Precautions for the use of fully automatic insulating glass production lines in summer
The fully automatic insulating glass production line integrates multiple processes such as glass cleaning, gluing, laminating and pressing. The equipment has a high degree of automation and many precision components. In the high-temperature and high-humidity environment of summer, it requires more targeted maintenance. The following are the core precautions for summer use, covering aspects such as environmental control, system maintenance, production operation and emergency management:
一、Environmental and Energy System Management
1.Precise control of temperature and humidity
l Workshop environment: The temperature is controlled at 25℃±5℃ through central air conditioning or industrial refrigeration systems, and the humidity is maintained at 40%-60% (to prevent condensation water from affecting electrical components). If the humidity exceeds the standard, the dehumidifier should be turned on, especially during the early morning or after rain when the air becomes damp again.
l Equipment heat dissipation: For heat-generating units such as control cabinets and frequency converters, it is necessary to ensure that the fans operate normally. Temperature monitoring and alarm devices can be installed (such as setting an automatic alarm when the temperature exceeds 40℃). Heat source equipment such as cleaning machines and dryers should be kept at a safe distance from electrical cabinets to prevent local overheating
2. Optimization of compressed air system
l In summer, the moisture content of compressed air is high. Therefore, a refrigerated dryer and a precision filter (with a filtration accuracy of ≤0.01μm) should be installed on the main pipeline. The condensate water in the air storage tank should be discharged at least three times a day (once in the morning, once at noon and once in the evening) to prevent moisture from entering the pneumatic valve and cylinder, which may cause the operation to lag.
l Pressure stability: Ensure that the gas supply pressure is maintained at 0.5-0.7MPa. Regularly check the sealing of the air pipeline. Replace aged hoses (such as PU hoses) in a timely manner to prevent uneven gluing or deviation in the positioning of the lamination due to air leakage.
二、Key points for core system maintenance
1.Glass cleaning and drying system
l Water quality management: The circulating water of the cleaning machine should be replaced daily. In summer, high temperatures are prone to the growth of algae. A small amount of bactericide (such as sodium hypochlorite) can be added. The water tank and nozzles should be cleaned regularly to prevent blockage by impurities. For pure water equipment (if any), it is necessary to check the lifespan of the filter element. The RO membrane should be backwashed weekly to prevent bacterial growth at high temperatures, which may affect the cleanliness of the glass.
l Drying temperature: The temperature setting for the drying section should be 10-15℃ higher than the ambient temperature (usually 50-60℃), but avoid exceeding 70℃ (to prevent the glass from overheating and deforming). Regularly clean the dust on the surface of the heating tube to ensure thermal efficiency.
2.Gluing and laminating system
l Glue path control: For fully automatic glue dispensing machines, special attention should be paid to the storage temperatures of A glue (base glue) and B glue (curing agent). In summer, the temperature of the glue tank should be controlled at 20-25℃ (which can be cooled by circulating a chiller) to avoid unstable glue output or excessive curing speed due to the decrease in glue viscosity. Regularly inspect the sealing parts of the rubber pump. Rubber is prone to aging at high temperatures. If rubber leakage is found, the sealing ring should be replaced in time.
l The clamping accuracy: The suction cups of the clamping mechanical hand need to be checked for air tightness regularly. In summer, rubber suction cups are prone to softening and deformation. The surface can be wiped with alcohol every week to remove oil stains and delay aging. The guide rails of the laminating platform need to be cleaned daily and coated with high-temperature resistant grease (such as lithium-based grease) to prevent glass transmission jamming and affect the alignment accuracy.
3.Pressing and transmission system
l Laminating pressure: Fine-adjust the pressure of the laminating roller according to the thickness of the glass (usually 3-5 kpa). In summer, the glass expands significantly due to heat, and excessive pressure may cause the glass to break. A pressure sensor can be installed on the equipment for real-time monitoring.
l Transmission components: The oil level of chains and gearboxes should be checked every two weeks. Use high-viscosity gear oil (such as ISO VG 220) to avoid wear caused by the thinning of lubricating oil at high temperatures. The tension of the synchronous belt needs to be adjusted. High temperatures can easily cause the belt to become loose. It can be adjusted through the tensioning wheel to ensure smooth transmission without slippage.
