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管理员 shiela
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收藏(0)制杯作业指导书

制杯作导书

1目的

规范制杯工序的操作过程,使操作工掌握其工艺方法。

2适用范围

制杯工序及制杯机的使用。

3内容

3.1制杯生产流程介绍

3.1.1片材上机

3.1.2点动送片链条按纽

3.1.3开自动开关,开始自动送片吹杯

3.1.4拉伸吹气成型

3.1.5冲剪 

3.1.6模具分离  

3.1.7吹杯

4操作方法

4.1开机前:

4.1.1检查气路水路有无漏气或漏水现象 

4.1.2活动部位加油

4.1.3清理机台及周围地面卫生

4.2:

4.2.1开通电源:按加热键开始加热,开冷却水。

4.2.2准备好片材,根据模具的宽度,确定送片距离。

4.2.3电炉温度升高到温控表设定的温度时准备开机开启气阀。

4.2.4用刷子或布擦拭片材外围的灰尘及污物,然后将片材放置链条末端压 轮下,开始送片,片材宽窄与链条末端宽窄相适应。

4.2.5打开自动送片开关,自动送片,此时眼睛观察片材,通过电炉受热情况 掌握送片速度,防止片材前进中速度过慢受热过长,导致片材凹落电炉并容易引起着火,送片过快,受热不到位,可能导致掉片,并使链条容易磨损,送至模外时,开启自动开关。

4.2.6确定制杯机的运作速度,速度确定后,对每个杯子进行各方面的仔细观察(成型, 杯口,杯身,杯底的厚薄,透明度等),根据情况作相应的温度调控和机械部的调控

4.3识别:

4.3.1温度低:成型不好棱角不分明底部软透明度较高。

4.3.2温度高:棱角非常分明刺手杯身较软透明度差杯口较薄底部硬。

4.4度的调试:

调节温控表使电热升或降低来改变片材的受热情况, 液压制杯机,是上下电炉1—8区排列是从左到右相对应,调节时一般调动1至2摄氏度(根据机台另作掌握)

4.5操作要点:

经常观察产品的成型质量,加以调整,拉伸的高低要恰到好处,拉伸头太下会使杯底太硬,拉伸头太高会使杯子成型后杯底太软,遇到突然断电,机器停止运动或送片速度减慢等故障问题应马上退出电炉,并关掉自动开关。(防止片材受热过长,凹落电炉燃烧,产生黑点造成污染)及时查出原因或直接找机修人员。

生产过程中,若有紧急情况下,如模具内异物或模具有故障时,首先要关掉机器电源和关闭气阀排掉储气罐的气压,方可进行。

4.6停机

4.6.1制杯完成后,关掉自动开关,再关闭电热开关及电源和气阀开关。

4.6.2退出电炉和排掉储气罐的水清理机台卫生。

4.6.3做好生产统计。

4.6.4机器停止五分钟后方可停止冷却供水。

5、故障分析及排除

制杯机故障分析一般以三个方面着手:电路控制气路传动和机器部位损坏,并出现较多的是电路控制和机械损坏。

5.1送片时,片材掉入电炉。

原因:5.1.1片材不合格,宽度时大时小。

     5.1.2片材宽度和链条宽度不协调。

     5.1.3链条压板出故障,上片时未上好,压片板的距离未调好。

     5.1.4片材受热过高,送片过慢。

      5.1.5两边链条一边松一边紧。

解决办法:

      5.1.6割掉不合格片材。

      5.1.7调好链条宽度和压片板宽度。

      5.1.8消除压板故障上好片材。

      5.1.9送片时,注意观察片材受热软化情况。

      5.1.10调整链条使两链条松紧一致。

5.2送片突然停止或有时送不动。

原因:5.2.1电路接触不良。

      5.2.2链条跑偏,链条卡到链盖。

     5.2.3链条已被压死或被卡住。

      5.2.4送片电机或者变频器工作不正常。

解决办法:

     5.2.5检查线头接触点。

      5.2.6检查链条、链盖、链轨、轴承齿轮并解决。

     5.2.7查出链条压死部位并采取相应的解决。

     5.2.8查看电机变频器是否正常。

5.3机械模具分合模不正常。

原因:5.3.1电路出现接触不良,控制合模开模接近开关接触不好或已坏。

      5.3.2油压不够、缺液压油或者五支点缺油阻塞磨损。

     5.3.3模具安装不准确,上下模合模太紧。

     5.3.4模具台面不平行与导柱不垂直。

解决办法:

