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Zone A, Industrial Park of Hegui, FoShan, GuangDong, China

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Factors to consider when purchasing a splicer

If the paper splicing is not successful or the speed of paper splicing is not fast enough, it means break paper, and that leads to downtime, finally caused cost loss. Therefore, the following aspects should be considered when purchasing splicer:1. Splicer configuration and its speed (mainly considering the speed of paper splicing)2. Tension control (mainly to know tension range and control methods )3. Understand the control mode of PCS4. Calculation  of storage length of free roller5. Success rate of paper splicingNow to specifically introduce the factors to purchase splicer from these five aspects :1. To Consider Splicer Speed. The speed of paper splicing is divided into two types: 250m/min above and 200m/min below. The paper splicing speed above 250m/min is much shorter, this kind of splicer requires: 1). to have a longer distance to adjust the free roll storage paper;2). Faster servo motor speed;3). to have a higher precision of tension adjustment to prevent paper break;4). Generally, the speed ratio between linerboard and medium should be 1:1.5, because the speed of medium should be a little faster. While servo motors are not required for splicer with speeds below 200m/min.In addition,there is a reminder: the higher the speed of the splicer, the better, only the speed of the splicer is up, the whole speed will not be affected by paper splicing.2.To understand the Paper Tension Range and Tension Control Methods. In the production process, in order to ensure the quality of corrugated board, the base paper output tension of splicer should be kept as constant as possible during the operation of the splicer. The modern splicer has the  of tension induction and control, which can automatically detect and timely control of the original paper tension in corrugator production, so as to eliminate the corrugated board production process due to the change of the original paper tension caused by the paper break, greatly improve the production efficiency and the utilization rate of raw materials.As we all know, the relationship between tension and torque M=F * R: F -- tension, unit is N (Newton) R -- base paper roll radius, unit is M (meters) M -- torque N·M (newtons · meters) to keep the base paper tension constant, the base paper roll radius is decreasing, so the demand for torque is also decreasing.Tension control of the basic working principle is: according to the paper material, paper tension requirement when machine is running , set the desired tension values on the tension controller, sensors will detect the tension value of base paper and feedback to the tension controller, which to calculate the output of the corresponding values for converter, it then outputs the corresponding size of the pressure to the pneumatic brake, by the pneumatic brake to perform constant tension control action.Now, the suspension buffer is no longer controlled by spring or pneumatic pressure, but by torque control motor or similar equipment to control its tension, so as to avoid the paper web tension fluctuation after paper splicing. In order to connect paper oothly between two rolls, the splicer should be equipped with double brake tension control system. In addition, if the brake system on the original paper frame needs to change the air pressure, tension measurement equipment will usually send a signal, tension control equipment on the splicer can control its brake torque.3.We need to know how to control the PCS(Production Control system). The production control system is responsible for customer management, order management, production management, statement management and file management, etc., and it can control the single-side machine, double-side machine, gluing machine and splicer on the corrugator line.The operator can manually or through the PCS through the central control on the corrugator line to set the order parameters.The factors that affect the setting of the splicer include: paper grade, width and production line speed.After understanding these conditions, you can do paper control system programming, setting the brake of the base paper frame, and constantly adjust the brake setting to match the diameter of the changing base paper reel.In this way, during the processing of each order, the base paper rack can maintain appropriate tension control.In addition, through the application of PLC and computer control on the splicer, directly set the rest of the paper reel, in the whole process of paper splicing, the paper tension can be maintained at a constant level.Thus, when the speed of the single-sided machine reaches 500 meters per minute, the paper damage caused by the paper and cardboard adhesion problems can be avoided.In addition, the PCS by setting a certain parameter value, can ensure paper to reach the position. According to the paper material ,width, statistics of its length and area, when the paper is used up, the PCS can cut paper as well as achieving paper splicing, therefore zero-end paper can be achieved, avoiding unnecessary waste.4.We should pay attention to the calculation  of the length of storage paper. The paper storage  of the free roller is to ensure the uninterrupted paper splicing .When the paper on one end of the base paper shelf is running out or needs to be cut off and the paper on the other end of the base paper shelf, in order to slow down the paper tension and avoid  paper break, it is necessary to store paper in advance in the roller, and quickly run to the other end of the paper at the moment of paper breaking.The length of the paper and the speed of the roller are all set and controlled by the PCS.Because of the paper storage  of the free roller, the splicer can truly achieve automatic paper splicing, so that the splicer does not need to stop when changing paper and order, and the high-speed operation of the production line can be guaranteed on the premise of continuous paper.5.To consider the success rate of paper. The success rate of splicer directly affects the production efficiency of corrugator line.So what are the factors that affect the success of paper receiving machine?The factors influencing the success rate of paper splicing mainly include the following two points:1). Parameter setting, such as the parameter matching between the free wheel and the tension wheel, the time of the cutting tool and the clamping plate, etc.2). control the tension of the system program parameters, which directly affects the tension of the base paper.In view of the above two points, suppliers are generally required to have strong electronic control programming and design capabilities.    

