Introduce in detail: how to install and debug the small hole sleeve precision die cutting machine?

Small-hole nesting precision die-cutting machine is mainly used for high-precision die-cutting processing in the fields of electronics and optics (such as FPC flexible printed circuit board and optical diaphragm), and its installation and debugging standards need to take into account mechanical accuracy, visual registration system and electrical control. The following is a description from the technical standards, process steps, key parameters and other dimensions, with reference to the European Union Machinery Safety Code (2014/34/EU) and industry practice requirements:

I. Site preparation before equipment installation

1. Environment and space standards

Cleanliness: It should be installed in a Class 10000 clean workshop (suspended particles ≤352000/m, ≥0.5μm) to avoid dust affecting the accuracy of the optical system.

Temperature and humidity: the temperature is 23 2℃ and the humidity is 45%-55% RH (equipped with constant temperature and humidity air conditioner, with fluctuation ≤ 0.5℃/h).

Space requirements: 2-3 meters of maintenance passage shall be reserved around the equipment, and the overhead lifting area shall have a clearance of ≥5 meters (the load shall be ≥2 tons, which is used for mold lifting).

2. Basic engineering standards

Ground treatment:

Self-leveling floor with epoxy resin, flatness ≤0.05mm/m (detected by 3-meter rule), and bearing capacity ≥ 800 kg/m..

A 20mm thick damping pad (made of natural rubber with Shore hardness of 50±5A) shall be laid under the equipment base to reduce the influence of external vibration (vibration acceleration ≤ 50μ m/s).

Electrical configuration:

Independent distribution box: three-phase five-wire system (380 V 5%, 50Hz), equipped with surge protector (response time ≤25ns) and grounding resistance ≤1Ω.

Separate loop: the servo motor, vision system and laser (if any) need to be supplied separately to avoid interference.

Second, the mechanical system installation process and precision control

1. Installation of base and platform

Horizontal calibration:

Use an electronic level with a precision of 0.01mm/m, and adjust it at the four corners and the center of the base, so that the levelness of the whole machine is ≤0.03mm/m (fine-tuned by anchor bolts).

After the marble platform (thickness ≥300mm, made of Jinan black) is installed, the surface roughness Ra is ≤ 0.8μ m, and the flatness is ≤0.02mm/1000mm (detected by laser interferometer).

Fixed mode:

The base is connected with the ground through M16 expansion bolts, the bolt spacing is ≤500mm, and the tightening torque is 80-100 nm (controlled by torque wrench).

2. Installation of transmission and die-cutting unit

Linear motor and guide rail:

When the X/Y axis linear motor is installed, the straightness of the guide rail is ≤0.015mm/1000mm, and the parallelism is ≤0.02mm/1000mm (detected by laser collimator).

The clearance between the slider and the guide rail is ≤0.005mm (feeler gauge detection), and the fluctuation of running resistance is ≤5% (force sensor monitoring).

Die cutting mechanism:

The coaxiality of the cutting roller of the rotary die is less than or equal to ≤0.01mm (detected by dial indicator), and the surface runout is less than or equal to ≤0.008mm (when the rotating speed is 300rpm).

Parallelism between the flat die-cutting platform and the die is ≤0.01mm (the thickness difference of the plug is ≤0.005mm through precise plug calibration).

3. Feeding and receiving system

Unwinding tension control:

The tension fluctuation of magnetic powder clutch is ≤ 1% (rated tension is 5-50N), and it is equipped with tension sensor (accuracy is 0.1N) for real-time feedback.

Rectification device:

The response time of photoelectric rectification system is ≤50ms, and the rectification accuracy is ≤±0.05mm (in the width direction of the coil).

Third, the key steps of visual registration system debugging

1. Hardware calibration

Camera and lens installation:

When an industrial camera (resolution ≥ 5 million pixels, frame rate ≥60fps) is installed, the perpendicularity between the optical axis and the workbench shall be ≤ 0.1 (goniometer calibration).

The working distance error of telecentric lens is ≤±0.1mm, which ensures the consistency of magnification (the error is ≤0.1%).

Light source debugging:

The brightness uniformity of the annular coaxial light source is more than or equal to 95% (the difference between each point is less than or equal to ≤50lux when detected by an illuminance meter), and the color temperature is 5000 200 K (to avoid color deviation).

