As a key equipment on the battery production line, the stability and accuracy of the button battery sealing machine directly affect the sealing, safety, and production efficiency of the battery. Scientific maintenance strategies can not only extend equipment lifespan, but also reduce failure rates and ensure production continuity. The following elaborates on the maintenance points of button battery sealing machine from the aspects of environmental management, daily maintenance, periodic maintenance, operating standards, and long-term shutdown management.
1、 Environmental control and installation requirements
1. Temperature and humidity management
-The equipment should be placed in a constant temperature and humidity environment with a temperature of 18-25 ℃ and a humidity of 40% -60% to avoid high temperature causing aging of sealing materials or low temperature causing mechanical component brittleness.
-Equipped with a dehumidifier and air conditioning system to prevent condensed water from corroding circuit boards or metal components.
2. Dust prevention and cleanliness
-The production area needs to maintain a Class 100000 cleanliness level to avoid dust pollution of sealing molds or entering mechanical transmission parts.
-Clean the surface and surrounding environment of the equipment daily, wipe the body with a dust-free cloth to prevent the accumulation of particles.
3. Shock absorption and grounding
-The equipment should be installed on a stable and horizontal shock-absorbing platform, away from vibration sources such as punching machines and air compressors, to prevent vibration from affecting sealing accuracy.
-Ensure that the device casing is reliably grounded to prevent static electricity accumulation from causing circuit faults or battery short circuits.
2、 Daily maintenance operations
1. Check before startup
-Mechanical components: Confirm that the mold is securely installed and that there is no offset between the upper and lower molds; Check if there is any air leakage in the pneumatic system (such as cylinders, solenoid valves) and if the pressure gauge reading is normal (usually 0.4-0.6MPa).
-Electrical system: Check whether the emergency stop button, safety light curtain and other protective devices are sensitive, and whether the touch screen parameter settings are correct.
-Heating system: Preheat the sealing mold to the set temperature (such as 120-150 ℃), and use a thermometer to verify that the displayed value on the temperature control meter has an error of ≤± 2 ℃ compared to the actual temperature.
2. Monitoring during operation
-Sealing quality: The sealing electrode piece should be randomly inspected every 30 minutes to check whether the sealing ring is complete, without leakage or burn marks, and the thickness deviation should be controlled within ± 0.02mm.
-Abnormal sound: If there is any abnormal sound (such as friction sound or impact sound) when the device is running, immediately stop the machine for troubleshooting.
-Parameter recording: Record the parameters such as air pressure, temperature, and sealing time for each production, for easy traceability and analysis.
3. Maintenance after shutdown
-Cleaning the mold: Use compressed air to blow away the residual metal shavings inside the mold, dip a small amount of alcohol to wipe the surface of the mold, and prevent the adhesion and corrosion of the electrode metal on the mold.
-Shut down the system: sequentially turn off the heating, pneumatic, and power switches to avoid sudden cooling and heating that may cause component deformation.
3、 Periodic deep maintenance
1. Weekly maintenance
-Lubrication management: Apply high-temperature lubricating oil (such as molybdenum disulfide) to moving parts such as transmission gears, screw rods, and guide rails to avoid dry friction and wear.
-Tightening inspection: Use a torque wrench to recheck the screw connections (such as mold fixing screws, cylinder brackets) to prevent loosening and alignment deviation.
2. Monthly maintenance
-Sensor calibration: Check the accuracy of position sensors and pressure sensors, use standard block gauges or calibration instruments to calibrate, and ensure that the sealing pressure error is ≤ ± 5%.
-Electrical testing: Clean the interior of the electrical control cabinet, check if the wiring terminals are oxidized, tighten loose cables, and measure insulation resistance of ≥ 10M Ω.
3. Quarterly maintenance
-Mold maintenance: Disassemble the mold, repair the blade wear with diamond grinding paste, polish the surface roughness Ra ≤ 0.4 μ m, and ensure a smooth seal
-Pneumatic system maintenance: replace the filter element, drain the condensate water from the drain valve, and prevent cylinder corrosion or blockage.
4. Annual major overhaul
-Comprehensive disassembly: The equipment is disassembled by professional engineers to inspect the wear and tear of components such as bearings, gears, and belts, and to replace aging sealing rings and drive belts.
-Precision restoration: Use a laser interferometer to calibrate the parallelism of the mold, adjust the straightness error of the guide rail to ≤ 0.05mm/m, and ensure the consistency of the sealing.
4、 Operating standards and safety precautions
1. Operating standards
-It is strictly prohibited to operate the touch screen with gloves to avoid accidental contact or electrostatic interference; Special fixtures are required for manual feeding to prevent scratching of the mold.
-Parameter adjustments must be carried out by authorized personnel, and it is prohibited to arbitrarily modify core process parameters such as heating temperature and sealing time.
2. Safety protection
-It is strictly prohibited to insert any part of the body into the protective door during operation. Regularly check the safety light curtain and emergency stop button function.
-When dealing with stuck materials or malfunctions, be sure to press the emergency stop button and cut off the power first to avoid accidental start-up and injury.
3. Spare parts management
-Reserve key vulnerable parts (such as molds, heating tubes, cylinder seals), mark replacement cycles, and regularly check their status to avoid delays in maintenance due to missing spare parts.
5、 Long term suspension management
1. Rust prevention treatment
-Apply anti rust oil (such as Vaseline) to metal parts and wrap them with plastic wrap to prevent oxidation; Inject rust inhibitor into pneumatic components and seal the air inlet.
2. Power outage protection
-Disconnect the main power supply of the device, unplug the controller battery, and avoid capacitor aging or data loss caused by long-term power on.
3. Restore Enable
-Before reactivation, a comprehensive inspection of the circuit, pneumatic system, and mold status is required. A no-load trial run must be conducted and the product must pass the test before it can be put into production.
6、 Common faults and emergency response
1. Poor sealing
-Reason: Low temperature, insufficient pressure, or mold wear.
-Processing: Heat up to the process set value, calibrate the pressure sensor, and replace the mold.
2. Mold stuck
-Reason: Accumulation of metal debris or lubrication failure.
-Solution: Stop the machine to clean the gaps between the molds, and strengthen daily lubrication and cleaning.
3. Electrical malfunction
-Reason: The emergency stop circuit has not been reset or the sensor has malfunctioned.
-Solution: Check the status of the safety circuit, replace the faulty sensor, and restart the system.