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The Basic Principles of Splicer

In corrugated packaging industry, splicer is used to connect old and new paper rolls in corrugated board production process, so as to realize continuous production without a downtime. A splicer generally composed of the following basic components: frame, free roller, fixed roller, splicer frame, pressure roller, cutter unit and clamping rod, etc. Now let me introduce several components:Frame: all components are installed or suspended on the frame. Because it is suspended on the bridge support, the frame does not equipped with self-frame.Free Roll: Before the paper web leaves splicer, it is running back and forth between the immovable guide roller and guide roller of the storage frame on the side of the paper outlet of the machine. In this way in the storage rack to form a paper storage. In the process of paper splicing, the free roller moves towards the paper outlet side of the machine so as to release the paper web stored therein for continuous production. After that, the storage rack is moved back to the other end of the machine and the paper webare restocked.Splicer Frame: there is a paper frame at each end of the splicer. The paper frame is composed of an adhesive roller and a guard plate. In the paper frame, the new paper web is first cut in the protective plate, then the paper tape is pasted, and finally the new paper web and the original paper web are pasted through the adhesive roller.Pressure roller: in the process of paper splicing, the pressure roller is pressed to the adhesive roller, so as to press the adhesive points of two paper web.Cutter unit: the cutter unit is composed of a knife holder and a blade. The cutter unit cuts off the original paper web. During cutting, the cutter is inserted into a groove on the clip rod.     The following are a typical set of paper splicing process diagramSee the next page) : 1 represents the original paper web, 2 represents the new paper web, 3 refers to the paper frame, 4 refers to the adhesive roller, 5 refers to the clamping rod, 6 refers to the pressure roller, 7 refers to the cutter, 8 refers to the brake rod, 10 refers to the zero-tail join.The whole process of paper splicing can be simply summed up as: The old paper roll stops running, the brake bar is pressed down, the pressure roll is down, and the cutter cuts off the old paper. The old paper break joint is connected with the new paper with double-sided adhesive under the pressure of the brake roll. At the same time, the paper storage trolley provides the base paper to the corrugated line. After the paper splicing, the new paper roll began to rotate, and the paper cart gradually returns to the position of the maximum splicer. This kind of splicer called “Flying Splicer”. Operators at the time thought that their manual paper splicing technology was higher than the rapid paper splicing. But as far as performance is concerned, the rapid paper splicing is quite reliable. Modern paper splicer have an electronic tension control system that responds instantly. This means that it has two brake systems, one for rolls in process and one for new rolls. And paper tension control system, brake pad, knife, cutting pad, roller balance structure, chain and bearing lubrication degree have played very critical role to the operation of the equipment.Another characteristic of the modern splicer is that the whole process of paper splicing takes less time.Automatic splicer adopts artificial intelligence design, equipped with digital tension control system and computer terminal, so the paper splicing is quite efficient, reliable and fast.Although the procurement input cost is large, the automatic splicer can achieve zero-tail join, avoid unnecessary waste when paper splicing, reduce the downtime and quality problems of corrugated board production line, finally to effectively ensure stable high production speed and high quality of corrugated board.Now the modern splicer are equipped with the following three functions:1. Achieve 100% successful paper splicing according to the required speed2. Automatically conduct paper splicing according to PMS3. Enable a stable paper tensionIn addition, it is necessary to know the following additional s of splicer, such as1). zero tail, that is, no tail when paper splicing, and the paper roll can be basically used up until the light roller.2). Reducing the loss3).Zero paper splicing and break paper, that is, when the base paper used to roll or use to the end of the damaged, the splicer can automatically conduct paper splicing by determine the tension and electrical eye, to reduce the number of break paper.The following are a typical set of paper splicing process diagramSee the next page) :  

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Answers to several common questions for carton factory When configuring the splicer machine

