Operating Procedures of Embossing Machines

The operating procedures of embossing machines are a set of standardized operating guidelines formulated to ensure the safety of operators, the stable operation of equipment, and the qualification of products. These procedures cover the preparation before starting the machine, the operation during the machine running, and the work after stopping the machine, and must be strictly followed by every operator (operators must pass the training and assessment before operating the equipment, and obtain the operation qualification certificate).

Preparation before starting the machine is the first step to ensure safe production. Operators need to wear personal protective equipment (PPE), including anti-cutting gloves (to prevent hands from being cut by metal sheets or plastic films), safety shoes (with steel toes to prevent heavy objects from crushing feet), and goggles (to prevent debris from splashing into the eyes). Then, they check the equipment status: first, confirm that the power supply (380V three-phase AC) and the hydraulic oil supply are normal (the oil pressure gauge shows 0.5-1 MPa when the system is unloaded), then check the embossing pattern (install the upper and lower embossing rollers of the specified pattern, and use a feeler gauge to measure the gap between the rollers, which should be 0.1-0.3 mm larger than the thickness of the processed material to avoid excessive pressure causing roller damage), and finally test the empty operation of the equipment (start the equipment in empty mode, run it for 5-10 minutes, and check whether the transmission system, heating system, and cooling system work normally: the embossing roller speed should be stable without fluctuation, the heating temperature should rise to the set value within 30 minutes, and the cooling water should flow smoothly without blockage). In addition, operators need to prepare the raw materials: check the quality of the raw materials (such as the thickness tolerance of metal sheets should be within ±0.05 mm, and the surface of plastic films should be free of scratches or bubbles) and place them on the uncoiler (ensure the raw materials are aligned with the feeding direction to prevent deviation during feeding).

Operation during the machine running requires operators to focus on monitoring and standardize their operations. First, the operator sets the production parameters on the HMI according to the process requirements: embossing pressure (for metal sheets, 10-15 MPa; for plastic films, 5-8 MPa), embossing roller speed (5-15 m/min, adjusted according to the product requirements for pattern clarity), heating temperature (metal sheets: 90-110°C; plastic films: 60-80°C), and cooling water flow rate (10-15 L/min). After setting the parameters, the operator starts the feeding system and the embossing system in sequence, and observes the first piece of the product: check the clarity of the embossing pattern (using a magnifying glass with 10x magnification to observe whether the pattern details are complete without missing), the flatness of the product (for metal sheets, the flatness error should be less than 0.2 mm/m; for plastic films, there should be no wrinkles), and the size of the product (using a tape measure to measure the length and width, with an allowable error of ±1 mm). If the first piece is unqualified, the operator adjusts the parameters: if the pattern is unclear, increase the embossing pressure by 0.5-1 MPa or reduce the roller speed by 1-2 m/min; if the product is warped, adjust the cooling water temperature (lower the temperature by 5-10°C for metal sheets, or increase the temperature by 3-5°C for plastic films). During normal production, the operator must inspect the product every 30 minutes (sampling 5-10 pieces each time) and record the inspection results in the production record form (including product batch number, inspection time, pattern clarity, flatness, and size). At the same time, the operator must not leave the post without permission, and must not touch the moving parts of the equipment (such as the embossing roller and transmission belt) with hands or tools (to prevent mechanical injury). If an abnormal situation occurs during production, such as equipment noise, smoke, or product defects exceeding the standard, the operator must press the emergency stop button immediately, cut off the power supply, and report to the supervisor and maintenance team (do not attempt to repair the equipment without authorization).

Work after stopping the machine is essential to maintain the equipment and ensure the order of the workplace. First, the operator stops the equipment in the correct order: first stop the feeding system, then stop the embossing system after the remaining raw materials in the production line are processed, then turn off the heating system (wait for the temperature of the embossing roller to drop to below 50°C before turning off the cooling system to prevent the roller from cracking due to rapid temperature change), and finally cut off the power supply and the hydraulic oil supply. Then, the operator cleans the equipment: use a brush to remove the material debris on the embossing roller and guide rollers (for sticky materials such as plastic, use alcohol (concentration 75%) to wipe the roller surface), clean the filter of the cooling system (remove the filter screen to rinse with clean water), and clean the workplace (sweep the ground to remove raw material scraps and packaging materials, and stack the finished products neatly in the specified area, with labels indicating the batch number, production date, and quantity). In addition, the operator must fill in the equipment operation log, recording the start and stop time of the equipment, production quantity, qualified product quantity, defective product cause, and equipment operation status (whether there is abnormal noise or fault). Finally, the operator checks the personal protective equipment and places it in the designated position (clean the gloves and goggles, and check for damage; if damaged, report to the supervisor for replacement).

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