กระบวนการติดตั้งและทดสอบการใช้งานเครื่องตัดฟอยล์ปั๊มร้อนทั้งหมดได้รับการอธิบายอย่างละเอียด

As the core equipment of hot stamping material processing, the installation and commissioning quality of the hot stamping foil slitting machine is directly related to production efficiency and product quality. This article will systematically analyze the key technical points of the whole process of hot stamping foil slitting machine from preparation to official production.

1. Preliminary preparations

1.1 Site and environmental assessment

• Ground requirements: The installation area should have a solid and flat cement floor, with a load-bearing capacity of ≥ 2 tons/square meter, and the horizontality error should be controlled within the range of ±2mm/2m

• Space planning: reserve no less than 1.5 meters of operation and maintenance channels around the equipment, and reserve a clearance height of 2 meters above

• Environmental parameters: the temperature is maintained at 20-25°C, the relative humidity is 50%-60%, and the area is avoided from direct sunlight and areas with drastic changes in airflow

• Infrastructure: Ensure that a 380V three-phase power supply (voltage fluctuations ±5%), a stable air source (0.6-0.8MPa), and a lighting system are in place

1.2 Equipment inspection and acceptance

• Unpacking check: check the main machine, electronic control cabinet, tension system, tool components, etc. one by one against the shipping list

• Visual inspection: Investigate possible deformations, rust, or damage during transportation

• Data archiving: Collect technical documents such as electrical drawings, mechanical assembly drawings, PLC programs, and operation manuals

2. Mechanical installation process

2.1 Basic positioning and level adjustment

1. Use a laser level to determine the device installation baseline

2. Adjust the base to the horizontal state (longitudinal and horizontal bidirectional error≤ 0.05mm/m)

3. The equipment is fixed with high-strength chemical anchors, and the torque value is strictly controlled according to the requirements of the manual

4. Let it stand for 24 hours after installation, and retest the level after the stress of the foundation is released

2.2 Core component assembly

• Unwinding mechanism: install air expansion shaft to ensure concentricity ≤ 0.02mm, and configure automatic deviation correction system

• Tension control system: Floating rollers and tension sensors are installed, and the mechanical part is flexible and free of jamming

• Slitting unit: Assemble a circular knife or a flat knife according to the process requirements, and adjust the parallelism of the knife edge to ≤0.01mm

• Winding device: install the winding shaft and the roller pressing mechanism to ensure that the parallelism error with the unwinding shaft is ≤ 0.1mm

2.3 Auxiliary System Connection

• Air circuit system: use clean and dry compressed air, the pipeline layout avoids sharp bends, and the interface is sealed

• Dust removal device: connect the vacuum duct and adjust the distance between the air inlet and the cutter to the optimal position

• Safety protection: Install safety facilities such as emergency stop buttons, photoelectric protection devices, and protective covers

3. Electrical system installation and wiring

3.1 Power system configuration

• The main power cord adopts a ≥6mm² copper core cable with independent air switch and overload protection

• The grounding resistance is strictly controlled at ≤4Ω to prevent static electricity accumulation

• Control lines and power lines are slotted to avoid electromagnetic interference

3.2 Control system installation

• The PLC module is firmly installed in the electronic control cabinet, and sufficient heat dissipation space is reserved around it

• The inverter parameters are set according to the motor nameplate data, and the brake resistance is configured

• All sensors (encoders, proximity switches, tension detectors, etc.) are accurately positioned and initially debugged

3.3 Wiring and Identification

• Terminal wiring according to the drawings, using the wire number tube specification marking

• Maintain a minimum spacing of 200mm between strong and weak current lines

• Full insulation test (≥5MΩ) after wiring is completed

4. System debugging process

4.1 No-load trial run

1. Single-action test: Test the single-action function of unwinding, traction, slitting, winding and other units one by one through the operation panel

2. Linkage test: low speed (10-20m/min) overall operation, observe the coordination of each component

3. Safety Testing: Verify the response of safety features such as emergency stops, protective door interlocks, and overload protection

4.2 Tension system calibration

• Use a tension meter to calibrate the tension values of each control point

• Adjust the PID parameters to control the tension fluctuation within ±5% of the set value

• Simulate material breaking, acceleration, deceleration and other working conditions to check the tension stability

3.3 Slitting accuracy adjustment

• Use a feeler gauge to adjust the upper and lower knife clearance, usually set to 1.2-1.5 times the thickness of the material

• Adjust the cutter angle and pressure to the optimal state by trying to cut the spline

• Test different width specifications (commonly 3mm-20mm) to ensure that the slitting straightness error ≤ 0.1mm/10m

4.4 Automatic control system debugging

• Set the sensitivity and response speed of the correction system

• Programming the taper tension curve and winding logic for winding

• HMI parameter settings, including speed, length, alarm limit, etc

5. Trial production and optimization of strips

5.1 Preparation for trial production

• Prepare 3-5 different specifications of hot stamping foil materials for testing

• Configure the paper tube and slitting tool of the appropriate specification

• Develop a trial production record form to record key parameters

5.2 Trial production process

1. Low-speed trial cutting: Run at a speed of 30-50m/min to observe the winding flatness and slitting quality

2. Parameter optimization: Adjust the tension parameters, cutter pressure, and guide edge position according to the test cutting results

3. High-speed verification: Gradually increase to 80% of the rated speed to check the stability of the system

4. Continuous operation: Carry out continuous production for 4-8 hours to monitor the temperature rise and vibration of the equipment

5.3 Quality acceptance standards

• Slitting accuracy: width tolerance ≤±0.1mm, diagonal error ≤0.15mm

• Winding quality: the flatness of the end face is ≤ 0.5mm, and there is no ruffle or split layer

• Production efficiency: more than 90% of the design speed, and the reel change time ≤ 2 minutes

• Scrap rate: Scrap rate ≤ 0.5% under stable production conditions

6. Operation training and document delivery

6.1 Systematic training

• Basic operation: power on and off process, daily parameter setting, material change operation

• Maintenance: daily inspection items, lubrication cycles, and replacement of wearing parts

• Fault handling: common alarm identification and troubleshooting methods

• Safety regulations: personal protection requirements, emergency handling procedures

6.2 Technical documentation collation

Deliver the user's complete technical profile, including:

• Mechanical assembly drawings and wearing parts lists

• Electrical schematic diagrams and PLC program backup

• Commissioning report and acceptance certificate

• Maintenance schedules and operation video materials

7. Common problems and solutions

บทส่งท้าย

The installation and commissioning of hot stamping foil slitting machine is a systematic project that requires expertise in mechanical, electrical, and technological aspects. Through standardized installation processes and refined commissioning methods, it can not only ensure the rapid commissioning of equipment, but also lay a solid foundation for long-term stable operation. It has been proven that the time and effort spent in the installation and commissioning phase will pay off several times over the life of the equipment – reducing downtime, improving product quality, and extending the life of the equipment. With the development of intelligent technology, modern hot stamping foil slitting machines are evolving in the direction of automatic diagnosis and remote operation and maintenance, but a solid foundation installation and commissioning work is still the premise guarantee for the best performance of the equipment.