The main machine for making cards, smart cards, game cards, etc. is the die-cutting machine. The quality and speed of the die-cutting machine depend on the accuracy of its punching. Die-cutting machines are the most
Main parts and structure of a die-cutting machine
The core components of the die-cutting machine need to work together to make it work normally and continuously. The automatic die-cutting machine system has a frame, a paper feeding mechanism, a die-cutting mechanism, and a pressure
The frame is the part that supports the die-cutting machine and keeps it stable. The Shenzhen die-cutting machine adopts high-strength steel welding, and stress is eliminated by aging treatment. It ensures no deformation under long-term high-load operation and is durable. The modular design makes it easy to move and set up, and it is suitable for workshop layouts all over the world.
The feeding mechanism is the guaranty of die-cutting precision, and its main function is to accurately send the raw materials to the die-cutting area.
The mainstream system adopts a 7.5 kW servo motor drive, a high-precision ball screw and guide rail, and the feeding accuracy is ±0.01 mm. The parameters can be changed according to the characteristics of raw materials such as cardboard and plastic to prevent slippage and damage. This makes it ideal for making smart cards.
The quality of die-cutting is directly affected by the die-cutting mechanism. The die-cutting machine made in Shenzhen adopts a customized mold structure, which can realize flat-round switching, and the positioning accuracy is ±0.02 mm. The intelligent pressure adjustment system can die-cut paper, PVC, and other materials, and the cutting is burr-free. The lightweight wooden mold is adopted to realize the rapid switching of the production of books, filter paper, and cards.
The receiving mechanism and waste removal system are two important components to improve production efficiency. In terms of material collection, Shenzhen-made die-cutting machines innovatively adopt two methods: sequential collection and classified collection. Sequential collection is most suitable for large-scale production of standardized products. It ensures that the finished products are neatly arranged for subsequent packaging. The sorting and collection process uses an intelligent identification system to automatically sort products of different specifications or models. This method is most suitable for the situation of small batch production of various types of products. The waste removal system uses a combination of negative pressure adsorption and mechanical scraping to remove the waste generated during the die-cutting process. This not only prevents the accumulation of waste from affecting the die-cutting accuracy but also reduces the cleaning time and ensures the continuity of production.
The control system is the "brain" of the die-cutting machine. It has an industrial-grade PLC controller and a touch screen operation interface. It can switch between multiple languages and can be set to the operating habits of operators in different regions. The control system can store more than 1,000 sets of production parameters. For different products, the set parameters can be directly called, which reduces the parameter debugging time. The system also has a real-time fault monitoring and alarm function, which can monitor the equipment operation status throughout the process. This allows for the quick discovery and reporting of problems such as excessive pressure and abnormal feeding, providing accurate information for equipment maintenance.
Die-cutting process
The working process of the die-cutting machine is carried out according to the standard steps of "material preparation, accurate feeding, die-cutting molding, waste removal, and finished product collection." Each link is closely connected, and automatic control ensures stable and efficient production. The following is an example of card production, step by step, to see the die-cutting process.
Step 1: Prepare the raw materials and pre-treat them. Select PVC, PETG, and other sheets according to the card material, and then cut, clean, and use them. The integrated equipment made in Shenzhen can make things that need to be hot stamped. It can also perform hot stamping and punching at the same time, making the process faster and better.
Step 2: Set parameters and troubleshoot. Set the feeding speed and die-cutting pressure according to the size and thickness of the card. For example, the pressure of a standard credit card is 5-8 MPa, and the speed is 30-50 sheets/min. After the trial production test, the setting is fine-tuned to meet the standard.
Step 3: Precise feeding. The feeding mechanism sends the raw materials to the die-cutting area according to the set parameters. The photoelectric sensor is aligned with the servo motor, with an error of ±0.01 mm. For thin materials with a thickness of less than 0.1 mm, vacuum adsorption is used to prevent the material from wrinkling and shifting.
Step 4: Punching and forming. The die-cutting machine punches holes according to the shape of the mold. The flat-bed type has upper and lower dies that are combined. The round-to-round type is the continuous rolling of the knife roller. The equipment made in Shenzhen adopts rigid connection and intelligent pressure feedback to ensure accurate punching without burrs.
Step 5: Waste removal. After die-cutting, the waste removal system immediately starts to work. The negative pressure adsorption device sucks the waste material after die cutting into the waste material collection box. The mechanical scraper device simultaneously cleans the surface of the mold to prevent the waste from sticking and affecting the next die-cutting. For products with complex hollow structures, the system can also control the accurate placement of hollow waste so that the surface of the finished product is clean and tidy.
Step 6: Finished product collection and inspection. After the waste is removed, the finished products are sent to the collection mechanism and are classified and collected according to the preset method. When collecting in order, the finished products are transported to the collection station by the conveyor belt, and the mechanical arm places them in order. When collecting by category, the intelligent identification system quickly classifies the finished products and moves the products of different specifications to the corresponding collection boxes. After the collection is completed, the operator can obtain production data through the control system and view the number of finished products, the pass rate, etc. In this way, they can see how the entire production process is operating.
