What should be paid attention to in the processing of high-speed bottom film machine?

High-speed base film machine (commonly used in packaging, printing, composite material processing and other fields, which completes the processes of unwinding, laminating, cutting and winding the base film through high-speed operation) needs to give consideration to efficiency, quality and equipment safety in the processing process. The following are the key points to pay attention to:

First, preparation and inspection before startup

Equipment status check

Check whether all transmission parts (such as motor, gear, chain and guide rail) are flexible, abnormal sound or stuck, and regularly add lubricating oil (such as chain oil and guide rail grease) to avoid equipment wear or shutdown due to excessive friction.

Confirm that the braking system (such as magnetic powder brake and clutch for winding/unwinding) is sensitive and effective, so as to prevent the base film from slipping and running off at high speed.

Check whether the electrical system (wires, sockets, sensors) is leaking or short-circuited, and whether the emergency stop button works normally, so as to ensure that it can be stopped immediately in case of emergency.

Material and parameter confirmation

Check whether the material (such as PE, PET, CPP, etc.) and thickness (usually 0.01-0.2mm) of the base film are suitable for the equipment, so as to avoid tearing due to excessive tension caused by too thick material or wrinkling due to too thin material.

Accord to that characteristics of the basement membrane:

Tension control: the tension of unwinding and winding should match the strength of the material (for example, the tension of thin film should be small, and the tension of thick film can be appropriately increased) to prevent the base film from stretching and deforming or relaxing and wrinkling.

Speed setting: Adjust the running speed according to the base film material (usually, the speed of high-speed base film machine can reach 300-800m/min). When processing new materials for the first time, try the machine at a low speed and gradually increase it to the target speed to avoid material breakage due to too fast speed.

Temperature parameters (such as thermal bonding process): Make sure that the temperature of the heating roller matches the temperature resistance of the base film (for example, the temperature resistance of the PET film is about 120℃ and that of the PE film is about 80℃) to prevent the base film from melting or deforming.

Second, the core operating points in the process of processing

Tension control and flatness of film surface

When running at high speed, the tension fluctuation of the base film is easy to cause wrinkles, deviation or fracture, so it is necessary to monitor it in real time through the tension sensor and adjust the unwinding/winding tension in time (for example, the current of the magnetic powder brake is automatically adjusted through the PLC system).

If the film surface deviates, it is necessary to fine-tune the deviation correction device (such as photoelectric deviation correction sensor) immediately to ensure that the edge of the base film is aligned (the deviation is controlled within 1 mm) to avoid burrs or dimensional deviation during cutting.

Avoid material damage and pollution.

Check whether the surfaces of guide rollers and pressure rollers are smooth, and whether there are scratches, oil stains or foreign objects (such as dust and glue stains). Wipe them regularly with a dust-free cloth to prevent the surface of the base film from being indented, scratched or polluted.

For materials that are prone to static electricity (such as CPP film), it is necessary to turn on the static electricity removing devices (such as ion fans and static electricity eliminating rods) to avoid electrostatic dust adsorption affecting the cleanliness of the film surface or causing potential safety hazards due to electrostatic sparks.

Quality control of cutting and winding

Cutting knives (such as round knives and flat knives) should be sharp and firmly installed, and the gap of the blade should be adjusted according to the thickness of the base film (for example, the gap should be reduced for films below 0.05mm to prevent curling), so as to avoid burrs, tears or overheating of the blade during cutting (for composite films).

When winding, ensure that the winding diameter is uniform, the tension is gradually increased (to prevent the inner layer from being too loose and the outer layer from being too tight, resulting in the deformation of the winding core), and the winding speed is synchronized with the speed of the main machine to avoid the phenomenon of "film pulling" or "film stacking".

III. Equipment Maintenance and Safety Specifications

Regular maintenance

Clean the dust on the surface and inside of the equipment daily (especially the motor cooling holes and sensor probes) to prevent dust from affecting heat dissipation or signal failure.

Check the tool wear every week, and replace the blade in time (such as grinding or replacement after the cutting edge is passivated), so as to avoid the degradation of processing quality caused by tool aging.

Calibrate key parameters (such as tension sensor and speed encoder) every month to ensure accurate data and reduce batch scrap caused by parameter drift.

Personnel operation safety

Operators should wear protective equipment (such as anti-slip gloves and goggles), and it is forbidden to touch transmission parts (such as chains and rollers) when the equipment is running to avoid the risk of being involved.

In case of any abnormality (such as abnormal sound, sparks and membrane rupture) during the operation of the equipment, the emergency stop button shall be pressed immediately, and the fault shall be checked after the equipment is completely stopped. It is forbidden to "run with risks".

Non-professionals are not allowed to disassemble the electrical box and adjust the core parameters (such as motor frequency and PLC program) without authorization to prevent equipment damage or electric shock.

Fourth, emergency treatment and quality traceability

Common fault handling

If the basement membrane suddenly breaks: immediately stop the machine, check whether the tension is too high and whether the material has defects (such as thin spots and pinholes), replace the broken part and restart at a low speed, and then speed up after confirming that there is no abnormality.

If there is "elastic edge" in winding: adjust the pressure at both ends of the winding roller (such as the air pressure of the pneumatic roller), or check whether the unreeled film roll is flat (which may be caused by eccentricity of the original film roll).

If the equipment is overloaded, alarm: stop the machine to check whether the transmission system is stuck and the motor load is too large, and reset the alarm after troubleshooting before starting.

Quality record and traceability

Record the processing parameters (such as speed, tension, temperature), material specifications and finished product quality (such as cutting size and film surface flatness) of each batch, so as to facilitate the follow-up tracing of the root cause of the problem (like repeated wrinkles under the same parameter, it is necessary to check the parallelism of equipment guide rollers).

summary

The core of high-speed base film machine is "stable operation"-through strict startup inspection, accurate parameter control and standardized operation flow, the precision and efficiency of base film processing can be ensured, the service life of the equipment can be prolonged and the safety risk can be reduced. Especially at high speed, any slight deviation (such as tension fluctuation and tool wear) may be magnified, so it is necessary to strengthen the concept of "prevention first" and control the details throughout the machining process.