Metal Composite Panel Production Line Series: Practical Operation Guide - How to Efficiently Solve Core Production Issues?

As the core equipment cluster for metal composite panel manufacturing, the Metal Composite Panel Production Line Series directly determines an enterprise's production efficiency, product qualification rate, and overall costs. In actual production, every link—from startup preparation and daily maintenance to troubleshooting and personnel management—contains practical optimization points. From a full-process perspective and combined with frontline operational experience, this article details the practical methods for key links of the production line, helping enterprise operators quickly master core skills, reduce production losses, and improve equipment operational stability.

1. Pre-Startup Inspection of the Production Line: Which Key Components Must Be Checked One by One? How to Ensure No Omissions in Inspection?

Comprehensive pre-startup inspection is the first line of defense against sudden failures during production and for ensuring product quality. Inadequate inspection may lead to issues such as bubbles in the composite layer, cutting dimensional deviations, and even equipment damage or safety accidents. Inspections must be conducted in four modules—"mechanical system, electrical system, material preparation, and auxiliary facilities"—following the principle of "static first, then dynamic; overall first, then local".

(1) Mechanical System Inspection: Focus on Precision and Operational Safety

1. Composite Unit Core Component Inspection
   
   

The composite roller is critical for panel bonding quality. Check its parallelism with a feeler gauge of 0.01mm accuracy at three positions (both ends and the middle of the roller), ensuring the gap error is ≤0.05mm. If the gap is uneven, adjust it via the bolts on both ends of the roller shaft (each adjustment should not exceed 1/4 turn). Clean adhesive residues on the roller surface with a scraper (30° blade angle to avoid scratching) and industrial alcohol; for scratches ≤0.1mm deep, polish them with 1200-grit sandpaper until the surface roughness is restored to Ra ≤0.8μm. Test the pressure adjustment system by gradually increasing the pressure from 0 to the rated working pressure (usually 1.0MPa), ensuring the pressure gauge pointer moves steadily without jamming.

2. Conveying System Inspection
   
   

For conveyor chains: Lift the middle part of the chain by hand to check the sag, which should be ≤5mm; adjust the tensioner if the sag exceeds the standard. Inspect the wear of chain pins and rollers—if the rollers fail to rotate flexibly or the pin diameter is reduced by more than 0.5mm, replace the corresponding chain links. For conveyor belts: Check for surface damage (replace the belt if the damaged area exceeds 10cm²) or edge wear (trim the edge if wear width exceeds 5mm). Adjust the driven roller to align the belt centerline with the equipment centerline. Rotate the drive wheels manually to ensure uniform rotation resistance without jamming or abnormal noise.

3. Cutting Unit Inspection
   
   

Examine the edge of the cutting tool for gaps, burrs, or dullness. For small gaps (≤0.2mm), polish the edge with 800-grit sandpaper; replace the tool if it is severely dull (resulting in burrs wider than 0.3mm on cut panels). When installing a new tool, ensure the coaxiality between the tool and the tool shaft is ≤0.03mm (verify with a dial indicator). Test the laser positioning system: After startup, check that the laser line is clear and straight, with a deviation from the cutting reference line ≤0.1mm. If the deviation exceeds the standard, clean the laser emitter lens with a dedicated lens cleaner or adjust the emitter's angle and position.

(2) Electrical System Inspection: Ensure Stable Power Supply and Precise Control

1. Power Supply Circuit Inspection
   
   

Open the distribution box and check the terminal blocks for looseness or oxidation—if oxidation is found, polish the terminals with fine sandpaper and re-tighten them. Use a multimeter to measure the insulation resistance between wires, which should be ≥1MΩ for live wires to live wires, live wires to neutral wires, and live wires to ground wires. Verify the three-phase power supply voltage, which should be within the range of 380V±10%; if voltage fluctuation exceeds this range, contact the power supply department for adjustment or install a voltage stabilizer. Test the equipment's ground resistance with a ground resistance tester, ensuring it is ≤4Ω; replace rusted ground electrodes or damaged grounding cables if the resistance is excessive.

