1、 Failure during the molding stage
1. Bubble cap molding is not full/damaged
Mainly caused by insufficient sealing of the mold or abnormal air pressure. It is necessary to adjust the parallelism of the upper and lower molds, check the condition of the sealing ring, replace damaged parts, and optimize the compressed air pressure (0.6-0.8MPa) and blowing time. If PVC shrinks unevenly after heating, the material should be replaced in a timely manner.
2. PVC film deviation or unilateral tightness
It is necessary to calibrate the installation position of the mold to ensure alignment with the centerline of the track, adjust the track width to match the film width, and increase the cooling water flow if necessary to prevent PVC from being deformed by heat.
2、 Fault during heat sealing stage
1. Poor heat sealing/unclear mesh pattern
When the temperature is insufficient or the pressure is uneven, it is necessary to increase the heat sealing temperature (usually 120-150 ℃) and level the contact surface between the upper and lower films. Mesh blockage requires cleaning residue with a steel brush, while aluminum foil penetration requires reducing temperature or pressure.
2. Aluminum foil wrinkles/diagonal wrinkles
Adjust the left and right height knobs of the front pressure rod of the heat sealing module to eliminate unilateral tension, while checking the parallelism of the aluminum foil pressing wheel and aligning it with the track.
3、 Abnormal materials and cutting
1. Leakage or accumulation of excess pieces
By adjusting the opening size of the feeder to match the material flow rate, optimizing the temperature of the upper and lower heating plates (usually 90-110 ℃ in the forming section) to improve the foaming effect, and adjusting the contact height between the brush and the material.
2. Offset of punching position
The lateral offset needs to be corrected for the installation angle of the forming/heat sealing mold, and the longitudinal offset can be calibrated by adjusting the punching and moving handle to adjust the stroke. Regularly check the tension of the synchronous belt to prevent slipping.
4、 Abnormal operation of equipment
1. The heat sealed component does not heat up
Prioritize troubleshooting for circuit breaks, damaged heating tubes, or blown fuses, and replace faulty components accordingly. When the temperature is out of control, it is necessary to detect a short circuit in the thermocouple circuit or replace the temperature regulator.
2. Transmission system stuttering
Lubricate the guide rail and gear set, remove foreign objects from moving parts, regularly check the wear of the belt and adjust the tension, and check the starting capacitor and driver status when the motor is abnormal.
Operation tip: Preheat for 10-15 minutes before each startup, avoid scratching the stainless steel working surface with hard objects during operation, and take emergency shutdown or gradual troubleshooting measures according to the classification of sudden/gradual faults.