     5.3.5请示班长协助处理。

      5.3.6检查油量及油压、油温,给五支点加油,磨损更换。

     5.3.7模具重新安装准确。

     5.3.8模具台面调平行。

5.4生产中杯底太薄太软。

原因:5.4.1拉伸位置不到,太高或拉伸头偏小。

     5.4.2运行动作不协调。

     5.4.3温度调控不当。

      5.4.4模具气孔排气有问题或模具漏气。

解决办法:

      5.4.5调整好拉伸位置约杯高3/4处。

      5.4.6观察调整各步动作。

      5.4.7温度调整好。

      5.4.8检查排气和防止模具漏气。

5.5杯口出现条纹或花纹。

原因:5.5.1拉伸已松动(左右不平)。

     5.5.2上模时间、成型时间不协调。

     5.5.3模具安装不准确,。

5.5.4左右链条运行速度不同步如单边有阻力跳齿。

解决办法:

     5.5.5把拉伸头调平整。

     5.5.6调好上模延时与成型延时角度时间。

     5.5.7调整链条。

5.6重量偏动

原因:5.6.1片材厚度有偏动,温度高低有变动。

     5.6.2链条宽度有调动。

     5.6.3拉伸快慢有变动。

解决办法:

     5.6.4确定片材厚度。

     5.6.5适当调整链条宽度。

     5.6.6合理调拉伸的时间。

5.7温控表显示温度下降,但做出来的杯子表现高温杯。

原因:5.7.1带探头的电热片损坏或者掉线,无通电导致温度下降,而温控表为了保持设定温度一直加热,导致高温杯。

解决办法:

      5.7.2更换带探头电热片或者从新把线接好。

5.8温控表显示的温度与设定的温度上下波动大

原因:5.8.1带探头的电热片的探头线接触不良、氧化、损坏。

解决办法:

     5.8.2检查探头线是否接触不良,是否氧化,接触不良从新接好,氧化用壁纸刀刮掉氧化层从新接好,损坏更换带探头电热片。

5.9刚换好带探头电热片温控表显示英文字母。

解决方法:探头线正负极接反,从新把探头线对调。

5.10正常生产过程中模具突然有个别杯子冲剪不断。

原因:5.10.1模具上刀口水路堵住,导致通水不畅,上刀口温度升高,从而使刀口受热膨胀与下刀口间隙加大,从而剪不断。

      5.10.2五支点、导柱缺油,阻力过大,导致行程不到位,从而冲剪不断。

      5.10.3合模大泵停和合模停的接近开关没有在合理位置。

      5.10.4小泵大泵的油压不足。

      5.10.5冲剪开跟合模开的角度时间太短。

解决办法

      5.10.6清理上刀口,使其通水顺畅。

      5.10.7给五支点、导柱加油。

      5.10.8调整合模停和大泵停接近开关,使其在一个合理位置。

      5.10.9找班长或者经理帮忙解决,不懂不能乱调,会烧电机。

      5.10.10延长冲剪时间。

6、达标产量

38口径模具每分钟24到28模。

48口径模具每分钟22到26模

62口径模具每分钟20到25模

80口径模具每分钟18到24模

7、损耗

7.1在正常情况下,制杯机没有损耗。

7.2 在生产过程中如有损耗:

7.2.1有操作不当所引起,追究操作工责任。

7.2.2由机械故障所引起的,须由班长签名说明原因及解决措施。

7.2.3由片材原因所引起的,须由班长签名,将追究片材操作工责任。

8、产品质量要求:

      每个杯子的前后左右温度调控均匀、平衡、透明、杯身薄厚均匀成型好、重量达标、气孔不出现割手感觉,杯子不出现条纹和花纹。



9相关文件

10相关记录

成形生产记录

位禁止

       1.严禁赤膀赤脚操作

       2.严禁在机器通气、通电情况下,身体任何部位伸入冲剪模具内。

       3.严禁在机器运行时,手脚伸向机器任何转动部位,:链条、五支点、导柱拉伸气缸,防止手脚衣服被拉进链条内。

      4.严禁在自动制杯查看杯子时,手伸进成型模具内取杯,应在包装中察看。

       5.机器运转时,严禁刀、木棍或螺丝伸入模具和传动部位。

       6.严禁在控制台、制杯机上面堆放东西。

       7.严禁在全自动制杯机工作过程中去调试拉伸高低。

       8.在安装或调试模具时,速度必须归零。

违规处理方法:

