1.Uneven Winding and Wrinkling
Problem Manifestations: Uneven end faces of the roll material (e.g., "flared" or "bamboo shoot" shape), with longitudinal or transverse wrinkles on the film surface.
Possible Causes:
Uneven unwinding tension;
Malfunction or insufficient sensitivity of the web guiding system;
Uneven pressure on the pressure rollers or wear on the roller surface;
Fluctuations in workshop temperature and humidity causing material expansion and contraction.
Solutions:
Calibrate the tension control system to ensure stable unwinding tension;
Clean the web guiding sensor and adjust its sensitivity parameters;
Check the parallelism of the pressure rollers and replace them promptly if severely worn;
Control the workshop temperature and humidity within the range of 22±2℃ and 50%±5% humidity.
2. Slitting Marks and Burrs
Problem Manifestations: Burrs, debris, or wavy marks on the slitting edges.
Possible Causes:
Dulled blades or incorrect installation angle;
Improper adjustment of the blade holder gap;
Material properties incompatible with blade type;
Incoordination between operating speed and blade shaft speed.
Solutions:
Solutions: Regularly check blade sharpness and establish a replacement schedule;
Adjust blade gap according to material thickness (usually 10-15% of material thickness);
Select specialized blades for different materials (e.g., flat blades for film, round blades for paper);
Optimize the ratio of slitting speed to blade shaft speed.
3. Abnormal Equipment Vibration and Noise
Symptoms: The machine vibrates noticeably during operation, accompanied by abnormal noise.
Possible Causes:
Bearing wear or insufficient lubrication;
Poor alignment of transmission components;
Roll dynamic imbalance;
Loose anchor bolts.
Solutions: Establish a regular lubrication plan and use the specified type of lubricant;
Use a laser alignment instrument to check the alignment of the transmission system;
Perform dynamic balancing and calibration annually;
Check the tightness of anchor bolts and critical connections weekly.
4. Abnormal Tension Control
Symptoms: The roll material is not taut or breaks during operation.
Possible Causes:
Unwinding/rewinding tension controller not turned on;
Reset button not pressed;
Tension setting too low or too high;
Tension controller or speed controller malfunction.
Solutions:
Turn on the tension controller switch;
Press the reset button on both tension controllers;
Adjust the output current to the appropriate range;
If still ineffective, contact the manufacturer for repair.
5. Bearing Seat Wear (High-Frequency Fault)
Symptoms: Shaft runout, abnormal noise, increased bearing temperature, which can lead to machine shutdown in severe cases.
Common Locations: Bottom roller, guide roller shaft bearing seats.
Main Causes:
Long-term high-load operation;
Poor lubrication or foreign matter intrusion (such as paper dust);
Installation accuracy deviation;
Defects in traditional repair processes (such as thermal stress deformation after welding).
Advanced Solutions:
Utilize polymer composite material online repair technology (such as Fusilan 2211F), which requires no disassembly, causes no thermal stress, and restores shaft diameter and concentricity after repair; Use specialized molds for repair to ensure accuracy and significantly reduce downtime.