2. Control System Inspection
   
   

Start the control system power supply and confirm that the touchscreen or operation panel displays normally without garbled characters, black screens, or freezes. Test each control button (start, stop, emergency stop, parameter adjustment) to ensure sensitive response. For the temperature control system: Set the target temperature of the heating unit to 150℃, start the heating function, and record the actual temperature every 5 minutes—the error between the actual temperature and the set temperature should be ≤±2℃. If the error exceeds the standard, calibrate the temperature control instrument (using a standard thermometer for comparison) or check the installation position of the thermocouple (ensure it is inserted into the heating chamber and fully contacts the heated medium). For the servo control system (e.g., cutting tool holder movement): Start the servo motor and control the tool holder to move along the X-axis and Y-axis, ensuring smooth movement without vibration. Use a laser interferometer to measure the positioning accuracy, which should be ≤0.05mm/1000mm.

3. Safety Protection System Inspection
   
   

Test each emergency stop button: When pressed, the equipment should immediately power off and stop all moving parts; after releasing the button, the control circuit must be reset to restart the equipment. If the emergency stop function fails, check the internal contacts of the button or the continuity of the control circuit. Verify the safety light curtain: Place an obstacle (e.g., a 100mm×100mm wooden board) in the light curtain's sensing area—the equipment should immediately stop dangerous operations (such as cutting or composite roller rotation) and trigger an audible and visual alarm. Simulate an overload condition for the overload protector (e.g., increase the conveyor system load artificially)—the protector should trip when the current reaches 1.2 times the motor's rated current; adjust the protector's setting or replace it if it fails to trip or trips prematurely.

(3) Material Preparation Inspection

1. Metal Substrate Inspection
   
   

Check the substrate surface under natural light for oil stains, scratches, or rust. For oil stains, clean the surface with an eco-friendly degreaser (verify cleanliness via the water film test—water should form a continuous film on the surface without breaking). For scratches ≤0.1mm deep, polish them with 1200-grit sandpaper; for rust spots, remove the rust with sandpaper and apply a thin layer of anti-rust oil. Measure the substrate thickness at 5 different positions using a micrometer (0.001mm accuracy), ensuring the thickness deviation is ≤±0.05mm. Measure the width with a tape measure, requiring a deviation of ≤±1mm; classify and discard substrates that exceed the specification range.

2. Core Material Inspection
   
   

For polyethylene core materials: Use a densitometer to measure the density, which should be 0.92-0.96g/cm³; use a caliper to check the thickness deviation, which should be ≤±0.3mm. For rock wool core materials: Check for moisture absorption (use a moisture meter to ensure the moisture content is ≤5%) and surface flatness (use a 2m straightedge to measure the gap, which should be ≤2mm/m). For polyurethane core materials: Inspect for bubbles, shrinkage cavities, or cracks—discard cores with bubbles larger than 5mm in diameter or more than 3 bubbles per square meter.

3. Adhesive Inspection
   
   

Check the adhesive's packaging label to confirm it is within the shelf life. After opening the package, observe the adhesive's texture—it should be a uniform viscous liquid without stratification, sedimentation, or peculiar smell. If stratification occurs, stir the adhesive thoroughly for at least 10 minutes; if sedimentation remains after stirring, do not use the adhesive. Measure the adhesive's viscosity at 25℃ using a rotational viscometer, which should be 1500-2500mPa·s; if the viscosity is too high, add a dedicated thinner (addition ratio ≤10%) as per the supplier's instructions. Before mass use, test the bonding strength: Apply a small amount of adhesive between the metal substrate and core material, press according to the standard process, and measure the bonding strength with a tensile testing machine—this should be ≥1.0MPa.

(4) Auxiliary Facility Inspection

1. Compressed Air System Inspection
   
   

Start the air compressor and observe the pressure gauge—the compressed air pressure should be stable at 0.6-0.8MPa. If the pressure fluctuates excessively, remove and clean the air intake filter (replace the filter if it is severely clogged). Check the tightness of the compressed air pipeline by applying soapy water to the joints—if bubbles form, tighten the joints or replace the sealing gaskets. Drain the condensed water from the air dryer and air storage tank (at least once a day) to prevent moisture from entering the pneumatic components.

