The influencing factors of coating uniformity in the transverse and longitudinal directions are different, so the control measures are also different accordingly. In the specific implementation, it is not only related to the design and manufacturing of the machine, but also related to the operation and process control. So what are the common faults that affect the coating process?
There are many factors that affect coating quality, including people, machines, materials, methods, and environment. However, the basic factors are several conditions directly related to the coating process: coating substrate, adhesive, coating steel Rollers/cots and laminating machines, etc.
Coating substrate: mainly material, surface characteristics, thickness and uniformity, etc.
Adhesive: Mainly its working viscosity, affinity and adhesion to the substrate surface, etc.
Coating steel roller: It is not only the direct carrier of the adhesive, but also the supporting base for the coating base material and rubber roller, so it is the core of the entire coating mechanism. Its geometric tolerance, rigidity, dynamic and static balance quality, surface quality, temperature uniformity and thermal deformation conditions all affect the uniformity of coating.
Coating rubber roller: The rubber roller refers to an important variable in coating quality. Its material (such as rubber layer life), hardness, geometric tolerance, rigidity, dynamic and static balance quality, surface quality, thermal deformation conditions, etc. also affect the coating quality. uniformity of cloth.
Composite machine: It is the basic platform for coating. In addition to the accuracy and sensitivity of the coating steel roller and rubber roller combined pressure mechanism, it also includes the maximum designed operating speed and the overall stability of the machine.
The influencing factors of coating uniformity in the transverse and longitudinal directions are different, so the control measures are also different accordingly. In the specific implementation, it is not only related to the design and manufacturing of the machine, but also related to the operation and process control. So what are the common faults that affect the coating process?
Fault 1: Unwinding and correction limit
Reason: The unwinding mechanism does not thread in the center mode when threading the tape.
Solution: Adjust the sensor position or adjust the reel position in the middle position
Fault 2: Faulty upper and lower limits of the discharging roller
Reason: The discharge roller is not pressed tightly or the winding tension is not opened, and the potentiometer is abnormal.
Solution: Tighten the discharge roller or open the winding tension switch and recalibrate the potentiometer.
Fault 3: Travel correction limit
Reason: The travel correction is not centered or the probe is abnormal
Solution: Re-center the setting and check the probe position and whether the probe is damaged.
Fault 4: Winding correction limit
reason:The winding mechanism does not thread in the center mode when threading the tape.
Solution:Adjust the sensor position or adjust the reel position in the center position
Fault 5: The back roller has no opening and closing action
reason:The back roller has not completed the origin calibration or the calibration sensor status is abnormal.
Solution:Recalibrate the origin or check whether the origin sensor status and signal are abnormal
Fault 6: Back roller servo failure
reason:Communication abnormality or loose wiring
Solution:Press the reset button to reset the fault or power on again, and check the alarm code query instructions.
Fault 7: The second side is coated intermittently
Solution:Check whether the coating parameters or optical fiber signal are abnormal
Fault 8: Scraper servo failure
reason:The tool adjustment servo driver alarms or the sensor status is abnormal, and the equipment stops suddenly.
Solution:Check the emergency stop button or press the reset button to eliminate the alarm, recalibrate the origin of the scraper roller and check whether the sensor status is abnormal.
reason:Caused by slurry particles or chipped scraper
Solution:Use feeler gauge to clean particles and check scraper
Fault 10: Fans falling off
reason:a. Over-baking causes powder to fall off; b. The humidity in the workshop is high and the pole piece absorbs water; c. The adhesiveness of the slurry is poor; d. The slurry has not been stirred for a long time
Solution:Contact Site Quality Technology
Fault 11: Insufficient surface density
reason:a. Large difference in liquid level; b. Travel speed c. Knife edge
Solution:Check the speed and knife edge parameters, and maintain a certain liquid level.
Fault 12: Too many particles
reason:a. Brought or precipitated by the slurry itself; b. Caused by the roller during single-sided coating; c. The slurry has not been stirred for a long time (static state)
Solution:Wipe the roller clean before coating. If the slurry has not been used for a long time, you need to consult the quality technology whether to stir it.
reason:Slurry tailing, back roller or coating roller gap is not parallel, back roller bounce speed
Solution:Adjust the coating gap parameters and increase the back roller bounce speed
Fault 14: Frontal misalignment
reason:Alignment parameters are not corrected when there are errors in alignment
Solution:Check whether the foil is slipping, clean the back roller, press the reference roller and the pressure roller, and correct the alignment parameters.
Fault 15: The paint on the reverse side is trailing in parallel
reason:The spacing between the backing rollers is too small or too small or the springing distance of the backing roller is too small.
Solution:Adjust the spacing between the coating back rollers to increase the back roller bounce distance
Fault 16: Thick head and thin tail
reason:The head and tail thinning parameters are not adjusted properly.
Solution:Adjust head-to-tail speed ratio and head-to-tail starting point distance
Fault 17: Long coating and intermittent process changes
reason:There is slurry on the surface of the back roller, the traction rubber roller is not pressed, and the gap between the back roller and the coating roller is too small and too tight.
Solution:Clean the surface of the back roller, adjust the intercoating parameters, and press the traction and rubber rollers
Fault 18: There are obvious cracks on the pole piece
reason:Drying speed is too fast, oven temperature is too high, baking time is too long
Solution: Check whether the relevant coating parameters meet the process requirements
Fault 19: The pole piece is wrinkled during operation
reason:1. Parallelism between the rollers; 2. There is serious slurry or water on the surface of the back roller and the roller; 3. The tension on both sides is unbalanced due to poor joints of the foil belt; 4. The correction system is abnormal or the correction is not turned on; 5. The tension is too high Too big or too small; 6. The back roller's opening stroke gap is inconsistent; 7. The rubber surface of the back roller undergoes periodic elastic deformation after being used for a long time.
Solution:1. Adjust the parallelism of the roller; 2. Deal with foreign matter between the back roller and the roller in a timely manner; 3. Adjust the tension adjustment roller of the machine head first, and then adjust it to the original state after the foil is stable; 5. Check the tension setting value, Check whether the rotation of each transmission roller and retracting roller is flexible, and deal with the inflexible rollers in time; 6. Expand the gap appropriately, and then slowly reduce it to the appropriate position; 7. When elastic deformation is serious, replace the rubber roller with a new one
reason:Damping board foam blocking caused by
Solution:When installing the baffle plate, it can be in an outward shape or when moving the baffle plate, it can be moved from outside to in.
Fault 21: Material leakage
reason:The baffle foam or scraper plate is not installed tightly
Solution:The gap between the scraper plate is slightly larger than the thickness of the layer by 10-20 microns, and the foam on the scraper plate is pressed tightly.
Fault 22: Incomplete winding
reason:The winding reel is not installed, not inflated, the deflection correction is not turned on, or the winding tension is not turned on.
Solution:Install and fix the rewinding shaft, inflate the air shaft, turn on the deviation correction function, rewinding tension, etc.
Fault 23: Uneven white space on both sides
reason:The installation position of the baffle plate and the unwinding correction are not turned on.
Solution:Move the baffle and check the winding deviation.
Fault 24: The reverse coating cannot be traced
reason:Optical fiber has no inductive input or no spacer coating on the front
Solution:Check the detection distance of the fiber head, fiber parameters, and front coating effect
Fault 25: Correction does not work
reason:The fiber parameters are incorrect and the correction switch is not turned on.
Solution:Check whether the fiber parameters are reasonable (whether the correction indicator light flashes left and right) and whether the correction switch is turned on.
