What should be paid attention to in the installation and debugging of special bottom die machine for knife die?

The special bottom die machine for knife die is a special equipment used to process the bottom die of knife die (such as wood board, rubber board, density board and other materials), and its standardization of installation and debugging directly affects the machining accuracy, equipment life and production safety. The following is a detailed description from four aspects: preparation before installation, installation process, debugging points and precautions:

First, the preparation before installation

Site and environmental requirements

Space planning: reserve equipment operation space (at least 1.5 meters around the equipment without obstacles) to ensure the safety of loading and unloading, maintenance and personnel walking; The bottom die machine is mostly numerical control equipment, so it needs to be far away from the seismic source (such as punching machine and large air compressor) to avoid vibration affecting the machining accuracy.

Ground conditions: the ground should be flat and hard (recommended concrete strength ≥C20). If the ground is uneven, it should be calibrated with a level meter, and if necessary, a shockproof pad should be laid (especially for high-precision models).

Environmental parameters: the temperature shall be kept at 10-30℃ (to avoid overheating of the motor caused by high temperature or influence of low temperature on lubrication), the humidity shall be ≤70% (to prevent short circuit of electrical components due to moisture), and it shall be kept away from dust and corrosive gases (such as painting workshop).

Power supply and gas source preparation

Power supply configuration: Connect the corresponding voltage (common 380V three-phase alternating current) according to the nameplate requirements of the equipment, and separately wire and install a leakage protector (rated current is more than 1.5 times of the rated current of the equipment), and the grounding resistance is ≤4Ω (to prevent static electricity or leakage).

Air source requirements: If the equipment is equipped with pneumatic components (such as pneumatic material pressing device), 0.6-0.8MPa compressed air should be connected, and an oil-water separator should be installed in front of the air source (to prevent water vapor and oil pollution from entering the cylinder and damaging parts).

Auxiliary tools and materials

Prepare debugging tools such as level gauge (accuracy 0.02mm/m), torque wrench, Allen wrench and dial indicator;

Prepare the equipment manual, circuit diagram and parts list, and check whether the attached accessories (such as tools, fixtures and data cables) are complete.

Second, the key points in the installation process

Equipment positioning and leveling

Use forklift or crane to move the equipment to the installation position (pay attention to the marking of lifting points, and do not lift non-load-bearing parts), and slowly put it down to avoid impact.

Leveling steps:

Place the level in the X-axis, Y-axis direction and diagonal position of the workbench;

By adjusting the anchor bolt at the bottom of the equipment, the levelness error in all directions shall be ≤0.05mm/m (if the levelness is not up to standard, the workpiece will be tilted during machining, and the stress on the tool will be uneven, which will affect the accuracy);

Lock the anchor nut after leveling to prevent the equipment from shifting.

Electrical and pneumatic connection

Electrical connection: A professional electrician shall connect the wires according to the circuit diagram to ensure that the phase, neutral and ground wires are connected correctly (wrong connection may burn the motor or control system); After connection, use multimeter to detect insulation resistance (≥1MΩ) to avoid short circuit.

Pneumatic connection: apply sealant (or use raw tape) to the trachea joint to ensure no air leakage; After connecting the air source, test whether the pneumatic components (such as the pressure cylinder) move smoothly and without jamming.

Tool and table installation

Tool installation: Select suitable tools (such as milling cutter and saw blade) according to the processing materials, and the fit clearance between the tool handle and the spindle chuck shall be ≤ 0.01 mm. After installation, lock them evenly with a wrench (to avoid vibration caused by eccentricity), and check whether the extended length of the tool meets the processing requirements.

Inspection of the workbench: clean up the oil stain and impurities on the workbench, install the positioning fixture (such as backing and sucker), and ensure that the fixture is closely attached to the workbench (check the gap ≤0.03mm with a feeler gauge).

Third, the core steps and matters needing attention in the debugging stage

Empty machine operation test

After turning on the power supply, first turn on the equipment control system and check whether the touch screen, buttons and indicator lights are displayed normally;

Manually operate each axis (X, Y, Z axis) to observe whether the guide rail runs smoothly (no abnormal sound or jamming) and whether the limit switch is sensitive (the axis movement stops immediately when triggered);

Test the spindle: start it gradually from low speed to high speed (for example, 1000r/min→3000r/min→5000r/min), and listen to whether the running sound of the spindle is even (abnormal noise may be caused by improper bearing installation or insufficient lubrication).

Precision calibration

Calibration of positioning accuracy: use laser interferometer to detect the positioning error of each axis (for example, the error of X axis per meter should be ≤0.03mm), and if it is out of tolerance, it should be compensated by control system parameters (operated by professional technicians).

Repeated positioning accuracy calibration: fix the dial indicator on the workbench, move the shaft at the same position for many times and record the readings, and the error should be ≤0.02mm (excessive error will lead to inconsistent batch processing dimensions).

Verticality calibration: use a square ruler or a square box to detect the verticality between the spindle and the workbench (the error is less than or equal to 0.02 mm/100mm). If it is unqualified, adjust the fixing bolt of the spindle seat.

Trial cutting and parameter optimization

Select materials consistent with actual production (such as 18mm thick density board) and write simple processing programs (such as cutting 100mm×100mm rectangular grooves);

Reduce the feed speed (50% of the normal speed) during the first trial cutting, observe the cutting state of the tool (whether there is edge collapse or burr), measure the deviation between the machining size (such as groove width and depth) and the drawing, and correct it by adjusting the compensation parameters of the tool;

Test the cooling system: start the cooling pump and check whether the cooling liquid is evenly sprayed to the cutting area (to avoid overheating and wear of the tool).

Iv. Precautions for long-term use

Safety protection inspection

Confirm that the protective cover, emergency stop button and safety grating (if any) function normally, and it is forbidden to remove the protective device and start it;

Operators should wear protective glasses and gloves (to avoid personal injury caused by sawdust or tool fragments).

Lubrication and maintenance

Fill the guide rail and screw rod with special lubricating oil (such as guide rail oil ISO VG32) regularly according to the instructions to avoid wear caused by dry friction;

Clean the dust and debris in the spindle taper hole (which can be blown clean by air gun) to prevent inaccurate positioning when loading the cutter.

Parameter backup and recording

After debugging, back up the equipment parameters (such as shaft compensation value, spindle speed and feed speed) to U disk to avoid parameter loss caused by misoperation;

Record the qualified parameters of the first trial cutting (such as cutting parameters for different materials) as a reference for mass production.

exception handling

In case of abnormal sound, vibration or out-of-tolerance in machining, stop the machine immediately for inspection, and then start it after eliminating the problems such as tool wear, loose guide rail and parameter error;

Electrical faults need to be checked by professional electricians, and it is forbidden for non-professionals to dismantle and repair the control system without authorization.

The installation and debugging of the special bottom die machine for knife dies should pay attention to "accuracy, safety and stability". It is recommended that it be operated by technicians or experienced engineers from equipment manufacturers, especially for high-precision CNC models. Improper handling of details may lead to long-term machining errors. After commissioning, operators should be trained to ensure that they master the skills of parameter setting, daily maintenance and emergency treatment, so as to prolong the service life of the equipment and ensure the production quality.