How to install and debug the knife die equipment of nonmetallic engraving machine?

The installation and debugging of non-metallic engraving machine tool die equipment is a key link to ensure the normal operation of the equipment and ensure the machining accuracy and efficiency, and it needs to be operated step by step according to the standard process. The following are detailed installation and debugging steps and precautions:

First, preparation before installation

Before the equipment is in place, it is necessary to prepare the basic environment and tools to avoid omissions during installation.

1. Site and environmental requirements

Space planning: ensure that there is enough space in the installation area (at least 1.5 times larger than the equipment size) to facilitate operation, maintenance and material handling; Reserve equipment cooling, cable routing and waste collection areas.

Ground requirements: the ground should be flat and hard (concrete pouring is recommended, and the bearing capacity should be 1.5 times or more of the self-weight of the equipment) to avoid vibration or deformation of the equipment due to uneven ground; If the ground is uneven, it needs to be calibrated and leveled with a level in advance.

Power supply and air supply:

Power supply: according to the power of the equipment, an independent loop (such as 380V three-phase alternating current, a voltage regulator is required to avoid voltage fluctuation affecting the operation of the motor), the grounding resistance is ≤4Ω, and a leakage protector is installed.

Air source: If the equipment is equipped with pneumatic components (such as material clamping device), clean compressed air (air pressure 0.6-0.8MPa) shall be connected, and an oil-water separator shall be installed to filter impurities.

Environmental control: avoid direct sunlight, humid (humidity ≤70%), dusty or corrosive gas environment; The temperature is controlled at 15-30℃ to prevent the deformation of precision parts due to temperature difference.

2. Preparation of tools and auxiliary materials

Tools: level (accuracy 0.02mm/m), torque wrench, Allen wrench set, multimeter, dial indicator, laser calibrator (optional), crowbar (for mobile equipment).

Materials: Shockproof pad iron (prepared according to the number of equipment anchors), insulating tape, cable fixing card, cleaning cloth and lubricating oil (the model specified in the equipment manual).

Second, the equipment installation steps

1. Equipment in place and leveling

Unloading and handling: use forklift or crane (according to the weight of the equipment) to handle smoothly to avoid violent vibration; If it is moved manually, it is necessary to pad a hard roller at the bottom of the equipment and move it slowly.

Preliminary positioning: move the equipment to the installation position, roughly aligned with the preset direction of power supply and air supply interface.

Precise leveling:

Place anti-shock pad iron (for height adjustment) at the position of the anchor bolt, and adjust the pad iron to make the equipment workbench level.

Use a level to detect the X-axis and Y-axis directions of the workbench, and the error shall be ≤ 0.05 mm/m; If it is uneven, fine-tune the shim in the corresponding direction and repeat the detection until it reaches the standard.

Fix the anchor bolt: fasten the anchor after leveling, and recheck the level again to prevent the equipment from shifting during fastening.

2. Connect the pipeline and cable

Power connection:

When the power is off, connect the main cable (distinguish the phase wire, neutral wire and ground wire) according to the electrical schematic diagram of the equipment to ensure that the wiring is firm and the insulation layer is not damaged.

Check the resistance of each loop with multimeter to confirm that there is no short circuit or open circuit; The grounding line needs to be connected separately and cannot be shared with the neutral line.

Air source connection: connect the pneumatic pipeline to the air source interface of the equipment, use soapy water to detect whether the interface leaks, and fix the pipeline after ensuring the air pressure is stable (to avoid pipeline shaking interfering with the operation of the equipment).

Other pipelines: If the equipment has a cooling system (such as a water-cooled spindle), connect the water inlet pipe and the water outlet pipe to ensure smooth water flow and no water leakage.

3. Parts assembly inspection

Check whether the removable parts such as the tool magazine, spindle and guide guard are firmly installed and whether the screws are tightened according to the specified torque (refer to the torque value in the manual).

Cleaning the inside of the equipment: remove impurities such as fixed pads and foam during transportation, and wipe the anti-rust oil on the surfaces of guide rails and lead screws with a cleaning cloth.