2. Registration algorithm and parameter setting

Mark point identification:

Mark points such as circle, cross and L shape are supported, and the recognition accuracy is ≤±0.5pixel (corresponding to the actual size ≤0.005mm, calculated according to the camera resolution of 20μm/pixel).

Dynamic registration compensation: when the equipment speed is 100m/min, the registration error is ≤±0.03mm (adjust the motor pulse in real time through PLC).

Calibration process:

The camera distortion is corrected with a standard calibration board (accuracy ±0.002mm), and the distortion rate is ≤0.1%.

The mapping relationship between visual coordinate system and mechanical coordinate system is established, and the conversion error is ≤0.01mm (by at least 9-point calibration method).

Four, electrical and control system debugging

1. Servo drive and motion control

Parameter setting:

The speed loop gain is ≥2000rad/s (response frequency is ≥500Hz) and the position loop gain is ≥10000rad/s to ensure that the tracking error is ≤0.5μm during high-speed operation.

Motor temperature rise test: continuous operation for 4 hours, stator temperature ≤ 75℃ (monitored by PT 100 sensor), bearing temperature ≤60℃.

Encoder calibration:

The synchronization error between grating ruler (accuracy 0.1μm) and servo motor encoder (24-bit absolute value) is ≤1 pulse (corresponding displacement ≤0.0005mm).

2. Safety and protection system

Emergency stop response:

The emergency stop loop adopts dual-channel design (conforming to EN ISO 13849-1 PLd grade), with response time ≤0.05 second and stopping distance ≤5mm (at a speed of 1m/s).

Laser protection (if any):

If equipped with ultraviolet laser drilling module, the protective screen shall meet the standard of EN60825-1 Class 4, with light transmittance ≤0.0001% and response time of interlocking device ≤0.1 second.

V. Load Debugging and Performance Testing

1. Material trial cutting and accuracy verification

Machining accuracy of small holes:

When the aperture is 0.1-1mm, the dimensional tolerance is ≤±0.01mm, and the hole position deviation is ≤ 0.02 mm (detected by 30 times microscope).

The hole wall roughness Ra is ≤ 1.6 μ m (for metal foil), and the burr height is ≤ 0.005 mm..

Registration accuracy test:

Continuous die cutting for 1000 times, the average registration error is less than or equal to ≤0.02mm, and the maximum value is less than or equal to ≤0.03mm (sampling by optical image measuring instrument).

2. Efficiency and stability test

Capacity test:

Rated speed: the flatting machine type is ≥150 times/minute, and the circular pressing machine type is ≥300 times/minute, and it runs continuously for 8 hours without failure.

Power consumption and noise:

The fluctuation of full-load power consumption is ≤ 2%, and the noise of the whole machine is ≤70dB (1 meter away from the equipment, a is weighted).

VI. EU Compliance and Acceptance Standards

1. Certification basis

EN 60204-1:2018 Mechanical and Electrical Safety

EN ISO 14121-1:2015 Risk Assessment

EN 13700:2006 Safety Requirements for Die Cutting Machines

2. Acceptance documents

Accuracy Test Report: contains data such as platform flatness, motor positioning accuracy and visual registration error.

Operation Test Curve: Speed-load characteristic and temperature-time curve (oscilloscope waveform diagram is required).

Safety compliance certificate: an EMC test report (radiation ≤34dBμV/m, 30-1000MHz) issued by a third party (such as SGS).

Seven, typical faults and debugging skills

Out of tolerance of registration deviation:

Check whether the camera mounting screws are loose (torque needs to reach 15N・m) and re-calibrate the vision system.

Confirm whether the material tension is stable (if the fluctuation is ≥ 2%, it is necessary to adjust the current of the magnetic powder clutch).

Small hole burr exceeds the standard:

Adjust the die-cutting pressure (the standard value is 8-12MPa), and check the wear of the cutting edge of the die (the fillet of the cutting edge is ≤0.003mm).

Optimize the feeding speed and die-cutting phase matching (recommended speed deviation ≤ 1%).

Note: Special tools (such as laser interferometer and high-precision level meter) should be used for debugging, and the operators should have ISO 14644-1 clean room operation qualification and servo system debugging experience. For micro-hole machining below 0.1mm, additional tool dynamic balance test (balance accuracy G0.4, ISO 1940 standard) is needed.