Fully automatic high-speed bottle sorting machineIt is the core equipment in modern bottle production lines, designed specifically for quickly organizing and orderly transporting disorderly stacked bottle bodies to subsequent processes such as filling and labeling. It achieves efficient and precise bottle orientation arrangement through mechanical transmission and intelligent control technology, and is widely used in industries such as pharmaceuticals, food, beverages, daily chemicals, and chemical engineering, becoming a key equipment for improving production efficiency and ensuring product quality.
It adopts a dynamic quantitative feeding system and a multi-stage transmission mechanism, with core components including a storage bottle bin, a centrifugal turntable, a four section belt conveyor, a bottle flipping and standing device, and a PLC control system. During work, the manual or automatic feeding system sends the bottle body into the storage bottle bin, and the material is transported to the high-speed rotating centrifugal turntable through a quantitative feeding device. The turntable uses centrifugal force to disperse the bottle body to the periphery, and uses a web wheel correction device to remove non-standard bottle bodies (such as inverted or tilted). Qualified bottles are fed into a four section conveyor belt at a set speed by a bottle sorting mechanism, and the spacing is adjusted by a clamping belt. Then, the bottle flipping and standing device completes the orientation correction, and finally outputs them to the subsequent process in an upright and orderly state.
Fully automatic high-speed bottle sorting machineCommon problems and solutions:
1. Wrong direction of bottle mouth after sorting (such as mouth up but mouth down)
Possible reasons:
The position or angle of the mechanical bottle sorting device (flipping mechanism) is incorrect.
Wear or deformation of bottle blocking/bottle shifting components.
The bottle specifications do not match the currently set bottle shaped parts (such as flower trays and guide rails).
The bottle entry speed is too fast or too slow, resulting in unstable posture of the bottle entering the bottle sorting area.
resolvent:
Adjust the flipping mechanism: According to the equipment manual, readjust the position and angle of the flipping guide rail, lever, or cylinder to ensure that the bottle can be flipped correctly.
Check and replace: Check the bottle stopper block, dial wheel and other components. If there is wear or deformation, replace them in a timely manner.
Check the bottle type: Confirm whether the currently installed flower tray, guide rail, etc. are suitable for the bottles being produced. Replace the correct bottle components if necessary.
Optimize bottle feeding speed: Adjust the feeding screw/conveyor speed of upstream equipment (such as bottle washing machines) or bottle sorting machines themselves to ensure that bottles enter the sorting area smoothly and orderly.
2. Bottles stuck or blocked
Possible reasons:
The track, turntable or bottle sorting mechanism is blocked by foreign objects (such as broken glass, label paper, oil stains).
Improper adjustment of mechanical components (such as screws, pulleys, and stoppers) results in insufficient clearance.
The bottle itself has defects (such as deformed bottle mouth, non-circular bottle body).
The bottle feeding speed is too fast, causing the bottles to pile up.
Downstream equipment (such as filling machines) is not synchronized or stuck, resulting in poor bottle dispensing from the bottle sorting machine.
resolvent:
Immediately stop and clean: Press the emergency stop button to remove all stuck bottles and foreign objects. Thoroughly clean the track and turntable.
Adjust the gap again: Measure and adjust the screw spacing, the clearance between the dial and the track, etc., to ensure suitability for the current bottle shape (usually the gap is 1-3mm larger than the diameter of the bottle body).
Check incoming materials: Check the quality of upstream bottles and eliminate non-conforming products.
Reduce bottle feeding speed: temporarily reduce the bottle feeding speed and observe if there is any improvement.
Check downstream equipment: Confirm that the downstream equipment is operating normally, the online signal (synchronization signal) is connected correctly and functioning properly.
3. Pour bottle (bottle pouring)
Possible reasons:
The position of the bottle slide or transition plate is incorrect, deformed, or has foreign objects.
Loose, worn or unsynchronized bottle extraction claws (or bottle pushing blocks).
