Fully Automatic Cartoning Machine Commissioning Guide

Guide to debugging of automatic carton machine (step-by-step analysis + safety Regulations)
I. Pre-commissioning Safety Check (core principles: power outages, kit)
Physical protection inspections
Make sure all covers (drive belt, box pusher mechanism) are securely fastened and latched.
Check that the emergency stop button is in the "reset" position and that the pedal switch wiring is damaged or compressed.
Case: The test operator failed to check the screws on the protective sleeve, resulting in a wrist abrasion while the box was operating.
Power Supply and Wiring Check
Verify that the circuit breaker on the distribution box is off and voltage is stable (±5% fluctuation range).
Check that the motor and sensor cable plugs are not oxidized and the cable sheathing is not damaged (wrap damaged area in insulation).
Risk: Damaged cable sheathing can lead to electrocution. The operator was shocked that he hadn't checked the line.
Human-Machine Isolation
Use warning tape to delineate the commissioning area around the machine and put up "No entry during test" signs.
Stand on the side or in front of the machine during operation, avoiding the path box pusher and fixtures. Case in point: A passerby was hit in the arm by a push plate during a test run at a factory, delaying the test run.

II. Box Size Adjustment (step + Tool Usage)
Box Holder Adjustment
Tools: Allen wrench, vernier caliper.
Steps:
Place the carton on the box holder and adjust the box holder guide board close to the four sides of the box (leaving a 0.5mm gap to prevent overtightening).
Mark the position of the guide plate with a marker to prevent deviations during subsequent adjustments.
Case: At a pharmaceutical factory, the gap between the guide plates was too large, causing the cardboard box to shift as it slid downward, causing it to jam.
Chain Width Adjustment
Highlights:
Loosen the two outer sprocket screws on the main chain.
Place the cardboard box in the middle of the chain and adjust the width of the chain to align with the box (similar to aligning a bicycle chain with gears).
Tighten the sprocket screws and verify width error ≤ 0.2mm using a cursor caliper.
Risks: Too wide a chain can cause the carton to tilt; too narrow a chain can cause paper to jamming. Height Adjustment
Steps:
Loosen the front and back mounting screws on the upper pressure rail (loosen only 2 laps, do not remove completely).
Turn the upper handwheel until the rail gently touches the top of the box (similar to gently pressing down with a building blocks).
Tighten screws and adjustment position with marking.
Case study: a food factory rail pressure, resulting in the flattening of the carton, resulting in carton sealing failure.
Adjust feed grille;
Tip: Place the product first, then adjust the tailgate (similar to trying on shoe sizes).
Steps:
Unscrew the fixing bearing screws and place the product into the feed grille.
Slide the baffle left and right until there is a gap of 1-2mm between the product and the baffle.
Tighten the screw and mark the screw holes with a marker (to prevent false tightening).
Risk: Too many gaps in the baffle can lead to product displacement; too few gaps can lead to product jamming.

III. Mechanical Parameter Adjustment (Product Adaptation + Operation Verification)
Box Feeding speed, ​​and Positioning
Set principles:
Set the initial velocity to 70% of normal and observe if the boxes align in orbit. If there is "box stacking" (two boxes glued together), slow the feeder down; if the track is empty, increase the speed.
Case study: In an electronics factory, too fast a box feed caused the box to be crushed and deformed in orbit.
Box Pushing Angle and force
Debugging Method:
Touch the box with a manual thruster to observe where it is going.
If the box is diagonal, use a spanner to adjust the angle of the pusher arm (screws should be tightened moderately).
If the carton is still stuck, adjust the thrust pressure (cardboard boxes pressure can be set to 0.4-0.6 MPa and soft packaging pressure can be set to 0.2-0.4 MPa).
Risk: Too much pressure may damage the product, and too little pressure may lead to blockage of the box.
Box Sealing System Parameters
Thermal Sealing Machine:
Temperature: 80-100°C (adjust to material; 85°C for aluminum foil).
Pressure: 0.3-0.5 MPa.
Time: 0.8-1.2 seconds. Case in point: A pharmaceutical factory returned product after aluminum foil fell off because the heat seal was too low (60 degrees Celsius).

IV. INTRODUCTION Electrical Parameter Debugging (Sensor Calibration + Logic Verification)
Sensor Sensitivity
Photoelectric Sensor:
Adjust the sensitivity knob so that the sensor outputs the signal when the box passes through and when there is no box.
Test method: Cover the sensor with white paper to observe if the indicator light is glowing.
Color Sensor:
Adjust the position of the color marker to make sure it detects the orientation of the box.
Case: a cosmetics factory due to misalignment of color-coded sensors, resulting in box sealing failure.
PLC Program Verification
Checkpoints:
Match the spindle feed command with spindle speed (spindle feed frequency = spindle speed x number of boxes per rotation).
Increases the feed delay time (0.2-0.3 seconds) of the box feed to prevent the next box feed from being triggered before the mechanical action is complete.
Case in point: A programming error in a cartoning machine disrupted the feed rhythm of the carton, resulting in a 20% reduction in productivity. Trial Run and Initial Inspection (Low-Speed ​​Start + data recording)
Low-Speed ​​Trial
Set the initial speed at 10 cartons perminute. Watch for 5 minutes without any lag, then gradually increase speed.
Case study: The manufacturer increased the speed directly to 50 cartons perminute, causing the machine to overheat and damage parts.
Preliminary inspection rules
Inspection Items:
Cartridge tongue alignment (error less than1mm).
No glue leaks.
Correct label placement.
Records: Fill out the initial inspection record form and save the data for troubleshooting.
6. Contingency plan (Cartridge Handling + safe operation)
Cartridge Handling
Press the emergency stop button immediately and don't reach into the cardboard box (see the "crocodile rule": Your hand may get stuck inside).
Tools: Use long-handled hooks to clean cartons and avoid direct contact with moving parts.
Daily maintenance
Daily: Clean magazine tracks, suction cups and sensors, and check cylinder stability.
Weekly: Adjust the tilt angle the box, check the tension of the timing belt tension, lubricate the guide rails of the carton push mechanism. Monthly: Replace suction cups and seals, calibrate sensor sensitivity, and back up PLC programs.