What matters should be paid attention to in the installation and debugging of precision engraving machine for knife die?

The installation and debugging of the precision engraving machine for knife die directly affects the precision, stability and service life of the equipment, and it needs to be strictly controlled from the aspects of site preparation, mechanical installation, electrical connection, precision calibration and function test. The following are specific precautions and technical points:

I. Site and Environment Preparation

1. Foundation and bearing requirements

Bearing capacity on the ground: The weight of the equipment is usually 1-3 tons, so it is necessary to ensure that the bearing capacity on the installed ground is ≥500kg/㎡ (the thickness of concrete is ≥150mm and the strength grade is above C25).

Levelness control: use a 0.02mm/m precision level to adjust in the longitudinal and transverse directions of the workbench, and the flatness error shall be ≤0.05mm/m (adjusted by the anchor bolt or the damping pad).

2. Environmental conditions

Temperature and humidity: the working environment temperature is 15-25℃ (fluctuation ≤ 3℃) and the humidity is 40%-60% (to avoid electrical failure caused by condensed water).

Anti-vibration requirements: Keep away from vibration sources such as punching machines and forging equipment (distance ≥5m), and install anti-vibration pads (natural frequency ≤10Hz) if necessary.

Power supply stability: three-phase five-wire power supply (380 V 10%, 50Hz), equipped with independent voltage regulator (capacity ≥ 1.5 times the total power of equipment) and grounding protection (grounding resistance ≤4Ω).

Second, the mechanical installation points

1. The host in place and fixed

Lifting specification: Use the equipment to specify the lifting point (usually located at the top of the fuselage), the steel wire rope shall bear more than 2 times the weight of the equipment, and keep it horizontal during lifting (inclination angle ≤ 5).

Installation of anchor bolts: the embedding depth of bolts is ≥100mm, and the tightening torque shall be in accordance with the manufacturer's instructions (for example, M12 bolt torque is 80-100 nm) to prevent vibration and displacement during equipment operation.

2. Installation of transmission system

Lead screw and guide rail:

When installing the linear guide rail, first wipe the installation surface with alcohol, and then apply the special guide rail oil (viscosity 32cSt) evenly. The parallelism error between the slider and the guide rail is ≤0.03mm/1000mm.

Check the pre-tightening force of the ball screw nut pair (the resistance is even when the screw is turned manually, without jamming), and the axial movement is ≤ 0.01 mm..

Belt drive (e.g. X/Y axis): The belt tension should be 5-10mm when the middle part is pressed. If it is too loose, it will slip, and if it is too tight, the motor bearing will be overloaded.

Three, electrical and numerical control system connection

1. Cable laying specification

Separation of strong and weak current: the distance between power cable (such as spindle motor wire) and signal cable (such as encoder wire) is ≥300mm to avoid electromagnetic interference (shielded by metal bellows).

Grounding treatment: CNC system, servo motor, electric box, etc. are independently grounded, and the cross-sectional area of grounding wire is ≥ 4 mm to avoid multi-point grounding to form a loop.

2. CNC system debugging

Parameter initialization: input the parameters provided by the manufacturer (such as pulse equivalent of each axis and soft limit value), the positioning accuracy of X/Y/Z axis is ≤0.02mm, and the repeated positioning accuracy is ≤ 0.01 mm..

Servo debugging: observe the running waveform of the motor through an oscilloscope, and adjust the gain of the speed loop (usually 200-500rad/s) and the gain of the position loop (5-10rad/s) to eliminate low-speed crawling and high-speed vibration.

Four, precision calibration and function test

1. Geometric accuracy calibration

Verticality of spindle: measure the verticality of spindle end face in X/Y direction with a dial indicator, and the error is ≤0.02mm/100mm (corrected by adjusting the gasket on the mounting surface of spindle box).

Worktable flatness: use precision leveling ruler and feeler gauge to detect, the flatness within the whole length range is ≤0.03mm, and local high points can be corrected by grinding the worktable.

Positioning accuracy test: measured by laser interferometer (such as Renishaw XL-80), the whole positioning error of X/Y axis is ≤0.03mm, Z axis is ≤0.02mm, and the reverse clearance is ≤ 0.005mm..

2. Functional commissioning

No-load test: each shaft runs at 50% rated speed for 1 hour, and check the lubrication state of the guide rail (automatic oil supply every 15 minutes), and the motor temperature rise is ≤40℃.

Cutting test: contour machining is carried out with 45# steel specimen (100mm×100mm×20mm), the feed speed is 800-1200mm/min, the spindle speed is 10000-15000rpm, and the roughness (Ra≤1.6μm) and dimensional tolerance (±0.03mm) of the machined surface are detected.

V. Commissioning of safety and protective devices

1. Emergency stop and limit function

After pressing the emergency stop button, the main shaft should stop within 0.5 seconds, and the movement of each shaft will be terminated immediately, and the electrical system will be powered off for protection.

Double protection of soft limit and hard limit: the set value of soft limit is 5-10mm smaller than the travel of the workbench, and the hard limit switch needs to be reset manually when triggered (to avoid the damage of the travel switch caused by frequent triggering).

2. Installation of protective devices

The gap between the protective cover and the fuselage is ≤5mm to prevent the chips from splashing; The transparent observation window needs explosion-proof glass (thickness ≥5mm), and the visual field covers more than 80% of the processing area.

The height of the cutting fluid protective baffle is ≥300mm, and the edge needs to be equipped with sealing strips to prevent liquid leakage (leakage ≤50mL/h).

Six, common debugging faults and solutions

Possible causes of fault phenomena and solutions

When the motor is running, the abnormal sound bearing is short of oil, the coupling is not concentric with grease, and the coaxiality of the coupling is adjusted (≤0.05mm).

The clearance of the screw rod with out-of-tolerance machining size is too large, and the parameters are set incorrectly. Adjust the pre-tightening force of the screw rod and re-enter the pitch compensation parameters.

System alarm (such as overload) servo gain is too high, mechanical jamming reduces gain parameters, and check whether the guide rail slider is stuck.

Cutting fluid leaks, pipe joints are loose, water tanks are cracked, joints are tightened (torque is 15-20N・m), and water tanks are repaired.

Seven, acceptance and training points

Acceptance of technical documents: check the equipment manual, electrical schematic diagram, calibration report (including laser interferometer test data), list of wearing parts and other materials.

Operator training: focus on manual tool alignment (accuracy ≤0.02mm), parameter backup (once every quarter) and emergency fault handling (such as unloading operation when the spindle is locked).

summary

The logic of "environmental control → mechanical accuracy → electrical stability → functional verification" should be followed in the installation and debugging of the precision engraving machine for knife dies, and each link needs quantitative indicators (such as water flatness, verticality and positioning accuracy). Pay special attention to temperature control (affecting the thermal elongation of the lead screw) and anti-vibration measures (avoiding the cutting edge of the die from cracking). Finally, the machining ability (such as 0.1mm narrow groove machining and R0.2mm fillet transition) is verified by trial cutting of the workpiece, so as to ensure that the equipment meets the high-precision requirements of the die industry (such as the straightness of the cutting edge of the stamping die ≤0.01mm/100mm).