Glass bottle production companies in the replacement of product speed, is bottleneck glass enterprise bottle level of technology reflects the level of high and low. The scenes we sometimes see are: the scene is in a hurry, the molds and accessories in the fields, hot and cold glass bottles flying indiscriminately, this group of jump material, that group of clamp arms can not turn over; this set of clamp bottles can not be seen, The group of blow heads was blocked; this group of squeezed bottles was not able to close the mold.... The work that should have been done for one hour, the two hours of the machine is still unreliable, and sometimes half the class does not produce products, and the products that are slightly more difficult have one or two classes that do not produce qualified products. The resulting loss over time is enormous. These phenomena indicate that the bottle-making technology is not mature and the bottle-making management needs to be improved. Over the years we have devoted ourselves to improving the research of bottle-making technologies, and in particular, we have actively explored and summarized how to quickly replace products.
1, quick replacement product preparation work to be fine.
After receiving the notification of product replacement, the leading team of the bottling plant analyzed the technical points and difficulties of the new product according to the standard, reviewed the historical records and carefully checked the user's special requirements to form the idea of ​​changing the product. Arrange to repair molders, bottle-changers, operators, and maintenance workers and implement their respective preparations.
1.1 The work of deputy director of bottling.
1.1.1 Responsible for notifying the relevant machine squad leader and repairer of the specific product replacement time and product number.
1.1.2 According to product standards, provide the necessary measurement equipment for changing the product group. For example, the capacity of sample bottles, collars, plug gauges, bottle calipers, and so on, so that the control of product technical parameters in front of the machine is more consistent, to ensure product quality and increase production.
1.1.3 Write the product standard on the front board of the machine, and at the same time, indicate the relevant requirements and precautions. This will make it easier for the rank machine operators to clearly know the product characteristics and accurately take control measures.
1.1.4 Sampling the molds and accessories sent to the front of the machine, and finding out the problems in a timely manner to the relevant departments. In this way, it can avoid the loss caused by unqualified molds on the machine and can check whether the mold changer and the bottle-changer have accepted the mold work.
1.1.5 Select the right mold lubricant. Mold lubricants should be selected according to the characteristics of the product on the machine, the defects that may occur in the production process, the user's special requirements and other aspects.
1.1.6 Determine the mechanism and action timing required to be adjusted. This requires careful comparison of the technical parameters of the on-board product, the ready-to-operate product, and the specific product conditions.
1.1.7 Adjust the drip temperature 15 minutes in advance. This requires timely adjustment of the heating and cooling system of the forehearth according to the structure of the product on the machine and the change of the discharge amount, so as to ensure the dropping temperature of the product.
1.2 repair work.
1.2.1 Pick up the qualified molds and related accessories in time after receiving the notice from the workshop.
1.2.2 Carefully and meticulously check whether the moulds and accessories are qualified. The following points must be observed when inspecting the mold: Firstly, ensure that there is no obvious wear and bump on the edges of the mold, mold, and die; secondly, ensure that the mold cavity is clean and free of damage and meet the requirements of the machine; and thirdly, ensure that the accessories are correct. Normal; fourth to ensure that the mold with a good relationship between the mold.
1.2.3 Perform the necessary repairs on the mold in question. This needs to be sent back to the workshop and received instructions from the relevant department.
1.3 The work of the bottle-changer.
1.3.1 Review one by one, whether the success, the initial mode, and the die before the machine are sent to the machine are normal.
1.3.2 Carefully inspect the fittings to ensure that the vents of the bulkhead, core, and blowhead are unblocked and not blocked by oil or glass. Ensure that the internal blowpipe is properly positioned on the blowhead.
1.3.3 Carefully inspect the clamp jaws to ensure that each clamp jaw is exactly sized and the two halves are well meshed.
1.3.4 Properly arrange personnel to preheat the mold, mold, and die. For new molds that are used for the first time, they must be preheated and then preheated after sandblasting.
1.3.5 Ten minutes before the product is placed on the machine, check the rack balance scale before the machine. Select the appropriate weight according to the weight of the product so that the weight and capacity of the product can be accurately controlled.
1.3.6 Check that there is enough water in the discharge tank to ensure smooth flow when the glass melt passes through the discharge tank.
1.4 The work of the operator.
1.4.1 Prepare the necessary tools for changing the product, such as special handles for special molds, special tools, etc.
1.4.2 Classifying and fixing the mould parts placed on the product in a designated position so that they can be accessed at any time.
1.4.3 Put the preformed, initial, and mouth molds that have been preheated in advance to be lubricated and set and placed. The moulding group is set to be discharged on the ground in front of the bottle conveyor, the die is placed on the front platform of each group of clamp bottle mechanism, and the initial mode is grouped and set to be discharged on the ground behind the line machine.
1.4.4 Make a suitable brush as required to facilitate timely and proper use of mold lubricants.
1.5 Maintenance work.
1.5.1 Prepare accessories that need to be replaced when the product is changed, such as holding pliers, funnel arms, etc.
1.5.2 Transport clean, well-conditioned attachment equipment to the rank machine.
1.5.3 Prepare relevant spare parts for necessary minor repairs when changing products according to the workshop arrangement.
2. The method of scientific division of labor is clear.
2.1 To ensure faster product change speeds, proper product change methods are a must. We adopt two replacement methods. That is to say, we have to replace three groups of six machines. At this time, the weight of products is based on the products on the machine. The three groups that are not exchanged are normal production. Re-adjust to the new product bottle weight, and then change the other three groups. For eight sets of machines, this is divided into two changes.