      申诫: 6   8   ( 经济处罚50元,抄写岗位禁止条例2遍)    小过:1   2  3  7( 经济处罚100元,抄写岗位禁止条例4遍) 大过:4  5 ( 经济处罚200元,抄写岗位禁止条例6遍)


送花(0)臭鸡蛋(0)引用回复2019-07-12 20:53 [1楼]
管理员 shiela
等级:
上将
发帖:
382/232
积分:
35619
经验值:
235571
上次发言:
09-05 15:15
1212

送花(0)臭鸡蛋(0)引用回复2019-07-19 13:51 [2楼]
管理员 shiela
等级:
上将
发帖:
382/232
积分:
35619
经验值:
235571
上次发言:
09-05 15:15

Work instruction of cup making

 

 

1.Purpose

Standardize the operation process of cup making so that operators can master the process method.

 

2. Scope of application

Cup making process and use of cup making machine.

 

3.Content

3.1 introduction to the production process of cup making

3.1.1 sheet loading machine

3.1.2 click the button of the feed chain

3.1.3 turn on the automatic switch and start the automatic feeding and blowing cup

3.1.4 stretch blowing molding

3.1.5 shearing

3.1.6 mold separation

3.1.7 blow cup

 

4 operation method

4.1 before starting:

4.1.1 check air there is any leakage or water leakage in the air route and waterway

4.1.2 refueling at active parts

4.1.3 clean the machine and surrounding ground

 

4.2 when starting up:

4.2.1 power supply: press the hot button to start heating and open cooling water.

4.2.2 prepare the sheet material and determine the feeding distance according to the width of the mold.

4.2.3 when the temperature of the electric furnace rises to the temperature set by the temperature control meter, prepare to start the air valve.

4.2.4 wipe the dust and dirt on the periphery of the sheet with a brush or cloth, then place the sheet under the press wheel at the end of the chain and start feeding the sheet. The width of the sheet is appropriate to the width of the end of the chain.

4.2.5 open automatically send switch, automatic sending piece, eye observation sheet at this time, through the furnace heating master piece of feeding speed, prevent the sheet in the forward speed too slow heat too long, cause sheet concave electric furnace and easy to cause fire, sent too fast, heat does not reach the designated position, may lead to drop, and make the chain easy to wear and sent to die outside, open automatic switch.

4.2.6 determine the operation speed of the cup making machine. After determining the speed, carefully observe all aspects of each cup (shaping, cup mouth, cup body, cup bottom thickness, transparency, etc.), and adjust and control the temperature and the mechanical department according to the situation

 

4.3 Temperature identification:

4.3.1 low temperature: bad molding, unclear edges, high soft transparency at the bottom.

4.3.2 high temperature: very sharp edges, soft cup body, poor transparency, thin mouth, hard bottom.

 

4.4 Temperature debugging:

Adjust the temperature control meter to raise or lower the electric heat to change the heating condition of the sheet material, the hydraulic pressure cup making machine is the upper and lower electric furnace 1-8 area arrangement from left to right corresponding, generally adjust 1 to 2 degrees Celsius (according to the machine).

 

4.5 operating points:

Often observe the molding quality of products, to adjust, the height of stretching should be just right, stretching head too low will make the cup bottom too hard, stretching head too high will make the cup bottom too soft after forming, encountered a sudden power failure, the machine stop movement or feed piece speed slow down and other fault problems should immediately exit the furnace, and turn off the automatic switch.(prevent the sheet from being heated too long, the electric stove from burning and black spots from pollution) find out the cause in time or directly seek the mechanic.

In the production process, if there is an emergency, such as foreign matter in the mold or mold failure, first turn off the power supply of the machine and close the air valve to exhaust the air pressure of the gas storage tank.

 

4.6 Close machine

4.6.1 turn off the automatic switch after the cup making, and then turn off the electric heating switch, power supply and air valve switch.

4.6.2 remove water cleaning machine from electric furnace and drain gas storage tank.

4.6.3 make production statistics.

4.6.4 the cooling water supply can be stopped after the machine stops for five minutes.

送花(0)臭鸡蛋(0)引用回复2019-07-19 14:42 [3楼]
管理员 shiela
等级:
上将
发帖:
382/232
积分:
35619
经验值:
235571
上次发言:
09-05 15:15

5. Fault analysis and troubleshooting

The fault analysis of cup making machine generally starts from three aspects: circuit control gas transmission and machine parts damage, and there are more circuit control and mechanical damage.