2. Cooling System Inspection
   
   

Check the water level in the cooling water tank, which should be within the range marked on the tank; add industrial pure water (tap water is prohibited to avoid scale) if the level is insufficient. If the cooling water is turbid, drain the old water, clean the tank, and refill with new water. Start the cooling water pump and use a flowmeter to measure the water flow, which should meet the equipment's rated flow (usually 5-10L/min). If the flow is insufficient, check for blockages in the pump impeller or pipeline leaks—clean the impeller or repair the leaks as needed.

3. Waste Recycling System Inspection
   
   

Start the waste conveyor belt and check that it operates smoothly without deviation—the belt speed should match the production line's cutting speed (usually 3-5m/min). Start the crusher and feed a small amount of waste (e.g., metal scraps) to test the crushing effect—the particle size of the crushed material should be 5-10mm; adjust the gap between the crusher blades if the particles are too large.

2. Parameter Adjustment During Production: How to Quickly Optimize Based on Panel Specifications?

(1) Parameter Adjustment by Panel Thickness

Thickness Type	Total Thickness Range	Heating Temperature (℃)	Composite Pressure (MPa)	Conveyor Speed (m/min)	Dwell Time (seconds)	Key Notes
Thin Panels	≤3mm	120-140	0.8-1.0	7-8	10-15	Shorten the dwell time to avoid panel deformation; ensure uniform heating to prevent local overheating
Medium-Thick Panels	3-8mm	150-170	1.2-1.5	3-5	20-30	Adopt segmented heating (pre-heating → main heating → heat preservation) to ensure sufficient curing of the core material; add support rollers to maintain uniform pressure
Thick Panels	＞8mm	180-200	1.5-2.0	1-3	30-40	Embed temperature sensors to monitor the internal temperature of the core material (ensure it reaches the curing temperature); add side guide plates during conveying to prevent panel deviation

Example: For 1.5mm-thick aluminum-polyethylene composite panels (0.5mm aluminum plate + 0.5mm polyethylene core + 0.5mm aluminum plate), set the heating temperature to 130℃, composite pressure to 0.9MPa, conveyor speed to 7.5m/min, and dwell time to 12 seconds. Sample and measure the panel thickness every 30 minutes to ensure the deviation is ≤±0.05mm, and test the bonding strength regularly to avoid bonding failure due to parameter errors.


(2) Parameter Adjustment by Panel Width

Width Type	Width Range	Conveyor Guide Spacing (mm)	Cutting Speed (m/min)	Edge Heating Temperature (℃)	Deviation Correction Device Setting	Key Notes
Narrow Panels	≤1200mm	Width + 2-3	8-10	Main Heating Temperature + 5-10	No additional correction required	Install wear-resistant rubber strips on the inner side of the guides to reduce edge wear of the panels
Wide Panels	＞1200mm	Width + 3-5	5-7	Main Heating Temperature + 10-15	Photoelectric correction (triggered when deviation ≥2mm)	Adopt dual-drive conveying to ensure stable movement; install one temperature sensor every 300mm along the width to monitor heating uniformity

Example: For 1800mm-wide steel-rock wool composite panels, set the conveyor guide spacing to 1804mm, cutting speed to 6m/min, and the temperature of the edge infrared heating tube to 172℃ (12℃ higher than the main heating temperature of 160℃). Activate the photoelectric deviation correction device—when the panel deviation exceeds 2mm, the device will automatically adjust the conveyor to ensure precise cutting. Sample and measure the width deviation every 5㎡ of production, requiring it to be ≤±1mm.


(3) Parameter Adjustment by Material Combination

Material Combination	Heating Temperature (℃)	Composite Pressure (MPa)	Adhesive Type	Adhesive Coating Amount (g/㎡)	Post-Processing Procedure
Aluminum-Polyethylene	120-140	0.8-1.2	Epoxy-Based	80-100	Air-cool to <50℃ (air speed: 4 m/s) post-compounding
Steel-Rock Wool	160-190	1.5-2.0	Phenolic Resin-Based	100-120	Perform sandblasting rust removal on the steel plate before compounding  (reach Sa2.5 grade); cool naturally after compounding
Aluminum-Aluminum (Honeycomb Core)	130-160	1.0-1.5	Modified Epoxy-Based	60-80	Conduct aging treatment at 50-60℃ for 24 hours after compounding to improve bonding stability

