1. Check the tension control system
Closed-loop control: Use a PID algorithm to adjust the tension in real time, ensuring the fluctuation range is ≤±0.5N.
Sensor calibration: Check whether the tension sensor (such as a strain gauge or micro-displacement type) is functioning properly, and troubleshoot using the voltage or resistance method.
2. Optimize the diameter fluctuation of the reel
Dynamic compensation: Automatically adjust the torque based on the diameter fluctuation of the reel to avoid increasing tension due to a decrease in diameter.
Air pressure on the air shaft: Ensure that the air pressure reaches the standard value (such as 0.6MPa) to prevent slippage between the shaft and the tube core.
3. Adjust process parameters
Paper feed speed: Match the speed to the material properties (such as thickness and elasticity) to avoid excessive tension due to too high a speed or relaxation due to too low a speed.
Slitting blade selection: Use tungsten carbide blades for hard materials (such as metal foil), and ceramic blades for soft materials (such as film). 4. Environment and Equipment Maintenance
Cleaning and Lubrication: Clean foreign matter from guide rollers and floating rollers daily, and lubricate the drive chain weekly.
Temperature Control: Maintain a constant temperature (20±2°C) to minimize the impact of material thermal deformation on tension.
5. Intelligent Monitoring and Alerts
IIoT System: Transmits data to the MES system via 5G, analyzing tension fluctuations in real time and automatically adjusting parameters.
Vibration Analysis: Monitors tool vibration frequency and triggers alarms in the event of anomalies (e.g., sudden vibration changes ≥10%).
6. Emergency Response
Emergency Stop: Immediately stop the machine in the event of a sudden change in tension, and check the air pressure, sensors, and mechanical components.
Professional Repair: If the correction system fails or a servo alarm occurs, contact the manufacturer for assistance.
