1. Packaging Film Deviation Failure
(I) Possible Causes
Guide Roller Installation Problem: If the guide roller is installed inaccurately, such as being misaligned in terms of horizontality or verticality, the packaging film will experience uneven stress during operation, leading to deviation. Additionally, if the surface of the guide roller is uneven or worn, it will also affect the smooth transportation of the packaging film.
Tension Control System Failure: The tension control system of the packaging machine is responsible for adjusting the tightness of the packaging film. If the tension sensor fails and cannot accurately detect the tension, or if the tension control motor fails and cannot adjust the tension in a timely manner, the tension of the packaging film will become unstable, resulting in deviation.
Film Feed Roller Speed Inconsistency: If the speeds of the film feed rollers are inconsistent, the packaging film will be pulled unevenly during transportation, leading to deviation. For example, if one of the two film feed rollers rotates slower, the packaging film will deviate towards the slower side.
Quality Problems of the Packaging Film Itself: If the thickness of the packaging film is uneven, or if there is uneven winding during the production process, it is also prone to deviation when the packaging machine is running.
(II) Troubleshooting and Solutions
Check the Guide Roller: Use a level and a vertical meter to check the installation accuracy of the guide roller. If there is a deviation, adjust the guide roller installation bolts or gaskets to calibrate the position. At the same time, inspect the surface of the guide roller. If it is worn or uneven, replace or repair it promptly.
Check the Tension Control System: Check whether the connection line of the tension sensor is normal, and use a calibration tool to calibrate the sensor. If the tension control motor fails, check the operation of the motor and the control signal, and replace the motor or related control components if necessary.
Adjust the Speed of the Film Feed Roller: Use a speed measuring instrument to detect the speed of the film feed rollers, and adjust the film feed roller with inconsistent speed through a frequency converter or speed regulating device to ensure that the speeds of all film feed rollers match.
Replace the Packaging Film: If it is determined that the packaging film itself has a quality problem, replace it with a packaging film of qualified quality, uniform thickness, and neat winding promptly.
II. Failure of Heat Sealing
(I) Possible Causes
Inaccurate Temperature Control: Heat sealing temperatures that are too high or too low will lead to poor heat sealing. If the temperature is too high, the PP film will easily melt and deform, or even burn through; if the temperature is too low, the PP film cannot be fully fused, resulting in a loose seal. Additionally, if the temperature of the heat sealing device is uneven and the local temperature does not meet the heat sealing requirements, it will also cause a loose heat seal.
Insufficient Pressure: During the heat sealing process, a certain pressure is required to make the PP film fit tightly and fully fuse. If the heat sealing cylinder pressure is insufficient or the pressure regulating device fails, it will cause insufficient pressure during heat sealing, resulting in a loose heat seal.
The Heat Sealing Time is Too Short: If the heat sealing time is too short, the PP film does not have enough time to complete the fusion process, which will also lead to a poor heat sealing effect.
The Surface of the Heat Sealing Knife is Uneven or has Impurities: The uneven surface of the heat sealing knife will cause uneven pressure distribution and affect the heat sealing effect. At the same time, if there are impurities, plastic residues, etc., on the surface of the heat sealing knife, it will hinder the normal heat sealing of the PP film and cause a loose seal.
(II) Troubleshooting and Solutions
Calibrate the Temperature Control System: Use a thermometer to measure the actual temperature of the heat sealing device and compare it with the set temperature. If there is a deviation, calibrate it through the temperature controller. Check whether the heating tube is working properly. If it is damaged, replace it promptly. For uneven temperature, check the distribution and heat conduction of the heating element and make corresponding adjustments.
Check the Pressure System: Detect the pressure value of the heat sealing cylinder to see if it meets the pressure range required by the equipment. If the pressure is insufficient, check whether there are leaks, blockages, and other problems in the cylinder, solenoid valve, air pipe, and other components, and repair or replace the faulty parts promptly. At the same time, check the pressure regulating device to ensure that it can adjust the pressure normally.
Adjust the Heat Sealing Time: According to the material and thickness of the PP film, appropriately extend the heat sealing time, set and adjust it through the control system of the equipment, and perform a test seal to observe the heat sealing effect until a satisfactory sealing degree is achieved.
Clean and Maintain the Heat Sealing Knife: Clean the surface of the heat sealing knife regularly, and use a soft cloth or special cleaning agent to remove impurities and plastic residues. If the surface of the heat sealing knife is uneven, polish and repair it or replace it with a new heat sealing knife.