3. Troubleshooting: How to Resolve Downtime Within 10 Minutes?

(1) Composite Quality Faults

Fault Type	Common Causes	Inspection and Resolution Steps (Completed Within 10 Minutes)	Preventive Measures
Bubbles in Composite Layer	1. Uneven adhesive coating or insufficient coating amount2. Low heating temperature or insufficient heating time3. Insufficient composite pressure4. Oil stains or moisture on material surfaces	1. Check the adhesive layer on the coating roller; increase the coating pressure by 0.1-0.2MPa or the roller speed by 5%2. Measure the material surface temperature with an infrared thermometer; increase the heating temperature by 5-10℃ or extend the heating time by 1 minute3. Increase the composite pressure by 0.1-0.2MPa and observe if the bubbles disappear4. Wipe the material surface with a degreaser (for oil stains) or dry the core material with a hot air gun (for moisture)	1. Check the adhesive coating amount hourly using the weighing method2. Calibrate the temperature control system once a week3. Clean the material surfaces before feeding them into the production line
Panel Delamination	1. Expired or unqualified adhesive2. Smooth surface of the core material (poor adhesion) or porous structure3. Excessively fast cooling rate after compounding4. Overheating causing adhesive carbonization	1. Check the adhesive's shelf life; test the bonding strength of a small sample (require ≥1.0MPa); replace the adhesive if unqualified2. Polish the smooth core material to reach a surface roughness of Ra 0.8-1.6μm; apply a layer of primer to porous core materials before compounding3. Switch to progressive cooling (first air-cool for 20 minutes, then water-cool) to reduce temperature difference stress4. Reduce the heating temperature by 10-15℃ and extend the heating time to avoid adhesive carbonization	1. Store adhesives in a dedicated warehouse with clear shelf life labels2. Inspect the surface state of core materials before storage3. Set the cooling rate to ≤5℃/minute and monitor it with a temperature sensor
Uneven Panel Surface	1. Large parallelism error of composite rollers2. Uneven thickness of substrates or core materials3. Excessively fast conveyor speed4. Improper stacking (excessive pressure causing deformation)	1. Use a feeler gauge to calibrate the composite roller gap (error ≤0.05mm); adjust the gaskets under the bearing seats if necessary2. Screen out materials with excessive thickness deviation (substrates

: ±0.05mm, core materials: ±0.3mm) and reselect qualified materials3. Reduce the conveyor speed by 1-2m/min and add a flattening roller after the composite unit to correct surface unevenness4. Stack panels horizontally with a maximum height of 1.5m, placing plywood pads between layers to avoid pressure deformation | 1. Calibrate the parallelism of composite rollers weekly using a feeler gauge2. Sample and inspect material thickness before production (at least 5 samples per batch)3. Formulate a standardized stacking procedure and mark the maximum stacking height on the storage rack 


