Analysis of common problems in coater maintenance

The phenomenon and cause of poor coating gap

1. Tailing

(1) Materials: slurry material, viscosity, solid content, slurry (surface) tension

(2) Equipment: coating-back roller distance. The speed of the coating roller when the back roller springs open, and the diameter of the back roller. The surface material of the back roller. Deformation of the back roller. The back roller is parallel to the coating roller, and the back roller is not parallel to the front roller of the oven. Tension in operation.

(3) Operation: parameters for head and tail adjustment

2. The head and tail are not parallel

(1) Materials: The gravitational force on both sides of the substrate is uneven.

(2) Equipment: the horizontal plane of the back roller and the coating roller are not parallel; When the back roller springs open, the left and right sides are uneven; The surface coaxiality of the back roller, the back roller and the traction roller are not parallel, and the level changes.

(3) Tension adjustment roller adjustment state

3. The front and back sides are not aligned

(1) Operation: consistency of the first surface clearance. The operating parameters are not adjusted. The light eye is blocked. Unwinding and clamping rolls forgot to clamp

(2) Equipment: the tension behind the second side is large. The front tension is small

4. The white space becomes smaller when the middle is turned on, and the back 3-4 pieces are inaccurate

Equipment: the initial tension is not accurate, there is no memory function on the first side, the foil belt slides forward 2-3mm when starting, the tension is opened first, the back roller is not turned, and the coating head is not clamped or clamped.

5. The last piece is parallel and tailed

Operation: coating back roller spacing (the first side is tailed, the second side is not tailed); The back roller pulls slowly when the machine is stopped.

6. The head is thick and the tail is thin or the head is thin and the tail is thick

Operation: The head and tail parameters are not adjusted.

7. There is no effect

(1) Material: the tightness on both sides of the foil is different

(2) Equipment: the foil tension is small and leaves the back roller instantly. Coating back roll spacing

8. Double-sided large blank space

The photo-eye is not sensitive, the first-side gap is abnormal, and the photo-eye is occluded

Two

The length of the coating section changes, and the spacing is unstable

1. The length of the section changes greatly (*becomes shorter) * the spacing changes small (narrows)

Cause of the failure

1) The surface of the back roller and the rear rubber roller is not clean;

2) The gap between the back roller and the rubber roller is too small and too tight;

3) The tension between the front and rear does not match, and the unwinding is greater than the rewinding.

solution

1) Clean the rolls

2) Adjust the inclined block to a fixed position

3) Adjust according to the set parameters

2. The length of the section changes greatly (* becomes shorter) and the spacing changes greatly (becomes larger)

Cause of the failure

If the length of the head of the detection piece and the head of the next piece changes greatly (becomes smaller), the tail between the two segments of the pole piece changes smallly, so that the solenoid valve (which controls the movement of the rubber roller) is not flexible.

3. Large change in section length (*lengthening) * large change in spacing (widening)

Cause of the failure

1) The surface of the back roller and the rear rubber roller is not clean,

2) There is no pinch roller, there may be no pinch or out of control

3) The front and rear tension does not match, and the winding is greater than the unwinding

solution

1) Clean the rolls

2) Add pinch rollers

3) Adjust according to the set parameters

Three

Causes and countermeasures of wrinkling of electrode pieces during the operation of the coating machine

1. The overall installation accuracy is low, the installation center of each component deviates from the design center line of the whole machine, or there is an angle with the design center, the foil belt will be seriously wrinkled, and the installation center must be adjusted.

2. The parallelism between the rollers will cause the foil belt to wrinkle, and it is necessary to carefully check whether the vertical projection plane is not parallel or the horizontal plane is not parallel, and then adjust it.

3. The roughness of the roll surface is out of tolerance, the roll surface is not smooth enough, and there is obvious processing texture, which will also cause the foil belt to wrinkle, and it needs to be replaced by the manufacturer.

4. There are foreign objects sticking to the back roller and each passing roller or using too much water. Isopropyl alcohol scrubbing needs to be checked frequently, found and cleaned in time, and care should be taken not to damage the roll surface.

5. If the foil belt joint is defective, and the tension on both sides of the foil belt is unbalanced, the pole piece is wrinkled, first adjust the tension adjustment roller under the coating head, and then adjust the adjustment roller to the original state after the foil belt is gradually stabilized.

6. When the back roller and the coating roller are in close contact, the gap between the two ends is inconsistent, and the pole piece is wrinkled. Coating online believes that whether it is the first side or the second side, the gap should be carefully adjusted, first the gap is appropriately expanded, and then slowly reduced, and at the same time, the dial gauge scale of the coating roller is just in contact with the foil belt, and then the gap is reduced by 0.03mm.

7. When the correction system is abnormal, there will also be wrinkles of the pole piece, check whether the correction system is in an automatic state in the front and back three places. According to the coating online, the length of both sides of the foil belt is inconsistent, that is, when the sickle is bent too large, the pole piece will also wrinkle, which exceeds the deviation correction ability, so the foil has to be replaced.

8. When the tension of the pole piece is too large, the pole piece is wrinkled. The tension setpoint should be checked to see if it is reasonable. Then check each drive roller. Whether the rotation of the rewinding and unwinding roller is flexible, and the inflexible roller is dealt with in time.

9. When the back roller is pulled apart and the stroke is inconsistent, the pole piece is wrinkled. It is necessary for the mechanic to check, confirm and adjust, and start the trial coating when the gap between the back roller and the coating roller is 1mm (see the dial gauge) after the back roller and the coating roller are opened, and the lock nut is tightened when the tail is qualified.

10. Periodic elastic deformation will occur during the reuse of the rubber roller surface of the back roller, and wrinkles will also occur when there is a certain degree of deformation residue, and a new product must be replaced at this time.

11. According to the coating online, the parallel state of each roller is destroyed due to the loosening of the fastening screws of a certain roller, and wrinkling will occur at this time. As long as it is detected in time, it can be adjusted and tightened in time.

Four

When the coater is running, the pole piece is torn off

1. The tie is not correct, and the additional tension increases, so that the foil tape is torn off at the weak point;

2. Damage caused by sampling, resulting in a significant decrease in the tensile strength of the foil tape;

3. The tension is large, unstable, and there is a sudden phenomenon;

4. The air volume is abruptly abrupt, and the distribution is seriously uneven;

5. The sudden change in temperature has a great impact on the strength of aluminum foil;

6. The quality of the foil strip is poor, and there is a notch on the edge;

7. The foil belt is seriously misaligned and cut off by the edge of the end face of the roller.

Five

Other fault signs

1. There are obvious convex marks and scratches on the pole piece, which are distributed longitudinally

1) The blade of the scraper roller is notched or sticky with foreign matter

2) The coating roller is not easy to use, if the gap material vacated on the coating roller is not scraped clean and applied to the substrate again, it will leave obvious traces on the substrate;

3) The parallelism between the axis of the scraper device and the axis of the coating roller is out of tolerance, resulting in the inconsistent pressure of the blade on the coating roller, the unsuitable shape of the knife edge, and the low elasticity of the blade.

2. There are obvious cracks on the pole piece

The drying speed is too fast, the oven temperature is too high, and the baking time is too long.

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