PU Foam cutting machines operating under harsh conditions for extended periods are prone to malfunction. Once a problem occurs, it must be quickly identified and effectively resolved. The following are vertical foam cutter's troubleshooting and solutions for common problems:
1. Blade Case Overheating
Cause: Continuous operation for extended periods of time or excessively high cutting foam density leads to a dramatic increase in frictional heat.
Solution:
First, adjust the blade case to ensure the blade belt slides smoothly and in a straight line within its step, ideally allowing for easy manual rotation.
Control the length of the blade extending from the blade case to 6-10 mm.
If this adjustment is ineffective, consider replacing the blade case.
2. Severe Vibration in the Sharpening Motor
Cause: Uneven grinding wheel or bent motor shaft.
Solution:
Check and correct the grinding wheel's circumferential flatness.
If the vibration originates from the motor, check for a bent motor shaft and replace if necessary.
3. Abnormal humming sound from the blade wheel
Cause: Scale buildup on the blade wheel surface, lack of oil in the bearings, improper blade belt tension, or incorrect installation.
Solution:
Clean the cutter wheel and remove any surface dirt with a fine emery cloth.
Check and lubricate the bearings of the passive cutter wheel.
Adjust the tensioner to ensure the cutter belt is centered on the cutter wheel regardless of forward or reverse rotation.
Check and correct the horizontal installation position of the cutter belt.
Ensure the cutter belt is sharp and free of curl.
4. Severe cut marks on the cut surface
Cause: The cutter belt is not sharp enough, is jerking, has uneven joints, or the equipment's running track is unclean or clogged.
Solution:
Check and replace the cutter belt with a sharp one that is free of curl and has smooth joints.
Ensure the cutter belt does not jerk.
Keep the cutter wheel surface clean.
Clean and lubricate the work platform track to ensure smooth travel.
Check and maintain the tension on the cutter clamp.
5. Uneven cutting thickness
Cause: The baffle is not parallel to the cutter belt, the cutter belt is improperly installed, or the equipment drive is out of sync.
Solution:
Align the baffle to ensure it is strictly parallel to the blade belt.
Reinstall the blade belt and ensure it is positioned accurately.
Ensure the blade belt is sharp and free of curl.
Adjust the meshing position of the rack and gear at each end to ensure synchronization.
6. The blade belt frequently breaks
Cause: The blade belt is off-center, poor quality, loose connections, or the blade wheel or bearings are wobbling.
Solution:
Adjust the blade belt to ensure it always runs centered on the blade wheel.
Use a blade belt of qualified quality with a secure connection.
Inspect and replace any shafts or bearings with play.
Inspect the blade wheel rubber for wear or cracks and replace if necessary.
7. The blade belt is noisy during operation
Cause: Damaged bearings or blade wheel, blade belt rubbing against components, or dirty surfaces.
Solution:
Inspect and replace damaged blade wheel bearings.
Inspect the blade wheel surface for damage.
Check if the blade belt is rubbing against the table rails or track pulleys, and adjust if necessary.
Keep the blade belt clean.
8. Severe gantry lifting noise.
Cause: Insufficient lubrication of the lifting screw or debris in the sleeve seal.
Solution:
Regularly add an appropriate amount of lubricant to the column screw to maintain proper lubrication.
Inspect and remove any debris or debris in the column sleeve seal.
The above troubleshooting and solutions for common problems with vertical foam cutting machines are intended to help operators quickly locate and resolve faults and resume production. However, prevention is always better than cure. Establishing and strictly implementing a regular equipment inspection and preventive maintenance system is the fundamental way to minimize failures, extend equipment life, and ensure consistent product quality.
