What are the common faults during the operation of the carton machine (such as paper jams, poor forming, etc.)? What are the corresponding troubleshooting and solutions?

Paper Jam

Fault Phenomenon

The paper suddenly stops during transportation or gets stuck in the paper feeding mechanism, forming channel, etc. The machine may make abnormal noises or stop automatically.

Troubleshooting and Solutions

 

Paper Itself

Troubleshooting: Check whether the paper is wrinkled, damaged, or if the edges of the paper are uneven (such as rough edges, curling). This type of paper is prone to getting stuck during transportation. Meanwhile, confirm whether the paper is stacked neatly. If the stack is skewed, it will lead to uneven force during paper feeding.

Solution: Replace with flat, undamaged paper, reorganize the stacked paper, and ensure the edges are aligned; if the paper is curled, it can be flattened in advance.

 

Paper Feeding Mechanism Failure

Troubleshooting: Check whether the paper feeding roller is worn (such as having dents on the surface or reduced smoothness), which results in insufficient friction and inability to feed paper stably; check whether the paper feeding gap is too small (the paper thickness does not match the gap) or too large, causing the paper to deviate during feeding.

Solution: Replace the worn paper feeding roller, adjust the paper feeding gap according to the paper thickness (generally, the gap is 0.1-0.2mm larger than the paper thickness); clean the dust and paper scraps on the surface of the paper feeding roller to restore friction.

 

Guide Component Problem

Troubleshooting: Check whether the guide plate and positioning rod are loose or offset, causing the paper feeding path to be skewed; check whether there are burrs and foreign objects on the surface of the guide component, which hinder the passage of paper.

Solution: Re-fix the guide plate and positioning rod and adjust them to be parallel to the paper feeding direction; grind the burrs on the guide component and remove foreign objects from the surface.

 

Poor Molding

Fault Phenomenon

The folding edges of the carton are not neat, the bonding is not firm (such as cracked corners), or the carton shape is skewed, with size deviations exceeding the standard.

Troubleshooting and Solutions

Crease and Indentation Issues

Troubleshooting: Check whether the pressure of the indentation wheel is uniform. If the pressure is insufficient, the creases will be indistinct, which may cause the folding edges to be skewed; if the pressure is too high, the paper may be crushed. At the same time, confirm whether the indentation position corresponds to the folding edge size of the carton. A deviation in position will directly affect the molding shape.

Solution: Adjust the pressure of the creasing wheel through trial production to ensure the creases are clear without damaging the paper; recalibrate the position of the creasing wheel to make it completely aligned with the folding line of the carton design.

Adhesion Mechanism Failure

Troubleshooting: If it is adhesive molding, check whether the amount of glue applied is uniform (excessive glue is prone to overflowing, while insufficient glue results in weak bonding), whether the glue has expired (leading to reduced viscosity), and whether the glue nozzle is blocked, causing partial areas to be without glue. If it is snap-on molding, check whether the mold of the snap-on structure is worn, resulting in loose snap-on connections.

Solution: Clean the glue nozzle, adjust the pressure of the glue pump to control the glue amount; replace with fresh glue; replace the worn snap-on mold to ensure accurate snap-on dimensions.

 

Insufficient Positioning Accuracy

Troubleshooting: Check whether the positioning devices (such as baffles, suction cups) of the carton at the molding station are loose, causing the paper placement position to shift; check whether the size of the molding mold matches the carton specifications. If the mold is worn or has size deviations, it will directly lead to the carton shape being skewed.

Solution: Tighten the positioning devices and calibrate the positioning reference; replace the molding mold with one that matches the carton specifications. If the mold is slightly worn, it can be polished and repaired.

 

Poor Carton Conveying

Fault Phenomenon

When the carton is output from the molding station, it gets stuck, is stacked chaotically, or fails to smoothly enter the next process (such as packaging, quality inspection).

Troubleshooting and Solutions

Conveyor Belt/Chain Issues

Troubleshooting: Check whether the conveyor belt is loose (resulting in insufficient conveying power) or too tight (increasing wear), and whether there is oil on the belt surface (which reduces friction and causes the carton to slip easily); check whether the chain is short of oil or jammed, leading to unstable conveying speed.

Solution: Adjust the belt tension and clean the oil on the belt surface; add lubricating oil to the chain and remove paper scraps and impurities from the chain.

 

Output Guide Issues

Troubleshooting: Check whether the width of the output channel matches the carton size (an overly narrow channel is prone to causing jams, while an overly wide one will cause the carton to shift); check whether the guide plate is smooth, as any protrusions will hinder carton conveying.

Solution: Adjust the width of the output channel according to the carton width to ensure the carton has a 0.5-1mm clearance; polish the surface of the guide plate to remove protrusions and burrs.

Abnormal Noise and Vibration of the Equipment

 

Fault Phenomenon

Abnormal noises (such as metal friction and impact sounds) occur during operation, and the machine body has a large vibration amplitude.

Troubleshooting and Solutions

 

Loose or Worn Parts

Troubleshooting: Check whether the transmission gears and bearings are worn (wear will cause excessive meshing gaps and generate impact sounds); check whether the connecting bolts are loose, especially for high-speed rotating components (such as paper feed rollers, motor fixing seats).

Solution: Replace worn gears and bearings, and re-tighten all loose bolts; apply grease to the transmission components to reduce friction noise.

 

Motor and Power System Issues

Troubleshooting: Check whether the motor overheats during operation. If it overheats, it may be due to a faulty motor bearing or an excessive load. For belt-driven equipment, check whether the belt is slipping (slipping produces a "sizzling" sound) and whether the belt pulleys are aligned.

Solution: Stop the machine to inspect the motor and replace the faulty bearing; if the load is excessive, check for issues such as paper jams and component jams, and restart the machine after resolving them; adjust the belt tension and calibrate the belt pulley positions to keep them parallel.