The speed of the bottle conveyor belt does not match the speed of the bottle sorting machine.
The track or turntable is not leveled, resulting in unstable center of gravity of the bottle.
The center of gravity of the bottle is too high (such as a tall bottle) or the bottom of the bottle is uneven.
resolvent:
Adjust the slide: Check the inclination angle and height of the bottle slide to ensure smooth connection with the downstream conveyor belt. Clean up foreign objects and replace deformed slides.
Tighten or replace the extraction claw: Check whether the fixing screw of the bottle extraction claw is loose and whether the extraction claw is worn. Tighten or replace as necessary. Check if the driving mechanism (such as cam, cylinder) is synchronized.
Matching speed: Adjust the bottle dispensing speed of the bottle sorting machine or the downstream conveyor belt speed to ensure coordination between the two.
Recalibrate level: Use a level to check the levelness of the equipment and readjust the anchor bolts.
Optimize bottle design or adjustment: For special bottle shapes, it may be necessary to customize dedicated guide rails or add auxiliary support.
4. The bottle sorting speed cannot reach the set value or is unstable
Possible reasons:
Poor bottle feeding: The upstream supply of bottles is unstable, with varying amounts of time.
The photoelectric sensor (such as in bottle and out bottle detection) is dirty, displaced or damaged, resulting in signal misjudgment.
Insufficient air source pressure or leakage in the air circuit can cause weak or delayed cylinder action.
Motor or frequency converter malfunction.
Mechanical transmission components (such as belts, chains) slip, wear, or have insufficient tension.
resolvent:
Ensure stable bottle supply: Check upstream equipment to ensure continuous and even supply of bottles.
Cleaning and calibrating sensors: Clean the mirror surface of the photoelectric sensor with a dry cloth, check if its installation position is correct, and realign or replace it if necessary.
Check the air source: Check if the pressure gauge reading is within the normal range (0.5-0.7MPa), check if there is any air leakage in the air pipe and joint, and if the FRL triple piece is working properly.
Check the electrical system: Check for alarm codes in the electrical control cabinet, check the motor operating current and temperature, and contact an electrician or manufacturer if necessary.
Check the transmission system: Check the wear and tension of the belts and chains, and adjust or replace them as required.
5. Excessive noise or abnormal vibration during equipment operation
Possible reasons:
Loose fasteners (screws, nuts).
Bearing damage or lack of oil.
The belt and chain are worn or tensioned too tightly/loosely.
Rotating components (such as turntables and pulleys) are unbalanced or installed eccentrically.
The equipment is not leveled or the foundation is not firmly fixed.
resolvent:
Full tightening: After shutdown, inspect and tighten all visible fasteners of the equipment.
Lubrication and replacement of bearings: Add lubricating grease to the bearings according to the lubrication cycle. If the bearing makes a "rustling" or "clanging" sound, it should be replaced in a timely manner.
Adjust or replace transmission components: Check and adjust the tension of the belt/chain, and replace if it is severely worn.
Check balance and installation: Check the dynamic balance and installation concentricity of high-speed rotating components.
Re level and fix: Check the levelness of the equipment again and ensure that the anchor bolts are securely locked.
6. Electric control system alarm (touch screen displays fault code)
Possible reasons: There are many types, including:
Emergency stop was pressed
The safety door is not closed
Motor overload
Inverter fault
Sensor has no signal/signal often exists
Low air pressure
resolvent:
View alarm information: First, check the specific alarm code and text description on the touch screen.
Refer to the instruction manual: Refer to the "Fault Code Table" in the equipment's "Operation Manual" to understand the specific meaning of the alarm and recommended handling methods.
Targeted investigation: Check according to prompts. For example:
Check if the emergency stop button has been pressed and reset.
Check if the safety door is fully closed and if the safety switch is triggered.
Check the motor and wiring.
Check the status of the corresponding sensor.
Reset: After troubleshooting, press the "Reset" button to clear the alarm.