(2) Equipment Operation Faults

Fault Type	Common Causes	Inspection and Resolution Steps (Completed Within 10 Minutes)	Preventive Measures
Conveyor System Jamming	1. Insufficient tension of the conveyor chain/belt causing slippage2. Wear of transmission gears or sprockets (tooth surface wear exceeding 10%)3. Foreign objects (e.g., metal scraps, adhesive residues) blocking the track4. Excessive load on the conveyor motor	1. Adjust the tensioner: For chains, ensure the sag is ≤5mm; for belts, tighten until the deflection under 5kg load is ≤10mm2. Inspect the tooth surface of gears/sprockets; if wear is severe, replace the damaged parts with new ones of the same model3. Use compressed air (0.4-0.6MPa) to blow off foreign objects in the track; for stubborn residues, use a plastic scraper to clean (avoid scratching the track surface)4. Measure the motor current with a clamp meter; if it exceeds the rated current, remove the excess load (e.g., reduce the number of panels on the conveyor)	1. Check the tension of the chain/belt daily before starting production2. Lubricate transmission gears/sprockets weekly with extreme-pressure gear oil3. Clean the conveyor track and surrounding area after daily production to prevent foreign object accumulation
Cutting Dimensional Deviation	1. Laser positioning system deviation (e.g., lens contamination, emitter offset)2. Cutting tool wear (edge dullness) or misalignment (coaxiality >0.03mm)3. Unstable conveyor speed (fluctuation exceeding 5%) due to inverter parameter errors4. Panel movement during cutting (insufficient clamping force)	1. Clean the laser emitter lens with a dedicated lens cloth and lens cleaner; re-calibrate the laser line to align with the cutting reference (deviation ≤0.1mm)2. Polish the tool edge with 800-grit sandpaper (if dull) or re-install the tool to ensure coaxiality ≤0.03mm (verify with a dial indicator)3. Enter the inverter parameter interface to adjust the speed stability coefficient; test the conveyor speed with a tachometer to ensure fluctuation ≤5%4. Increase the clamping force of the pneumatic clamping device (from 0.4MPa to 0.6MPa) and check if the clamping pads are worn (replace if the friction coefficient decreases)	1. Clean the laser lens and re-calibrate the positioning system daily2. Check the tool wear status every 4 hours of operation and replace the tool when the cutting burr width exceeds 0.3mm3. Inspect the inverter parameters monthly and back up the correct parameter settings
Composite Roller Abnormal Noise	1. Insufficient lubrication of the roller bearings (grease drying or contamination)2. Foreign objects (e.g., metal shavings) stuck between the roller surface and the bearing seat3. Damage to the shaft end seal (oil leakage causing bearing corrosion)4. Large parallelism error of the composite rollers (gap difference >0.05mm)	1. Disassemble the bearing end cover, clean the old grease with kerosene, and refill with lithium-based grease (filling 1/3-1/2 of the bearing cavity)2. Stop the equipment, rotate the roller manually to find the stuck position, and use tweezers to remove foreign objects (avoid using hard tools to prevent roller damage)3. Replace the damaged oil seal with a new one of the same specification (e.g., nitrile rubber material for oil resistance) and apply a thin layer of grease on the seal lip4. Use a feeler gauge to measure the gap at 5 points on the roller; adjust the bearing seat gaskets (thickness accuracy 0.01mm) to reduce the parallelism error to ≤0.05mm	1. Check the bearing lubrication status weekly and supplement grease if necessary2. Clean the composite roller surface and bearing seat area after daily production3. Calibrate the roller parallelism every two weeks to prevent long-term operation from causing deviation

(3) Electrical System Faults

Fault Type	Common Causes	Inspection and Resolution Steps (Completed Within 10 Minutes)	Preventive Measures
Control System Black Screen	1. Tripped main power switch or loose wiring in the control cabinet2. Blown power fuse (e.g., 5A/250V) due to short circuit in the internal circuit3. Electromagnetic interference from nearby high-power equipment (e.g., air compressors)4. Hardware failure of the touchscreen (e.g., damaged backlight or loose signal cable)	1. Check the main power switch in the distribution box; if tripped, reset it after confirming no short circuit; tighten loose wiring terminals in the control cabinet with a screwdriver2. Replace the blown fuse with one of the same specification; use a multimeter to measure the circuit resistance to exclude short circuit risks (resistance should be ≥1MΩ)3. Install a shielded cable for the control system and move high-power equipment away from the control cabinet (distance ≥2m)4. Reconnect the touchscreen signal cable; if the screen remains black, temporarily replace it with a spare touchscreen to restore production (send the faulty one for repair later)	1. Check the power connection and wiring terminals in the control cabinet daily2. Clean the control cabinet with compressed air weekly to prevent dust accumulation3. Record the normal operation parameters of the control system and back up the program monthly
Motor Failure to Start	1. Contactor not engaging (coil power loss or internal contact oxidation)2. Overload protector tripping due to excessive motor load3. Motor winding open circuit or short circuit (e.g., due to moisture or insulation aging)4. Bearing seizure caused by insufficient lubrication	1. Measure the contactor coil voltage with a multimeter (should be 220V/380V); if there is no voltage, check the control circuit; if the contacts are oxidized, polish them with fine sandpaper2. Press the reset button on the overload protector; reduce the motor load (e.g., clear the jammed material on the conveyor) before restarting3. Use a megohmmeter to measure the insulation resistance of the motor windings (should be ≥1MΩ); if the resistance is too low, dry the motor with a hot air gun (temperature ≤80℃) or replace the motor if short-circuited4. Disassemble the motor end cover, clean the bearing, and refill with lithium-based grease; if the bearing is worn, replace it with a new one of the same model (e.g., 6205 deep groove ball bearing)	1. Inspect the contactor contacts and coil status weekly2. Measure the motor current during operation daily to avoid overload3. Lubricate the motor bearing every month and check the insulation resistance quarterly
Temperature Control Malfunction	1. Faulty temperature sensor (e.g., broken thermocouple wire or incorrect insertion depth)2. Temperature control instrument error (display deviation >±2℃) due to uncalibrated parameters3. Damaged heating tube (open circuit or reduced power)4. Stuck solid-state relay (SSR) causing continuous heating or no heating	1. Replace the thermocouple with a new one of the same type (e.g., K-type); ensure the insertion depth into the heating chamber is ≥50mm to fully contact the heated medium2. Enter the instrument calibration mode, use a standard thermometer to measure the actual temperature, and adjust the compensation value to reduce the deviation to ≤±2℃3. Measure the resistance of the heating tube with a multimeter (e.g., 48.4Ω for a 1kW/220V tube); replace the tube if the resistance is infinite (open circuit)4. Disconnect the SSR power, use a multimeter to test its on-off state; if it is stuck, replace it with a new SSR of the same current rating (e.g., 40A)	1. Calibrate the temperature sensor and instrument monthly2. Check the heating tube surface for scaling every two weeks and clean it with a descaling agent if necessary3. Test the SSR function daily by switching the heating on/off and observing the temperature change