2.2 In order to achieve rapid replacement of products, a clear division of labor is also a must.
2.2.1 During the entire product change process, the deputy head of the bottle-making department is responsible for the supervision and coordination of work, paying close attention to all details and possible changes, and finding problems immediately corrected.
2.2.2 Line squad leader pays attention to controlling the weight of the product, promptly discovers product defects and removes them.
2.2.3 Each of the three rank machine operators on each machine segment cooperates with each other for replacement. One of the operators who are familiar with the performance of the rank machine structure is replaced on the side of the primary die. The operator must be careful and always control. The rhythm of good product replacement ensures that the person and machine on the local segment are in a safe state during each step of operation; another operator is standing on the bottle machine platform to perform the replacement. The operator must understand and observe the machine carefully. The change of segment action should ensure that the machine segment has been in a stable position during the operation and replacement; and there is an operator who is standing in front of the bottle conveyor. The operator must concentrate on the delivery of the upper and lower machine tools and accessories. , And at the right time do a good job at the end of the mold and clamp clamp replacement, and timely adjust the height of the mold bottom mechanism and clamp mechanism.
2.2.4 The workshop maintenance worker is responsible for the object cleaning work. It is necessary to evacuate the moulds and accessories of the next machine from the work site to ensure the neatness of the workplace and the operation is convenient and safe.
3, operating procedure optimization.
The ideal operating procedure plays a crucial role in increasing the speed of product change. This is the most critical part of product change. Our operations are generally divided into four areas.
3.1 To shut down properly. When the workshop leader issues a command to start product replacement, the operator on the primary mold side of each machine section immediately stops picking up, and the last bottle in the mold is clamped out. When the mouth clamp is turned over until the mold is not opened, the machine is stopped. Section work, and then operate the relevant gas path, so that the jaw and the shifter are in the open position, and a special collar is placed at the position where the jaw gear and the tilt mechanism mesh with each other to avoid unnecessary accidental return of the jaw. hurt.
3.2 Perform the replacement of the die, positive blow head, clamp jaw, sleeve and core. The primary mold operator operates the relevant gas path, replaces the core and the sleeve, and the operator on the platform of the bottle changer replaces the die and blows the gas head. After the replacement is completed, the operator on the primary mold side takes down the mouth. The collar of the pincer mechanism gear and the rack of the overturning mechanism are engaged with the collar, and the related gas path is operated and the returning jaw is clamped. At the same time, the operator at the front of the bottle conveyor removes the die bottom, replaces the clamp bottle clamp, and replaces the clamp bottle. When pliers, the opening of the bottle clamp should be compatible with the size of the mouth of the product.
3.3 Initial, mold and related tongs replacement. In the case of changing into a mold, a mold, and a pliers, it is safer to use a shop-made mold handle and a pliers handle. After the replacement is completed, the operator on the primary mold side operates the related air circuit to close the mold and causes the jaws to be in the reverse position. At this time, the operator in front of the bottle conveyor should adjust the height of the mold base in time.
3.4 calibration calibration of each agency.
3.4.1 Correction of the jaw mechanism. After closing the mold, when the clamp is turned over to form a mold, the clamp mechanism is calibrated. Before calibration, the air path through which the control clamp is turned over is turned on. The air path returned by the control clamp is disconnected, and the molding is ensured. The bottom of the mold is not placed. This is a prerequisite for accurate correction of the jaw mechanism. The person standing on the platform of the bottle machine should independently correct the height of the jaws. After the correction is completed, the gap between the die and the die should be maintained at about one millimeter. This is an important part of our rapid product change.
3.4.2 Air deflation mechanism and funnel mechanism correction. While correcting the arm of the pliers, the operator on the primary mold side immediately operates the relevant air circuit after replacing the bulkhead and the funnel, and closes the primary mold to allow the fluttering of the head and the bottom of the cover to correct the flue gas mechanism and the funnel mechanism. When correcting these two mechanisms, it is necessary to place the jaws in the inverted position, and also to correct the air lashing mechanism before correcting the funnel mechanism. When correcting the funnel mechanism, let the funnel fall to the top of the original mold, then let the air blow head fall over the funnel, and then adjust the funnel arm, and make the funnel away from the funnel arm about two millimeters.
3.4.3 positive blowing mechanism correction. After correcting the funnel mechanism, the operator on the primary mold side operates the relevant gas path, opens the primary mold, and returns the mouth jaws, so that the positive blowing gas head falls over the forming mold and the positive blowing mechanism is corrected. Correct the positive blowing mechanism so that the positive blowing head is tightly pressed in the center of the top groove of the mold.
3.4.4 Core cylinder height correction. When correcting the positive blowing mechanism, the operator on the primary mold side is responsible for adjusting the height of the core cylinder. It should be noted that: when adjusting the height of the core cylinder, the jaws should be in the fully returned position. The height of the jaw mechanism is not required. When adjusting, do not adjust the height of the core cylinder.
3.4.5 mold bottom height adjustment. After calibration of the above related mechanisms, the operator on the primary mold side operates the relevant gas path to open the mold, and the operator in front of the bottle transfer machine is placed in the mold bottom and the height of the mold bottom is adjusted to an appropriate position. The height of the mold base should ensure the mold switch. freely.
After the accessories have been replaced and the mechanism is in place, turn on the machine.
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