Third, check before debugging

Before power-on debugging, it is necessary to carry out static inspection of mechanical and electrical systems to eliminate potential safety hazards.

1. Mechanical system inspection

Guide rail and lead screw: manually push the spindle or workbench to check whether the movement is smooth, jammed or abnormal; If there is any abnormality, it may be that the parts are displaced during transportation, so it is necessary to loosen the fixing screws and readjust them.

Tool clamping device: install the handle and check whether the chuck is fastened. The runout of the handle (detected by dial indicator) should be ≤0.02mm to prevent the tool from shaking during machining.

Limit switch: manually trigger the limit of each shaft, and confirm that the switch can be triggered normally (which can be judged by the indicator light of the control cabinet) to avoid over-travel damage when the equipment is running.

2. Electrical system inspection

Before electrifying, use a multimeter to check whether the power supply voltage meets the equipment requirements (such as 380 V 5%) and whether the grounding is reliable.

Check whether the wiring terminals in the control cabinet are loose, whether the components such as relays and contactors are normal, and whether the cooling fan works.

Fourth, power-on debugging

1. Preliminary power-on test

Turn on the main power supply and observe whether the indicator light of the control cabinet is normal (no alarm light is on); Start the equipment control system (such as numerical control system), and check whether the display screen is started normally and whether there is any error code.

Test the inching operation of each axis: in manual mode, operate the X, Y and Z axes to move slowly, and observe whether the motor runs smoothly and the direction is consistent with the control panel (if it is in the opposite direction, adjust the motor steering in the system parameters).

2. Precision calibration

Axis parallelism calibration:

Use a dial indicator to adsorb on the spindle, contact the workbench, move the X axis, and observe the reading change of the dial indicator. The error should be ≤0.03mm/1000mm to ensure that the X axis is parallel to the workbench. Calibrate the y axis in the same way.

If the error is out of range, adjust the fixing screw of the guide rail (professional operation is required to avoid damaging the accuracy of the guide rail).

Spindle verticality calibration:

Fix the dial indicator on the workbench, contact the side of the spindle, rotate the spindle (at low speed), and detect the radial runout with an error of ≤ 0.01 mm; If it is out of tolerance, adjust the preload of the spindle bearing or replace the spindle.

Check the verticality between the spindle and the workbench: press the spindle with a square ruler, and check the verticality error with a dial indicator, which shall be ≤0.02mm/100mm.

Repeated positioning accuracy test: Set the X-axis to move back and forth for 100mm (multiple times) in the system, and record the end position of each time with a laser interferometer or dial indicator, and the error shall be ≤0.01mm to ensure the normal clearance of the screw nut.

3. Tool and parameter setting

Tool installation: Select appropriate tools (flat-bottomed knives, ball end mill, etc.) according to the processed materials (such as acrylic, wood, leather), calibrate the Z-axis tool length compensation value with a tool length measuring instrument after installation, and input system parameters.

Parameter debugging:

Spindle speed: according to the tool diameter and material setting (for example, cutting acrylic, 15,000-20,000 r/min is recommended for 10mm tool speed).

Feed speed: according to the hardness of materials, the feed of soft materials (such as foam) can be fast (500-800mm/min), and the feed of hard materials (such as PVC) can be slow (200-500mm/min).

Trial cutting test: simply cut (such as straight lines and round holes) with waste materials (consistent with the processed materials), check the dimensional accuracy (measured with calipers) and surface smoothness, and if there is any deviation, fine-tune the system parameters (such as compensating the screw clearance).

V. Commissioning and Acceptance

1. Run the test continuously

Select typical processing files (such as the path of the die with complex patterns), and continue processing for 3-5 hours to observe whether the equipment is stable;

No abnormal noise and vibration.

Temperature rise of motor and spindle is normal (≤40℃, detected by infrared thermometer).

Consistency of machining dimensions (machining the same figure for many times with an error of ≤0.05mm).

2. Safety function test

Test the emergency stop button: after pressing it, the equipment should immediately stop all movements, and it needs to be reset before it can run.

Test shield interlock: open the main shaft shield, and the equipment should be unable to start running to ensure safe operation.