4. Cost Control Techniques: How to Reduce Raw Material Waste and Energy Consumption?

(1) Raw Material Waste Control

① Cutting Link Optimization

Nesting Plan Improvement: Use professional nesting software (e.g., AutoCAD Nesting) to combine orders of different sizes. For example, a 1200mm×2440mm aluminum substrate can be nested into 3 pieces of 400mm×2440mm panels or 4 pieces of 600mm×1200mm panels, increasing substrate utilization from 85% to over 95%. For small-size orders (e.g., 300mm×300mm), nest them with large orders to avoid independent cutting that generates 15%-20% scrap.

Cutting Parameter Fine-Tuning: For aluminum plates (thickness ≤1mm), set the cutting speed to 8-10m/min and feed rate to 0.1-0.2mm/r to reduce burrs (burr width ≤0.1mm), reducing the rejection rate from 5% to 2%. For steel plates (thickness 2-3mm), lower the speed to 5-7m/min and increase the feed rate to 0.08-0.15mm/r, matching with cooling lubricant (concentration 8-10%) to extend tool life by 30%.

Scrap Splicing and Reuse: Collect scrap with a width ≥100mm, trim the edges to remove burrs, and splice them with adhesive (bonding strength ≥0.8MPa) for small non-load-bearing parts (e.g., decorative panels, equipment nameplates). This reduces scrap loss by 50㎡ per month, saving approximately 2,000 yuan in raw material costs.

② Compounding Link Optimization

Adhesive Dosage Precision Control: Install a weighing-type adhesive coating monitor (measurement accuracy ±2g/㎡) to track the coating amount in real time. For aluminum-polyethylene panels, set the coating amount to 80-90g/㎡ (instead of the traditional 100g/㎡); for steel-rock wool panels, set it to 100-110g/㎡. Every 10g/㎡ reduction in coating amount saves approximately 3,000 yuan in adhesive costs per month (based on a daily output of 1,000㎡).

Material Size Matching: Before compounding, ensure the core material size matches the substrate size (core material width ≤ substrate width by 5mm). For example, if the substrate width is 1220mm, select a 1215-1220mm core material to minimize trimming (only 5mm edge trimming), reducing trimming waste from 8% to 3%. If the core material is undersized (e.g., 1200mm width), splice it with a 20mm wide core material strip (coated with adhesive) before compounding, avoiding substrate waste.

Defective Product Reutilization: For panels with minor defects (e.g., small surface bubbles, edge delamination), cut them into 300mm×300mm samples for customer demonstrations or quality testing. For severely defective panels, separate the metal substrate from the core material (using a heating separator at 180-200℃), recover the substrate for reprocessing (e.g., polishing, painting), and reuse the core material for low-demand products (e.g., sound insulation pads).