三、Protection of electrical and control systems
1.Maintenance of circuits and components
l Line inspection: Check the terminal blocks of precision components such as servo motors and encoders every week. Due to thermal expansion and contraction at high temperatures, poor contact may occur. Use a multimeter to check if the lines are open or closed.
l Control cabinet maintenance: Clean the dust inside the control cabinet every month (using compressed air and insulating brushes), with a focus on cleaning the contacts of relays and contactors to prevent dust accumulation from causing short circuits.
l Install temperature and humidity sensors. When the humidity inside the cabinet exceeds 65%, the dehumidifier will be automatically activated to prevent electrical components from getting damp and rusting.
2.Program and Data Management
l System heat dissipation: For control units such as PLCS and industrial control computers, it is necessary to ensure that the cooling fans are functioning properly. An insulating layer can be installed on the top of the cabinet to reduce the influence of direct sunlight or environmental heat sources.
l Data backup: Back up the processing parameters of the equipment (such as gluing speed and lamination time) every week to prevent data loss due to storage device failure (such as hard disk) caused by high temperature. It is recommended to back up to the cloud or a portable hard drive at the same time.
四、Production operations and safety norms
1.Startup and operation monitoring
l Pre-start check: Before starting the machine, manually rotate the drive roller to ensure there is no jamming or lag before powering on to prevent excessive starting load due to the decrease in grease viscosity in summer. Check whether the water spray from the nozzles of the cleaning machine is uniform and whether the air volume of the fan in the drying section is normal to prevent the glass from entering the lamination process before it is dry, which may cause water vapor residue.
l Real-time monitoring: The operator needs to monitor the temperature of each module (such as the temperature of the glue tank and the motor) through the device's touch screen, and set an over-temperature alarm threshold (if the motor temperature exceeds 70℃, the machine will stop). Inspect the width of the glue application and the transmission speed of the glass once every hour. If any abnormality is found, adjust the parameters in time or stop the machine for maintenance.
2.Shutdown and maintenance process
l After the machine stops every day: Clean the residual glue in the gluing head (using a special cleaning agent) to prevent the glue from curing and blocking the channel. Wipe off the glass debris of the combined plate platform to prevent the guide rail from being scratched. Close the compressed air valve, drain the residual moisture in the pipeline, and conduct ventilation tests on pneumatic components (such as solenoid valves) to ensure normal startup the next day.
l Weekly deep maintenance: Check the wear of the impeller of the cleaning machine's water pump and clean the sediment at the bottom of the water tank. Lubricate the chain and adjust the tension; Test the sensitivity of protective devices such as emergency stop buttons and safety light curtains.
五、Emergency and materials management
1.Response to Emergencies
l Emergency power outage: Equipped with a UPS power supply (maintaining power for at least 30 minutes) to save current production data and safely shut down the machine; In case of a long power outage, the glass needs to be manually pushed out of the equipment to avoid being piled up on the roller conveyor.
l Equipment failure: In summer, it is common for the gluing machine to experience poor glue supply or overload of the transmission motor. It is necessary to stock up on vulnerable parts (such as sealing rings, belts, and bearings) in advance and replace them quickly in case of failure to reduce downtime.
2.Material storage requirements
l Sealant and desiccant: The rubber compound should be stored in a cool warehouse (temperature < 25℃), avoiding direct sunlight. Unused rubber drums should be sealed for storage to prevent the curing agent from evaporating and becoming ineffective. Desiccants (such as molecular sieves) should be stored in a dry environment. After opening, they should be used up within 24 hours. The remaining part should be sealed and placed in a moisture-proof box.
l Glass sheets: Stack in a well-ventilated area to avoid direct sunlight which may cause the surface temperature of the glass to be too high (exceeding 60℃ may affect processing accuracy). Handle with care during transportation to prevent breakage due to thermal expansion.
六、Personnel management and training
l Operation training: Organize special training before summer, focusing on explaining equipment heat dissipation, changes in rubber compound properties and emergency handling procedures, to ensure that employees are familiar with abnormal identification and handling in high-temperature environments.
l Heatstroke prevention arrangements: Shift adjustments are made to avoid the midday high-temperature period (such as advancing the morning shift and delaying the evening shift). The workshop is equipped with sufficient drinking water and heatstroke prevention medicines to prevent employees from fatigued operation and affecting the safety of equipment operation.
Through the above targeted measures, the failure rate of the fully automatic insulating glass production line in summer can be effectively reduced, ensuring the high-precision operation of the insulating glass equipment and the stability of product quality. At the same time, it can extend the service life of the equipment and improve production efficiency.
