Long-term stable operation of capacitor film slitting machine: key components and maintenance strategies

The long-term stable operation of the capacitor film slitting machine depends on the reliability maintenance and systematic management strategy of key components. Here's a professional analysis of the core components and maintenance points:

First, the key points of maintenance of key components

1. Slitting tool system

• High-precision round knives: diamond-coated tools are recommended and the roundness of the cutting edge is checked every 500 hours (tolerance≤ 0.002mm)

• Pneumatic/hydraulic turret: keep a stable pressure of 0.5-0.7MPa, and check the tightness of the air circuit every day

• Dynamic balance adjustment: calibrated with laser tool setter every week, radial runout needs to be <0.005mm

2. Tension control system

• Magnetic Particle Brake: Replace special cooling oil every 300 hours (ISO VG32 grade)

• Floating roller mechanism: ceramic bearings, monthly cleaning of the guide rails and application of PTFE grease

• Tension sensor: Weekly zero calibration (±0.1N accuracy)

3. Transmission system

• Servo Motor: Check the encoder connection quarterly to maintain a positioning accuracy of ±1arc-min

• Harmonic reducer: change special grease (with MoS2 additive) every 2000 hours

• Linear guides: use lithium grease, need to be replenished every 8 hours at a running speed of > 100m/min

Second, advanced maintenance strategy

1. Predictive maintenance system

• Installation of vibration analysis sensors (20kHz sampling rate recommended)

• Establish temperature trend model (bearing temperature alarm threshold = ambient temperature + 35°C)

• Oil spectroscopy (early warning at Fe content > 50ppm)

2. Optimization of process parameters

• Slitting speed gradient control: 5-8% increase in tension for every 100m/min increase

• Ambient temperature and humidity management: maintain 23±2°C/45±5%RH, and the electrostatic electricity of the film needs to < 0.3kV

• Tool angle compensation: For every 1 μm increase in thickness, the relief angle needs to be reduced by 0.05°

Third, fault Tree Analysis (FTA)

Common root causes:

1. Film edge burr (85% from tool axial clearance>0.01mm)

2. Winding serpentine (70% due to floating roller cylinder pressure fluctuation >10%)

3. Tension oscillation (90% of cases related to brake response delay >50ms)

Fourth, life extension measures

• Spindle bearing: oil and gas lubrication (0.03MPa oil pressure, interval 15min/time)

• Rail protection: IP54 grade bellow, internal maintenance of micro positive pressure

• Electrical system: Measurement of insulation resistance (>100MΩ@500VDC per month)

It is recommended to establish an equipment condition evaluation system based on the ISO 13379 standard, combined with OEE (Overall Equipment Effectiveness) analysis, to increase the MTBF (Mean Time Between Failures) from the conventional 800 hours to more than 1500 hours. Maintenance records should be digitally managed, and RFID tags are recommended for key components to achieve full life cycle tracking.

Note: The specific parameters need to be dynamically adjusted according to the film material (such as PP, PET, PI, etc.) and thickness (2-20μm range), and it is recommended to evaluate the process capability index (CPK) every quarter to ensure that the process stability ≥ 1.33.