③ Waste Recycling System

Metal Scrap Recycling: Classify aluminum and steel scrap separately. Aluminum scrap is sent to a professional smelter for remelting (recovery rate ≥90%), with a cost 30%-40% lower than new aluminum plates. Steel scrap is sold to scrap recycling enterprises at a market price of approximately 2,000 yuan/ton; recycling 100 tons annually generates 200,000 yuan in additional income.

Core Material Scrap Handling: Polyethylene scrap is crushed into particles (particle size 3-5mm) and mixed with new polyethylene particles at a 10% ratio for low-grade core material production. Rock wool scrap is crushed and mixed with cement to make lightweight building blocks, avoiding landfill disposal costs (approximately 500 yuan/ton) and generating 5,000 yuan in annual revenue from block sales.

Adhesive Scrap Recovery: Collect adhesive drips from the coating roller and pipeline, filter them through a 100-mesh filter to remove impurities, and mix them with new adhesive at a 10% ratio for core material splicing (non-critical bonding). This saves 10kg of adhesive per month, reducing costs by approximately 800 yuan.

(2) Energy Consumption Optimization

① Heating System Energy Saving

Segmented Heating and Temperature Gradient Control: For aluminum-polyethylene panel production, divide the heating unit into three sections: pre-heating (100-110℃), main heating (130-140℃), and heat preservation (120-130℃). Compared with full-section 140℃ heating, this reduces electricity consumption by 15-20kWh per hour (annual savings of 120,000kWh, approximately 96,000 yuan based on 0.8 yuan/kWh). For thick panels (＞8mm), extend the main heating time by 20% to ensure core material curing without increasing temperature.

Waste Heat Recovery Utilization: Install a shell-and-tube waste heat exchanger at the exhaust port of the heating unit to recover high-temperature exhaust heat (temperature 180-200℃) for preheating the incoming cold air (from 25℃ to 80-90℃) or heating the adhesive (from 25℃ to 40-50℃). This reduces the heating load of the main unit by 20%, saving 8-12kWh per hour (annual savings of 70,000kWh).

Heating Tube Upgrade and Maintenance: Replace traditional resistance heating tubes with electromagnetic heating tubes (energy efficiency 90% vs. 70% for resistance tubes). For 10 units of 2kW heating tubes operating 8 hours daily, this saves 21,600kWh annually. Clean the heating tube surface every quarter to remove scaling (scaling reduces heat efficiency by 20-30%); use a citric acid-based descaling agent (concentration 5-8%) to soak and clean, restoring heat transfer efficiency.

② Power System Energy Saving

Frequency Conversion Transformation: Equip all power motors (conveyor, cutting, compounding) with frequency converters (e.g., Siemens MM440). When the conveyor is waiting for materials, reduce the motor speed from 1450r/min to 500r/min, cutting electricity consumption by 3-5kWh per hour. When the cutting unit is idle, lower the speed to 50% of the rated speed, saving 20kWh daily.

Hydraulic System Pressure Optimization: Adjust the hydraulic system pressure according to actual needs. For example, if the composite roller requires a working pressure of 1.5MPa, set the system pressure to 1.8MPa (instead of 2.0MPa), reducing hydraulic pump energy consumption by 10%. Install a flow control valve to match the flow rate with the actuator speed (e.g., 10L/min for clamping actions), avoiding 15% of unnecessary energy loss.

Motor Maintenance and Efficiency Improvement: Clean the motor cooling fan and heat sink every two weeks to remove dust (dust accumulation increases motor temperature by 5-8℃, reducing efficiency by 1-2%). Lubricate the motor bearings with lithium-based grease every three months to reduce friction resistance, improving motor efficiency by 3-5% (saving 5,000kWh annually for a 10kW motor).

③ Auxiliary Equipment Energy Saving

Lighting System Transformation: Replace 40W fluorescent lamps (100 lamps in total) with 18W LED lamps (luminous flux 1800lm, same as fluorescent lamps). Each LED lamp saves 22W of power, operating 10 hours daily, saving 18,000kWh annually (approximately 14,400 yuan). Install human body induction switches in warehouses and corridors, automatically turning off lights when no one is present (reducing lighting time by 40%).

