制杯作業指導書

1目的

規范制杯工序的操作過程,使操作工掌握其工藝方法。

2適用范圍

制杯工序及制杯機的使用。

3內容

3.1制杯生產流程介紹

3.1.1片材上機

3.1.2點動送片鏈條按紐

3.1.3開自動開關,開始自動送片吹杯

3.1.4拉伸吹氣成型

3.1.5沖剪 

3.1.6模具分離  

3.1.7吹杯

4操作方法

4.1開機前:

4.1.1檢查氣路水路有無漏氣或漏水現象 

4.1.2活動部位加油

4.1.3清理機臺及周圍地面衛生

4.2開機時:

4.2.1開通電源:按加熱鍵開始加熱，開冷卻水。

4.2.2準備好片材,根據模具的寬度,確定送片距離。

4.2.3電爐溫度升高到溫控表設定的溫度時準備開機開啟氣閥。

4.2.4用刷子或布擦拭片材外圍的灰塵及污物,然后將片材放置鏈條末端壓 輪下,開始送片,片材寬窄與鏈條末端寬窄相適應。

4.2.5打開自動送片開關,自動送片,此時眼睛觀察片材,通過電爐受熱情況 掌握送片速度,防止片材前進中速度過慢受熱過長,導致片材凹落電爐并容易引起著火,送片過快,受熱不到位,可能導致掉片,并使鏈條容易磨損,送至模外時,開啟自動開關。

4.2.6確定制杯機的運作速度,速度確定后,對每個杯子進行各方面的仔細觀察(成型, 杯口,杯身,杯底的厚薄,透明度等),根據情況作相應的溫度調控和機械部的調控

4.3溫度識別:

4.3.1溫度低:成型不好棱角不分明底部軟透明度較高。

4.3.2溫度高:棱角非常分明刺手杯身較軟透明度差杯口較薄底部硬。

4.4溫度的調試:

調節溫控表使電熱升或降低來改變片材的受熱情況, 液壓制杯機,是上下電爐1—8區排列是從左到右相對應,調節時一般調動1至2攝氏度(根據機臺另作掌握)。

4.5操作要點:

經常觀察產品的成型質量,加以調整,拉伸的高低要恰到好處,拉伸頭太下會使杯底太硬,拉伸頭太高會使杯子成型后杯底太軟,遇到突然斷電,機器停止運動或送片速度減慢等故障問題應馬上退出電爐,并關掉自動開關。(防止片材受熱過長,凹落電爐燃燒,產生黑點造成污染)及時查出原因或直接找機修人員。