5.1 When feeding the piece, the piece falls into the electric furnace.

Reason: 5.1.1 the sheet material is unqualified, and the width varies from large to small.

5.1.2 inconsistent sheet width and chain width.

5.1.3 the chain platen is not in good condition when loading, and the distance of the platen is not adjusted properly.

5.1.4 high heat and slow delivery of the sheet.

5.1.5 loosen and tighten the chains on both sides.

 

Solutions:

5.1.6 cut off unqualified sheets.

5.1.7 adjust the chain width and sheet width.

5.1.8 eliminate pressure plate failure on good sheet.

5.1.9 when sending the tablet, observe the softening of the sheet when heated.

5.1.10 adjust the chain so that the tightness of the two chains is consistent.

 

5.2 sheet delivery suddenly stops or sometimes fails to move.

Reason: 5.2.1 poor circuit contact.

5.2.2 the chain runs out of alignment and gets stuck to the chain cover.

5.2.3 the chain has been crushed or jammed.

5.2.4 the chip feeding motor or frequency converter does not work normally.

Solutions:

5.2.5 check line head contact points.

5.2.6 check and solve the chain, chain cover, chain rail and bearing gear.

5.2.7 find out the dead part of the chain and take corresponding solutions.

5.2.8 check whether the motor frequency converter is normal.

 

5.3 abnormal parting and closing of mechanical molds.

Reason: 5.3.1 circuit contact is bad, the close switch of control mold closing and opening is bad or broken.

5.3.2 insufficient oil pressure, lack of hydraulic oil or lack of oil blocking wear at the five fulcrum.

5.3.3 inaccurate mold installation and tight upper and lower mold fitting.

5.3.4 the die table is not parallel to the guide pillar.

Solutions:

5.3.5 ask the monitor for assistance.

5.3.6 check oil quantity, oil pressure and oil temperature, add oil to the five fulcrum, and replace them with wear and tear.

5.3.7 mold reinstallation is accurate.

5.3.8 the mould table shall be parallel.

 

5.4 the bottom of production cup is too thin and soft.

Reason: 5.4.1 stretch position is not available, too high or stretch head is too small.

5.4.2 uncoordinated operation.

5.4.3 improper temperature regulation.

5.4.4 mold air vent problem  mold air leakage.

Solutions:

5.4.5 adjust the stretching position about 3/4 cup height.

5.4.6 observe and adjust each step.

5.4.7 adjust the temperature well.

5.4.8 check exhaust and prevent of mold air leakage.

送花(0)臭鸡蛋(0)引用回复2019-07-19 14:45 [4楼]
管理员 shiela
等级:
上将
发帖:
382/232
积分:
35619
经验值:
235571
上次发言:
09-05 15:15

5.5 stripes or patterns appear at the rim.

Reason: 5.5.1 stretch has been loose (uneven left and right).

5.5.2 inconsistency between upper mold time and forming time.

5.5.3 inaccurate mold installation.

5.5.4 left and right chain running speed is not synchronized, such as unilateral resistance skip tooth.

Solutions:

5.5.5 flatten the drawing head.

5.5.6 adjust the upper die delay and forming delay angle time.

5.5.7 adjust the chain

 

5.6 weight deflection

Reason: 5.6.1 sheet thickness is biased and temperature varies.

5.6.2 the chain width is adjusted.

5.6.3 tensile speed varies.

Solutions:

5.6.4 determine sheet thickness.

5.6.5 adjust the chain width appropriately.

5.6.6 adjust the stretching time reasonably.

 

5.7 the temperature control meter shows a drop in temperature, but the made cup shows a high temperature cup.

Reason: 5.7.1 the electric heating plate with probe is damaged or dropped, no power on causes the temperature drop, and the temperature control meter keeps heating in order to maintain the set temperature, resulting in high temperature cup.

Solutions:

5.7.2 replace the electric heater with probe or reconnect the wire.

 

5.8 the temperature displayed by the temperature controller fluctuates greatly with the set temperature

Reasons: 5.8.1 poor contact, oxidation and damage of the probe wire of the electric heating plate with probe.

Solutions:

5.8.2 check whether the probe wire is in bad contact and whether it is oxidized. If it is in bad contact, connect it again. Use wallpaper knife to scrape off the oxide layer and connect it again.

送花(0)臭鸡蛋(0)引用回复2019-07-19 14:46 [5楼]
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