1、 Daily maintenance: the core link of preventive maintenance

1. Cleaning and dust prevention management
   • Rubber debris cleaningAfter each production, use compressed air to blow away the rubber residue on the surface of the blade shaft, guide roller, and pressing roller to prevent scratches on the roller surface after the debris hardens.
   • Electrical cabinet dust removalClean the dust inside the electrical control cabinet with a vacuum cleaner every week to avoid short circuits or poor contact caused by dust accumulation.
   • Cooling system maintenanceCheck if the cooling water circuit is unobstructed and replace the circulating water regularly (recommended every 3 months) to prevent scale blockage from affecting heat dissipation.
2. Lubrication and rust prevention treatment
   • Lubrication of transmission componentsAdd high-temperature resistant grease (such as molybdenum disulfide grease) to gears, chains, bearings, and other parts every 2 weeks to ensure smooth operation.
   • Rust prevention of knife shaftWhen stopping, apply a thin layer of rust proof oil on the surface of the blade shaft, especially for coastal or high humidity environments, to prevent rust from affecting cutting accuracy.
   • Maintenance of pneumatic componentsCheck the three components of the air source (filter, pressure reducing valve, oil mist device) every month, drain condensed water, and replenish pneumatic special lubricating oil.
3. Parameter calibration and accuracy check
   • Cut width verificationUse a vernier caliper or laser rangefinder to randomly inspect 3-5 rolls of finished product width daily, ensuring an error of ≤± 0.1mm.
   • Tension control testVerify the stability of the winding tension through tension sensor data to avoid deformation or delamination of the rubber coil caused by tension fluctuations.
   • Blade clearance adjustmentAdjust the gap between the upper and lower blades (usually 1/3-1/2 of the material thickness) according to the rubber hardness (such as Shore hardness 60-90) to prevent overcutting or burrs.

2、 Regular maintenance: key nodes for deep maintenance

1. Blade replacement and grinding
   • replacement cycleHard alloy blades need to be replaced every 5000-8000 meters of rubber after cutting, while high-speed steel blades need to be replaced every 3000-5000 meters.
   • Grinding standardWhen the wear of the blade exceeds 0.2mm, it needs to be ground with a diamond grinding wheel to maintain the blade angle at 25 ° -30 ° and ensure a smooth cutting surface.
   • Dynamic balance correctionAfter installation, the new blade needs to undergo a dynamic balance test (allowable deviation ≤ 0.5g · cm) to avoid vibration during high-speed rotation.
2. Transmission system maintenance
   • Belt tension adjustmentCheck the tension of the synchronous belt every quarter, use a tension meter to ensure it meets the requirements of the equipment manual (usually 50-80N), and prevent slipping or breakage.
   • Gearbox oil changeReplace the gear oil (recommended to use ISO VG220 extreme pressure gear oil) every 2000 hours of operation, while checking the gear meshing and replacing worn gears.
   • Coupling alignmentEvery year, use a laser alignment instrument to check the coaxiality of the motor and reducer coupling, with an error controlled within 0.05mm.
3. Electrical system testing
   • Backup of frequency converter parametersBackup the parameters of the frequency converter every six months to prevent parameter loss caused by voltage fluctuations from affecting the cutting speed control.
   • PLC program updateAccording to the equipment upgrade requirements, contact the manufacturer every 1-2 years to update the PLC program and optimize the slitting logic (such as automatic correction and tension closed-loop control).
   • Grounding resistance testEvery year, use a grounding resistance tester to test the grounding resistance of the equipment (≤ 4 Ω) to ensure safe operation.

3、 Emergency Response to Malfunctions: A Guide to Quickly Restoring Production

1. Excessive cutting edges
   • reasonBlade passivation, excessive gap, uneven rubber hardness.
   • processImmediately stop the machine and replace the blade, adjust the gap to 40% of the material thickness, and check the consistency of the rubber raw material batch.
2. Unorganized winding of rolls
   • reasonTension fluctuations, parallelism deviation of guide rollers, and contamination of photoelectric sensors.
   • processClean the photoelectric sensor, calibrate the parallelism of the guide roller (error ≤ 0.05mm), and reset the tension curve (30% tension in the starting section and 100% tension in the stable section).
3. Equipment abnormal noise
   • reasonBearing damage, gear wear, belt looseness.
   • processUse a vibration analyzer to locate the source of the fault, replace the damaged bearing (recommended SKF or NSK brand), and adjust the belt tension to the specified value.

4、 Maintenance and Management Optimization: Digital Tools for Improving Efficiency

1. Application of CMMS system
   • Deploy a computerized maintenance management system (CMMS) to record equipment operation data (such as cutting meters, number of failures, spare parts consumption), and predict maintenance cycles through big data analysis.
2. AR remote assistance
   • Introducing augmented reality (AR) technology, remote expert guidance is achieved through smart glasses to quickly solve complex faults (such as PLC program debugging and mechanical structure disassembly).
3. Spare parts inventory management
   • Establish a safety stock model for key spare parts such as blades, belts, and bearings, and dynamically adjust inventory levels based on historical equipment failure data (such as blade inventory covering 15 days of production demand).

5、 Maintaining safety standards: dual protection of personnel and equipment

1. Pre operation inspection
   • Check the safety grating, emergency stop button, and protective cover before starting up daily to ensure that the equipment meets CE safety standards.
2. Principle of maintaining power outage
   • When conducting mechanical maintenance or electrical debugging, it is necessary to cut off the main power supply and hang a "Do Not Close" warning sign to prevent personal injury caused by misoperation.
3. Personal Protective Equipment (PPE)
   • Maintenance personnel should wear anti cutting gloves, safety shoes, and goggles, especially when replacing blades or cleaning debris, to avoid scratches or splashes.