Matters needing attention in installation and debugging of special bottom die machine for knife die

During the installation and debugging of the special bottom die machine for knife dies, it is necessary to focus on the three cores of safety protection, precision guarantee and equipment life to avoid operational risks and precision errors. The specific matters needing attention can be sorted according to the four stages of "preliminary preparation, installation and operation, debugging and verification, and final maintenance":

First, the preparatory stage: to avoid basic risks

Personnel qualification and safety training

Installation (especially circuit connection) must be carried out by professionals with electrician certificate and equipment operation qualification. Non-professionals are forbidden to touch the power supply and gas circuit interfaces to avoid the risk of electric shock and air pressure impact.

Before operation, be familiar with the "Safety Warning" chapter in the equipment manual (such as the position of emergency stop button and prohibited area), and wear protective equipment (non-slip shoes, protective gloves and goggles when debugging tools).

Site and environment verification

The ground should meet the dual requirements of "bearing+leveling": if the rated bearing of the equipment is ≥500kg, it should be confirmed that the ground is concrete (thickness ≥10cm) to avoid ground collapse; Pre-check the ground flatness with a level meter. If the error exceeds 0.5mm/m, it needs to be leveled in advance (such as laying steel plates) to prevent the equipment from vibration deviation in the later operation.

Keep away from inflammable and explosive materials (such as alcohol and paint), and the compressed air source needs to be equipped with an oil-water separator (to prevent water vapor and impurities from entering the gas path and corroding the cylinder or solenoid valve).

Inspection of equipment and accessories

After unpacking, it is necessary to check the models of accessories (such as leveling feet, gas path connectors and calibration tools) one by one, which are consistent with the specifications. It is important to check whether the precision parts such as tool chuck and transmission gear have transportation damage (such as deformation and jamming). If problems are found, contact the manufacturer immediately, and it is not allowed to install them forcibly.

Second, the installation operation stage: to ensure the safety and stability of the connection.

Positioning and fixing of equipment: anti-displacement and anti-toppling.

When moving equipment (such as forklift), it is necessary to wrap the corners of the equipment with soft cloth to avoid collision; Fork arms of forklift trucks need to support the load-bearing beam at the bottom of the equipment (not the table top) to prevent the deformation of the table top from affecting the accuracy.

After leveling, double fixation is required: firstly lock the leveling foot nut (tighten it with a wrench to prevent loosening), and if the weight of the equipment is ≥800kg, it needs to be fixed with additional anchor bolts (the bolt size is ≥M12, and the embedded depth is ≥10cm) to avoid "displacement" of the equipment during high-speed operation.

Circuit connection: short circuit prevention and leakage prevention.

Before power supply, it is necessary to confirm the voltage matching (usually 380V three-phase electricity, never connect 220V single-phase electricity), and the cross-sectional area of the power cord should be ≥ the corresponding specifications of the rated current of the equipment (for example, 10A equipment needs ≥ 2.5 mm copper wire) to avoid line overload and heating.

The "live wire, neutral wire and ground wire" must be strictly distinguished: the ground wire should be connected separately (not shared with the zero wire), and the grounding resistance should be detected by shaking table ≤4Ω to prevent electric shock accidents caused by charged equipment shell; After wiring, wrap the connector with insulating tape to avoid bare short circuit.

Gas path connection: anti-leakage, anti-impact.

The trachea should be high-pressure resistant (the working pressure is 0.6-0.8MPa, and the trachea pressure resistance should be ≥1MPa), and the joint should be sealed with a raw tape (it should not be too tight to cause damage to the joint). After connection, it should be pressurized with air pressure (0.6MPa) for 5 minutes, and the joint should be smeared with soapy water, and no bubbles can be observed before use.

"Slowly open the valve" for the first ventilation: first open the 1/3 air valve, drain the impurities (such as iron filings and water vapor) in the pipeline, and then gradually fill it up, so as to avoid the piston rod being damaged due to the instantaneous impact of high-pressure air flow on the cylinder.

Third, debugging and verification stage: avoiding precision error and mechanical damage.

Installation of bottom die and cutter: anti-dislocation and anti-collapse cutter

When fixing the bottom die, it is necessary to cling to the positioning datum (such as the positioning pin on the equipment table) and clamp it evenly with a fixture (excessive unilateral force is not allowed) to prevent the bottom die from "jumping" during processing, which will cause the groove position to shift; If the bottom die is made of wood, it is necessary to avoid the deep indentation of the fixture, which will affect the subsequent positioning accuracy.

When installing the tool, clean the chuck (wipe the oil stain with alcohol), and the insertion depth of the tool should meet the requirements of the manual (usually 3-5mm out of the chuck, and it should not be too long to cause vibration). When tightening the chuck nut, use a torque wrench (according to the rated torque, such as 25N・m for M10 nut) to prevent the tool from loosening and "chipping" or scratching the table top.

Parameter setting: Starting from "low speed and low load"

During the first trial run, the machining parameters should be set as "safe values": feed speed ≤500mm/min, rotating speed ≤3000r/min, and machining depth with a margin of 0.3mm (not directly according to the design depth), so as to avoid the overload wear of the cutter or the scrap of the bottom die caused by too high parameters.

It is forbidden to "skip the empty run test": it is necessary to carry out the "no-knife empty run" (check whether the path is consistent with the preset) before carrying out the "waste trial cutting" (test with the discarded bottom die), and it is not allowed to directly process the qualified bottom die to prevent the loss caused by the precision error.

Accuracy calibration: avoid "single point calibration" deviation

When calibrating with a dial indicator, it is necessary to measure levelness at more than three points (such as four corners+center) in the "X axis and Y axis" direction of the table top to ensure that the overall error is ≤0.1mm/m, and it is not allowed to measure only a single point; After trial cutting, it is necessary to measure the three dimensions of "groove width, groove depth and spacing between adjacent grooves" with calipers. If the error of a certain dimension exceeds 0.05mm, it is necessary to fine-tune the parameters (such as depth compensation and path deviation) instead of directly adjusting the mechanical structure.

Fourth, the final maintenance stage: lay the foundation for later use.

Safety functions must be checked and not omitted.

After debugging, safety interlocks should be tested one by one: the equipment can be started when the safety door is closed, and stopped immediately when the safety door is opened (response time ≤0.5 seconds); When the emergency stop button is pressed, the motor and gas circuit should be cut off at the same time to ensure the "full stop" of the equipment in case of emergency.

Check the "abnormal signals" during the operation of the equipment: such as abnormal noise of the motor (possibly due to oil shortage in the bearing), air leakage in the gas path (possibly due to loose joint) and flashing of the alarm light (fault code needs to be checked), and do not put it into use until it is solved.

Data recording and maintenance disclosure

Record the "Installation and Debugging Data" in detail, including levelness value, machining parameters (finally determined rotation speed and feed speed) and trial cutting accuracy report, so as to facilitate the later equipment fault investigation or parameter optimization.

Explain the "key maintenance points" to the operators: for example, it is necessary to check the gas path pressure (≥0.6MPa) before starting the machine every day, clean the tool chuck every week, and lubricate the transmission guide rail (with special guide rail oil) every month to avoid shortening the service life of the equipment due to lack of maintenance.

Summary of core principles: The whole process of installation and debugging should follow the principle of "safety first, precision first and step by step". For any uncertain operation (such as parameter adjustment and mechanical parts disassembly), it is necessary to consult the manual or contact the technical support of the manufacturer first, and it is not allowed to operate by experience to avoid irreversible equipment damage or safety accidents.