Попрощайтесь с частыми простоями: руководство по анализу надежности и обслуживанию основных компонентов машин для резки ленты

The ribbon slitting machine is a key equipment in the thermal transfer marking industry, and its operational stability directly affects the yield, quality, and delivery cycle of the ribbon. Frequent downtime not only leads to low production efficiency but also leads to huge material waste and cost losses. To solve this problem, it is necessary to start with reliability analysis and preventive maintenance of core components.

First, reliability analysis and common faults of core components

The core of the ribbon slitting machine can be summarized in four major systems: unwinding and rewinding system, tension control system, slitting system, and guide roller and correction system.

1. Unwinding and rewinding system

• Core components: unwinding shaft, rewinding shaft, air expansion shaft, plain clutch/magnetic powder clutch/servo motor.

• Reliability Analysis:

◦ Inflatable shaft: long-term use may cause the air bag to age and leak, causing it to slip with the paper tube and cause the coil to slide or break.

◦ Shaft head and bearing: Bearing huge radial force, if not lubricated or improperly installed, it is easy to cause bearing wear, heat or even jamming.

◦ Clutch/brake: If the magnetic powder is aged or damp, the tension will be unstable; the slip clutch may cause inaccurate torque output due to wear.

• Common faults:

◦ Uneven winding (chrysanthemum roll), coil slippage.

◦ Sudden material breakage during unwinding or rewinding.

◦ Abnormal noise or vibration during operation.

2. Tension control system

• Core components: tension sensor, floating roller, damper, tension controller.

• Reliability Analysis:

◦ This is the "nerve center" of the slitting machine. The stability of the tension is the key to determining the quality of the slitting (face flatness, no wrinkles).

◦ Tension sensor: High accuracy but fragile, overload or impact can easily lead to damage or inaccurate measurement.

◦ Floating rollers: The bearings and connecting rod mechanisms need to be flexible and non-jamming, otherwise the tension changes cannot be truly fed.

◦ Controller: Aging of electronic components or improper parameter settings can cause the entire system to respond slowly or oscillate.

• Common faults:

◦ The carbon belt wrinkled, stretched and deformed during the slitting process.

◦ Serpentine deviation occurs when slitting narrow strips.

◦ The end face coil is loose inside and tight on the outside or tight on the inside and loose on the outside.

3. Slitting system

• Core components: slitting knife holder, upper circular knife (blade), lower bottom knife (anvil roller).

• Reliability Analysis:

◦ Blade: Hardness, sharpness, and angle are key. Passivated blades can cause uneven cutting edges, create burrs or dust, and even tear the ribbon. The coated ribbon wears the blade particularly badly.

◦ Tool holder: Its rigidity and the precision of the adjustment mechanism determine the accuracy and consistency of the slitting width. A loose locking mechanism can cause changes in the cutter position during slitting.

◦ Bottom knife (anvil roller): Long-term cooperation with the upper knife will cause wear grooves on the surface, resulting in the inability to completely cut the material at this position.

• Common faults:

◦ There are burrs and powder drops on the cut edges.

◦ Continuous slitting produces the phenomenon of "broken silk connection".

◦ The slitting width is inconsistent.

4. Guide roller and correction system

• Core components: guide rollers, guiding sensors, correction actuators (slide table + motor).

• Reliability Analysis:

◦ Guide rollers: Surface finish is a top priority. Scratched, gruffed or rusty guide rollers can scratch the ribbon coating and cause product scrap. Poor parallelism introduces additional tension differences.

◦ Correction system: Mirror contamination of photoelectric sensors will lead to misjudgment; Actuators (such as cylinders or motors) are slow to respond or jam, which can cause the correction to fail, leading to material deviation and edge damage.

• Common faults:

◦ The ribbon coating is scratched.

◦ The material continues to deviate to one side during operation and cannot be corrected.

◦ The correction action is too frequent or violent, causing system oscillation.

Second, systematic maintenance guidelines: from daily to regular

To say goodbye to frequent downtime, it is necessary to establish a systematic and institutionalized maintenance system.

A. Routine maintenance (per shift/daily)

1. Cleaning:

◦ Use a soft, dust-free cloth and alcohol to clean all guide roller surfaces to ensure they are free of dust, oil, and ribbon debris.

◦ Clean the lens of the guidance correction sensor.

◦ Clean the ribbon dust around the tool holder.

2. Visual Inspection:

◦ Check whether the inflation shaft expands evenly after inflation and whether there is any air leakage sound.

◦ Check whether the round knife and bottom knife have visible wear and chipping.

◦ Observe whether there is any abnormal vibration or noise in the operation of the machine.

3. Functional Testing:

◦ No-load operation to test whether the correction system functions normally.

B. Regular Preventive Maintenance (Weekly/Monthly/Quarterly)

C. Operational data-based maintenance

• Record key data: record the number of slitting meters per female coil, the length of blade use, bearing replacement cycles, etc. Through data analysis, the life of components can be predicted more scientifically and "predictive maintenance" can be realized.

• Focus on performance trends: If you notice a slow decline in slitting quality (e.g., burr volume, face flatness), intervene to check the blade and tension system in advance, even if there is no alarm.

Third, establish a long-term management mechanism

1. Develop Standard Operating Procedures (SOPs): Develop detailed steps for all operations such as loading, unloading, tool changes, and commissioning to avoid damage to equipment caused by human error.

2. Spare parts management: According to the maintenance cycle and the number of equipment, reserve key wearing parts, such as round blades, airbags, bearings, etc., to ensure that they can be quickly replaced in case of failure.

3. Personnel training: Let the operation and maintenance personnel not only know what it is, but also know why. Understanding the role of each component and the principle of failure can help them better identify signs of problems.

заключение

Frequent downtime of ribbon slitting machines is not without its problems. By deeply understanding the reliability weaknesses of their core components and strictly implementing a systematic maintenance plan from routine cleaning to regular maintenance, companies can change "reactive maintenance" to "proactive prevention". This not only significantly reduces unplanned downtime, but also improves product qualification rates, extends equipment life, and ultimately establishes a solid core competitiveness in the fierce market competition.