1.Is it Necessary for Small and Medium-sized Carton Factories to Invest a Splicer   If a factory has nearly 60 orders each day, with the total length of paper about 60,000 square meters (all converted into 5 floors).The factory owner hesitated whether it was worth investing a splicer.I believe this is a question many all and micro factories have faced: "generally, it is large and medium-sized enterprises to configure automatic splicer, with such little orders, is it worth the cost?In fact, this is a misunderstanding.A corrugated line with good operators, if there is no operational error, then the most important loss is the loss of order change, and the most core role of production control system(PCS) and splicer is to reduce the loss of order change.So is this factory worth investing in splicer?If do not use automatic splicer, especially the linerboard part, then you must stop to change the order.60,000 square meters per day is calculated according to the base weight of 600 grams/square meters, 36 tons of paper is consumed every day, and 36 times of paper needs to be change.Remove the first 5 times, stop 31 times, each downtime to cause hot plate degumming about 20 meters, discount about 14$ (about 40 square meters,0.35$per square), the conclusion is loss about 442$ a day, equivalent to a year about 140,000$. While configuration of a splicer only about 20,000$, it produces economic benefits far higher than the purchase price, the investment is very cost-effective. The comparison is astonishing. Therefore it is necessary to purchase at least one splicer. 2.Why Paper Splicing Failure Happened?  Now most enterprises are using the splicer, however it is inevitably encounter the problem of paper splicing failure which affects both production loss and production efficiency.The purpose of using automatic splicer is to reduce production loss and improve production efficiency.So why the success rate is difficult to achieve in using automatic splicer?The reasons can be roughly divided into the following situations:Reasons:1. Fail to remove the damaged base paper of outer edge;2. Fail not deal with paper with too tight edges;3. Loose paper on the new paper roll;4. Paper splicing error;5. The clamping roller is not parallel, not glue the whole paper;6. Not run through the entire paper when crosscutting knife is cutting ;7. Slow movement of floating roll and splicer;8. The speed of paper splicing is too fast;9. The new paper roll is not lifted off the ground;10. The operation order of the machine is disordered11. There is damage to the middle or edge of the paper sheet on the paper roll, which is hung on the splicer. It happens to corrugated medium due toits fragile. According to above situation, the improvement measures include:Solutions:1. Cut off any damaged outer paper or notch with a moon shaped knife;2. Cut off loose paper edges, adjust paper edges to align paper web with paper roll, hold paper web tightly, press the paper clip button, then paper web can be accurately positioned, and the whole paper web is in the correct position;3. Check the degree of loose paper web on the new paper roll before starting a splicer. Too loose or too tight will affect the successful running of the splicer;4. If the brake is not properly set in the paper web preparation process, the splicer shall be in the preparation state as required;5. Adjust the clamping roller to make it parallel;6. Adjust the spacing between the cutter and the anvil pad, check the condition of the cutting edge, the anvil pad and the mechanical device, and ensure sufficient air pressure on the clamping rod and the knife;7. Check whether there is debris accumulation on the floating roller or the gear and rack of the splicer;8. Check the gear, whether the gear tooth excessive wear, each paper machine has its own best running speed due to the differences in design, model, paper material, base paper frame and paper machine preparation.It is recommended that both single-sided and double-sided machines be equipped with easy-to-see speed displays so that operators can control all the splicers running at the correct speed;9. Lift the paper off the ground in the order recommended by the supplier before the splicer starting to run ;10. Removing the edge damaged paper, finding and eliminating the cause of paper damage;11. Because the stripping of the paper web costs seriously waste, it is not recommended to peel the damaged scrap.3 . What kind of Splicer is the "First Choice" of Carton Factory?For many carton factories, there is misunderstanding, that is corrugated line production equipment is best equipped, but no paying attention on splicer, for it’s only used for paper splicing. Is this really the case?At present, the price of base paper fluctuates frequently. It is just like having a "virtuous housewife" to provide a piece of equipment that can effectively "save paper" for the carton factory. When facing the situations like lacking paper and high paper price, we have more confidence to break through the siege."Reduce loss" is the most important reference standard for customers in the purchase of splicer.Paper splicing of base paper suited for different paper gram weightIn the actual production process of carton factory, the situation is much more complicated than expected. Especially in our country, in the context of fierce price competition, many cardboard manufacturers have greatly reduced the paper standard, and the quality of the base paper varies: 1. The paper joint is not strong enough after being produced in the factory, or even the paper joint is not glued at all.2. In some paper rolls, there are more than one paper joint, the joint position of the paper roll is not marked, or other problems such as the two sides of the paper roll have different tightness, the water distribution of the paper roll is not uniform, dampness etc. These are seemingly trivial problems, but they are slowly wasting investors' hard-earned money. As is known to all,  because of quality control, the same paper roll with different tightness on its both left and right, or due to improper storage of paper (usually at the bottom of paper roll, paper roll diameter of one end that usually contacted with the ground enlarged due to damp, besides two paper rolls heavy burdened on the surface. We call this phenomenon "the elephant leg").Such paper rolls in the drying cylinder surface because the left and right tension is not uniform, the heat of the paper web in unit time is not the same, the temperature of the paper web between left and right  is not the same, resulting in poor gluing or cardboard warp.Break Papers equivalent to a flat tire. Avoiding break paper in the process of high speed paper splicing.In the normal production process, the break paper often occurs due to many reasons.For high speed corrugated line, break paper is fatal, just like the flat tire while driving on the highway. The waste of high-speed paper is huge, not only the paper, but also labor costs. Some industry experts have calculated that a comprehensive cost of break paper reaches 100-150$. It is easy to count the number of break paper every year, so as to know the annual loss of paper breaking. 

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