library establishment:

The optimal parameters (such as PE foam die-cutting: pressure 12 tons, speed 60 m/min, tension 10N) are stored by material type, and the historical data can be directly called for new orders;

Efficiency improvement:

Analyze the bottleneck link through OEE (such as optimizing the tool changing process to within 10 minutes when the tool changing time accounts for more than 15%).

Summary: core principles of machining

The processing of high-speed die-cutting machine should follow the logic of "material adaptation-accurate parameters-process monitoring-safety priority", and focus on controlling three elements: tension stability, die-cutting pressure uniformity and tool sharpness. Through strict inspection of the first article, dynamic adjustment of the process and data recording of the whole process, high-precision and high-efficiency production can be realized, and equipment loss and safety risks can be reduced at the same time.