生產過程中,若有緊急情況下,如模具內異物或模具有故障時,首先要關掉機器電源和關閉氣閥排掉儲氣罐的氣壓,方可進行。

4.6停機

4.6.1制杯完成后,關掉自動開關,再關閉電熱開關及電源和氣閥開關。

4.6.2退出電爐和排掉儲氣罐的水清理機臺衛生。

4.6.3做好生產統計。

4.6.4機器停止五分鐘后方可停止冷卻供水。

5、故障分析及排除

制杯機故障分析一般以三個方面著手:電路控制氣路傳動和機器部位損壞，并出現較多的是電路控制和機械損壞。

5.1送片時，片材掉入電爐。

原因：5.1.1片材不合格，寬度時大時小。

     5.1.2片材寬度和鏈條寬度不協調。

     5.1.3鏈條壓板出故障，上片時未上好，壓片板的距離未調好。

     5.1.4片材受熱過高，送片過慢。

      5.1.5兩邊鏈條一邊松一邊緊。

解決辦法：

      5.1.6割掉不合格片材。

      5.1.7調好鏈條寬度和壓片板寬度。

      5.1.8消除壓板故障上好片材。

      5.1.9送片時，注意觀察片材受熱軟化情況。

      5.1.10調整鏈條使兩鏈條松緊一致。

5.2送片突然停止或有時送不動。

原因：5.2.1電路接觸不良。

      5.2.2鏈條跑偏，鏈條卡到鏈蓋。

     5.2.3鏈條已被壓死或被卡住。

      5.2.4送片電機或者變頻器工作不正常。

解決辦法：

     5.2.5檢查線頭接觸點。

      5.2.6檢查鏈條、鏈蓋、鏈軌、軸承齒輪并解決。

     5.2.7查出鏈條壓死部位并采取相應的解決。

     5.2.8查看電機變頻器是否正常。

5.3機械模具分合模不正常。

原因：5.3.1電路出現接觸不良，控制合模開模接近開關接觸不好或已壞。

      5.3.2油壓不夠、缺液壓油或者五支點缺油阻塞磨損。

     5.3.3模具安裝不準確，上下模合模太緊。

     5.3.4模具臺面不平行與導柱不垂直。

解決辦法：

     5.3.5請示班長協助處理。

      5.3.6檢查油量及油壓、油溫，給五支點加油，磨損更換。

     5.3.7模具重新安裝準確。

     5.3.8模具臺面調平行。

5.4生產中杯底太薄太軟。

原因：5.4.1拉伸位置不到，太高或拉伸頭偏小。

     5.4.2運行動作不協調。

     5.4.3溫度調控不當。

      5.4.4模具氣孔排氣有問題或模具漏氣。

解決辦法：

      5.4.5調整好拉伸位置約杯高3/4處。

      5.4.6觀察調整各步動作。

      5.4.7溫度調整好。

      5.4.8檢查排氣和防止模具漏氣。

5.5杯口出現條紋或花紋。

原因：5.5.1拉伸已松動（左右不平）。

     5.5.2上模時間、成型時間不協調。

     5.5.3模具安裝不準確，。

5.5.4左右鏈條運行速度不同步如單邊有阻力跳齒。

解決辦法：

     5.5.5把拉伸頭調平整。

     5.5.6調好上模延時與成型延時角度時間。

     5.5.7調整鏈條。

5.6重量偏動

原因：5.6.1片材厚度有偏動，溫度高低有變動。

     5.6.2鏈條寬度有調動。

     5.6.3拉伸快慢有變動。

解決辦法：

     5.6.4確定片材厚度。

     5.6.5適當調整鏈條寬度。

     5.6.6合理調拉伸的時間。

5.7溫控表顯示溫度下降，但做出來的杯子表現高溫杯。

原因：5.7.1帶探頭的電熱片損壞或者掉線，無通電導致溫度下降，而溫控表為了保持設定溫度一直加熱，導致高溫杯。

解決辦法：

      5.7.2更換帶探頭電熱片或者從新把線接好。

5.8溫控表顯示的溫度與設定的溫度上下波動大

原因：5.8.1帶探頭的電熱片的探頭線接觸不良、氧化、損壞。

解決辦法：

     5.8.2檢查探頭線是否接觸不良，是否氧化，接觸不良從新接好，氧化用壁紙刀刮掉氧化層從新接好，損壞更換帶探頭電熱片。

5.9剛換好帶探頭電熱片溫控表顯示英文字母。

解決方法：探頭線正負極接反，從新把探頭線對調。

5.10正常生產過程中模具突然有個別杯子沖剪不斷。

原因：5.10.1模具上刀口水路堵住，導致通水不暢，上刀口溫度升高，從而使刀口受熱膨脹與下刀口間隙加大，從而剪不斷。

      5.10.2五支點、導柱缺油，阻力過大，導致行程不到位，從而沖剪不斷。

      5.10.3合模大泵停和合模停的接近開關沒有在合理位置。

      5.10.4小泵大泵的油壓不足。

      5.10.5沖剪開跟合模開的角度時間太短。

解決辦法

      5.10.6清理上刀口，使其通水順暢。

      5.10.7給五支點、導柱加油。

      5.10.8調整合模停和大泵停接近開關，使其在一個合理位置。

      5.10.9找班長或者經理幫忙解決，不懂不能亂調，會燒電機。

      5.10.10延長沖剪時間。

6、達標產量

38口徑模具每分鐘24到28模。

48口徑模具每分鐘22到26模

62口徑模具每分鐘20到25模

80口徑模具每分鐘18到24模

7、損耗

7.1在正常情況下，制杯機沒有損耗。

7.2 在生產過程中如有損耗：

7.2.1有操作不當所引起，追究操作工責任。

7.2.2由機械故障所引起的，須由班長簽名說明原因及解決措施。

7.2.3由片材原因所引起的，須由班長簽名，將追究片材操作工責任。

8、產品質量要求:

      每個杯子的前后左右溫度調控均勻、平衡、透明、杯身薄厚均勻成型好、重量達標、氣孔不出現割手感覺,杯子不出現條紋和花紋。

9相關文件

無

10相關記錄

成形生產記錄

崗位禁止條例

       1.嚴禁赤膀赤腳操作

       2.嚴禁在機器通氣、通電情況下,身體任何部位伸入沖剪模具內。

       3.嚴禁在機器運行時,手腳伸向機器任何轉動部位,如:鏈條、五支點、導柱拉伸氣缸,防止手腳衣服被拉進鏈條內。

      4.嚴禁在自動制杯查看杯子時,手伸進成型模具內取杯,應在包裝中察看。

       5.機器運轉時,嚴禁刀、木棍或螺絲伸入模具和傳動部位。

       6.嚴禁在控制臺、制杯機上面堆放東西。

       7.嚴禁在全自動制杯機工作過程中去調試拉伸高低。

       8.在安裝或調試模具時,速度必須歸零。

違規處理方法:

      申誡: 6   8   （ 經濟處罰50元，抄寫崗位禁止條例2遍）    小過:1   2  3  7（ 經濟處罰100元，抄寫崗位禁止條例4遍） 大過:4  5 （ 經濟處罰200元，抄寫崗位禁止條例6遍）

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.

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.

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.