Overheating of packaging machine servo motor will cause fluctuations in heat sealing temperature and unstable sealing pressure, which will lead to problems such as loose sealing and sealing failure. For this scenario, a three-level processing flow is formulated in combination with industry experience to help factories quickly resume production and reduce the risk of equipment loss.
1. Primary processing (slight overheating, slight poor sealing)
Phenomenon:
The surface temperature of the servo motor is greater than 60¡æ, and burrs or local weak seals appear on the edge of the sealing line.
The operating current fluctuation of the equipment is greater than 10% of the rated value.
Treatment measures:
Cooling system inspection
Clean the dust of the motor cooling fan and confirm that the fan is turning correctly (the standard wind direction is from the motor housing to the outside).
Check the ventilation gap of the heat sink. When the blockage rate is greater than 30%, it needs to be cleaned with compressed air.
Load and parameter adjustment
Reduce the operating speed of the packaging machine to 80% of the rated value and reduce the continuous high-load operation time of the motor.
Calibrate the heat sealing temperature parameters and reset the control module when the deviation is greater than 5¡æ. Instant verification
Run at no load for 20 minutes and monitor the motor temperature rise rate (industry standard <3¡æ/minute).
Resume production after the seal strength sampling pass rate is ≥95%.
II. Intermediate treatment (continuous overheating, intermittent seal failure)
Phenomenon:
The motor temperature is >75¡æ, and periodic air leakage or false seal occurs in the sealing area.
The driver alarm record shows that the number of overcurrents is >3 times/shift.
Handling measures:
Key component detection
Measure the insulation resistance of the servo motor winding. If it is <1MΩ, it needs to be dried or the coil needs to be replaced.
Check harmonic interference (using power quality analyzer), and install a filter when the total harmonic distortion rate is >15%.
Mechanical system optimization
Check the tension of the transmission belt, and adjust the idler position when the downward pressure is >5mm.
Replace worn bearings (radial clearance >0.1mm requires mandatory replacement).
Function recovery verification
After 1 hour of continuous production, the sealing pressure fluctuation range must be ≤±0.2kg/cm².
The repair is considered effective when the motor temperature is stable in the range of 55-65¡æ.
III. Advanced treatment (severe overheating, large-scale sealing failure)
Phenomenon:
The motor housing temperature is greater than 90¡æ, and the heat sealing knife temperature cannot reach the set value (such as 180¡æ is actually ≤150¡æ).
The driver frequently reports errors and reset is invalid.
Handling measures:
Systematic troubleshooting
Disassemble the motor to detect the demagnetization of the permanent magnet. If the magnetic flux drops by more than 20%, the rotor assembly needs to be replaced.
Test the driver IGBT module. If the switching loss is greater than the nominal value of 30%, replace the driver board.
Cooperative repair of the heat sealing system
Synchronize the heat sealing gasket and servo motor (it is recommended to test the compatibility of accessories from the same batch).
Reset the PID control parameters and adjust the response time to 200-400ms to match the characteristics of the new motor. Full process verification
During the 72-hour full-load test, the sealing defect rate must be ≤0.5%.
The temperature curve fluctuation of the motor during continuous operation is <±3¡æ.
IV. Preventive maintenance recommendations
Periodic maintenance
Check the harmonic content and insulation performance of the servo motor every month.
Clean the cooling system and replace the aging fan (service life ≤2 years) every quarter.
Environmental control
The workshop temperature is controlled at 25±5¡æ and the humidity is ≤60% to reduce the thermal stress of the motor.
Avoid the packaging machine from running continuously for 24 hours. It is recommended to stop and cool for 30 minutes every 8 hours.
Operation specification
It is prohibited to process over-specification materials (such as composite films with a thickness of £¾0.2mm need to match special motors).
The operator needs to record the daily peak temperature of the motor and the type of sealing defects.