Common technical types of die-cutting machines
There are three main types of die-cutting machines: flat-bed die-cutting machines, rotary die-cutting machines, and laser die-cutting machines. These machines are classified according to different cutting methods. Different types of technology have great differences in structural design, use, production efficiency, etc. Enterprises need to choose the right equipment according to the products they produce. The flat-bed die-cutting machine is the most widely used. Flat-bed pressing die-cutting. The die is easy to change and has high precision. It can be used for small batch production of different materials. The Shenzhen-made model uses servo and precision guide rails and can reach more than 8,000 times per hour. It also has automatic mold positioning, which is more efficient and more accurate.
The rotary die-cutting machine continuously die-cuts at a speed of 300 meters per minute through the rolling of the knife roller. It is suitable for mass production of coil materials, and the raw materials are evenly stressed. This model, produced in Shenzhen, has a knife roller precision of ±0.01 mm, a tension control system, and can quickly replace the roller to cope with the production of different sizes.
In recent years, a new type of die-cutting machine, the laser die-cutting machine, has been introduced. It uses a powerful laser beam to cut and shape raw materials. It does not need traditional die-cutting dies and can realize die-cutting work of various shapes through the computer control system. Laser die-cutting machines have many advantages, such as high processing precision (up to ±0.005 mm), smooth cutting edges without burrs, and no need to replace die-cutting tools. They are good at making complex shapes and very precise items, such as electronic parts and accessories.
The laser die-cutting machine made in Shenzhen adopts a fiber laser generator, with stable laser power and a cutting speed up to 500 mm/s. It also has an intelligent typesetting system, which can improve the typesetting rate of raw materials and reduce the waste of raw materials. Laser die-cutting machines are expensive and not suitable for cutting thick or highly reflective materials. When choosing, enterprises need to consider the characteristics of the products and their own budget.
In real life, Shenzhen-made die-cutting machines have also begun to integrate different die-cutting technologies in a single application. For example, the combination of flat-bed die-cutting and hot stamping technology has achieved the one-step process of "die-cutting + hot stamping." The combination of laser die-cutting and an automatic sorting system makes the production of precision products easier. The capabilities of this integrated technology demonstrate that the equipment can be used in a variety of different ways and provide more flexible production options for customers around the world.
Basic Troubleshooting and Maintenance Tips
Scientific daily maintenance and rapid troubleshooting are very important for the good operation of the die-cutting machine. Proper maintenance of the equipment not only extends its life but also ensures that the quality of production remains consistent. Here is some expert advice for equipment operators on two topics: how to troubleshoot common problems and how to keep equipment in good condition.
An important part of the daily maintenance of the die-cutting machine
Daily maintenance should follow the principle of "regular inspection, lubrication on demand, and thorough cleaning." The following are included:
1. Check the fastening of mechanical parts such as the paper feeding roller and die-cutting knife every day; clean the guide rail and lubricate it once a week; check the wear of the die-cutting knife every month, and grind or replace it as needed.
2. Regularly check the wiring of electrical systems such as servo motors and PLCs; clean the electrical cabinet once a month and check the heat dissipation; back up the system once every three months and update the software once.
3. Check the oil level and quality of the hydraulic oil tank every day to ensure that the oil level is within the correct range and the oil quality is not contaminated or damaged. Check the hydraulic lines for leaks every week, and replace the seals if there are any leaks. Check the air filter in the pneumatic system every month, remove the accumulated water in the air storage tank, and check whether the pneumatic components are working properly.
4. Cleaning and maintenance: After the production is completed every day, the surface of the equipment should be thoroughly cleaned to remove the residual raw materials and waste materials; the equipment should be deeply cleaned regularly to remove the dust and oil stains from the important parts such as the die-cutting mechanism and the paper feeding mechanism; for the equipment that is not used for a long time, the anti-rust oil should be applied and the dust cover should be covered to prevent the equipment from rusting.
Basic troubleshooting of die-cutting machine
Some problems may occur during the use of the die-cutting machine. The following are some common troubleshooting methods and steps. These can help operators quickly find and solve problems:
1. Check the feeding slip (replace the pressure or roller), mold positioning (recalibrate), pressure uniformity (adjust parameters), etc., to solve the problem of die-cutting accuracy deviation.
2. The finished product has burrs. Check the wear of the die-cutting knife (sharpen or replace), die-cutting pressure (increase parameters), and the flatness of the creasing roller (repair or replace).
3. If the raw material is stuck or deviated during the feeding process, first ensure that the raw material is pretreated in place so that the raw material size is consistent and the surface is clean. Then check whether the feeding sensor is working normally. If there is a problem, the sensor needs to be cleaned or replaced. Finally, check the running status of the servo motor to ensure that the motor speed is stable. If there is a problem, please ask a professional to repair it.
4. First, make sure that the suction of the negative pressure adsorption system is large enough to suck away all the waste. If the suction is not strong enough, either clean the suction pipes or replace the vacuum pump. Second, make sure the mechanical scraper device is in the correct position. If there is any deviation, the angle of the scraper should be adjusted. Finally, check the waste collection bin to see if it is full and clean it in time to keep the system working properly.
5. Is the noise too loud when using the equipment? First, check whether the moving parts are well lubricated. If there is not enough lubricating oil, add some. Secondly, check whether the mechanical parts are loose. If they are loose, tighten them. Finally, check whether the motor and bearing are worn. If wear is present, the worn parts should be replaced.
If you encounter a complex problem, call the manufacturer's after-sales service instead of trying to solve it yourself. The die-cutting machine made in Shenzhen provides 24-hour remote technical support for global customers to ensure the normal operation of the equipment.