1、 Mechanical structural failure

1. Knife holder fracture
   • reasonThe tool holder has manufacturing defects (such as pores, cracks) or insufficient material strength, which can lead to fracture due to long-term impact loads.
   • processReplace the tool holder that meets the material requirements (such as high-strength alloy steel), and check whether the countersunk bolts that fix the blades are loose, and tighten them in a timely manner.
2. Wear of guide rail
   • reasonLong term use can cause wear on the surface of the guide rail, or insufficient lubrication can lead to dry friction, exacerbating wear.
   • processRegularly check the gap between the guide rail and the tool holder, and repair or replace the guide rail if the wear exceeds the standard; Add calcium based grease (ZC-3) to the guide rail groove every shift to reduce friction.
3. Transmission component malfunction
   • performanceLoose belts, worn gears, or aging rubber rings of couplings can cause a decrease in transmission efficiency or abnormal noise.
   • processAdjust the belt tension to the specified value (such as the step belt tension of 50-80N), and replace the worn gear or coupling rubber ring.

2、 Hydraulic system malfunction

1. Joint/valve oil leakage
   • reasonHigh oil pressure (exceeding rated pressure) or aging of sealing rings, improper installation, leading to hydraulic oil leakage.
   • processAdjust the oil pressure to the rated value (such as below 5MPa), replace the oil resistant sealing ring (such as nitrile rubber material), and check whether the sealing surface is flat.
2. Oil pump overheating
   • reasonHydraulic oil contamination (such as metal shavings, moisture) or blockage of the oil suction filter screen can cause oil pump wear or insufficient oil suction.
   • processClean the hydraulic system and replace it with new oil (such as N32 anti-wear hydraulic oil), regularly clean or replace the 100-120 mesh filter screen.
3. Low oil pressure
   • reasonBlockage of the oil suction pipe, damage to the cup/seal ring, or malfunction of the hydraulic valve result in insufficient system pressure.
   • processClean the oil suction pipeline, replace damaged cups or seals, and inspect or replace hydraulic valves (such as overflow valves).

3、 Electrical control malfunction

1. Limit switch malfunction
   • reasonPoor contact or displacement of the limit switch causes the tool holder to be unable to accurately stop or reset.
   • processCheck the sensitivity of the limit switch in each shift, adjust its position to the specified range, and clean the contact dust.
2. Motor abnormality
   • performanceMotor overheating, vibration, or failure to start may be due to incorrect steering, unstable voltage, or internal faults.
   • processCheck if the motor direction is consistent with the requirements of the oil pump, use a multimeter to check the voltage stability, and replace the motor if necessary.
3. Control system malfunction
   • reasonPLC program error, microcontroller processor failure, or sensor obstruction, causing the equipment to malfunction.
   • processContact the manufacturer to update the PLC program, clean the sensor surface and adjust its position, or replace faulty hardware.

4、 Operation and usage malfunction

1. Cutting size not accurate
   • reasonBlade wear, incorrect cutting parameter settings, or material size deviation result in finished product width exceeding tolerance.
   • processRegularly check the sharpness of the blade, grind or replace it in a timely manner; Adjust cutting parameters (such as speed and tension) based on material characteristics.
2. Rubber material
   • reasonThe feeding device is unstable, the humidity of the rubber block is insufficient, or there are impurities in it, resulting in jamming during the cutting process.
   • processCheck the flatness of the feeding device, ensure that the humidity of the rubber block meets the process requirements (such as Shore hardness 60-90), and remove debris.
3. safety risk
   • performanceFailure to check if there are any hard objects such as metal trapped in the rubber block, resulting in damage to the knife holder or injury to personnel.
   • processStrictly inspect the rubber block before operation and prohibit cutting materials containing hard objects; Comply with safety regulations, such as a tool holder falling distance of ≤ 20mm during shutdown.