Air Compressor Energy Saving: Adjust the number of operating air compressors based on real-time air consumption. If the production line requires 0.8m³/min of air, operate one 1.0m³/min air compressor instead of two smaller units (0.5m³/min each), avoiding 30% of no-load energy consumption. Install a waste heat recovery device to utilize the heat generated by the air compressor (80% of input power is converted to heat) for workshop heating or domestic hot water, saving 15,000 yuan in annual gas costs. Clean the air compressor intake filter monthly (replace every 3 months if heavily soiled) to reduce suction resistance and lower energy consumption by 5%.

Dehumidifier and Air Conditioner Optimization: Set the dehumidifier to maintain a workshop relative humidity of 60%-70% (instead of ≤50%) to avoid overloading. Install a temperature-humidity linkage control system: in summer, first lower the temperature to 28℃ with the air conditioner, then start the dehumidifier to remove moisture, reducing the dehumidifier’s energy consumption by 20%. Clean the dehumidifier filter every two weeks and the air conditioner evaporator monthly to ensure heat exchange efficiency, saving 600kWh of electricity monthly.

(3) Auxiliary Material Saving

① Grease Saving

Quantitative Lubrication: Equip each lubrication point with a quantitative grease gun (e.g., Lincoln 1162) to control the dosage. For composite roller bearings, fill 1/3-1/2 of the bearing cavity with lithium-based grease (approximately 5g per bearing); for conveyor chains, apply 5-8g of extreme-pressure gear oil per meter. This reduces grease consumption by 30%-40% compared to arbitrary manual addition. Establish a lubrication record sheet to track the lubrication time, dosage, and operator for each point, avoiding repeated lubrication.

Grease Recycling: Collect used grease from non-critical components (e.g., conveyor rollers), filter it through a 200-mesh sieve to remove impurities, and heat it to 60-80℃ to evaporate moisture. Reuse the processed grease for lubricating workshop door hinges, crane wheels, or other low-load parts, saving 2kg of new grease monthly (approximately 300 yuan).

Long-Lasting Grease Selection: Replace ordinary lithium-based grease (service life 3 months) with composite calcium sulfonate grease (service life 6-9 months) for composite rollers and cutting tool holder bearings. This reduces the number of lubrication cycles by 50% and cuts annual grease procurement costs by 60%.

② Coolant Saving

Circulation Filtration: Install a three-stage filtration system (coarse filter: 100μm, fine filter: 20μm, magnetic separator) for cutting emulsion to remove metal chips and impurities. The service life of the emulsion is extended from 1 month to 3-4 months, reducing monthly procurement costs by 60%-70%. Use a refractometer to monitor the emulsion concentration weekly (maintain 8-10%); add new emulsion or water as needed to avoid waste from excessive concentration.

Coolant Regeneration: Entrust professional enterprises to regenerate waste coolant via distillation and centrifugation. The regenerated coolant has a purity of ≥95% and can be reused in production, with a cost 50% lower than new coolant. Regenerating 10 tons of waste emulsion annually saves 30,000-40,000 yuan.

Air Cooling Replacement: For small cutting tools (diameter ≤10mm), use compressed air cooling (0.5-0.6MPa pressure, 15-20m/s air speed) instead of emulsion. This eliminates coolant procurement, treatment, and disposal costs, saving 25,000 yuan annually and reducing environmental pollution.

③ Packaging Material Saving

Customized Packaging: Design dedicated cartons based on the size of finished panels. For 1200mm×2440mm panels, use cartons of 1210mm×2450mm×50mm that hold 5-6 panels each, reducing carton usage by 30% compared to universal 1500mm×3000mm cartons. For small panels (300mm×300mm), use reusable plastic turnover boxes (service life ≥50 times) instead of disposable cartons, cutting annual carton costs by 8,000 yuan.

Recycled Materials: Collect intact plastic film and foam pads returned by customers, clean them with industrial alcohol, and reuse them for packaging. Cut damaged cartons into 100mm×100mm pads to separate panels during stacking, reducing new carton usage by 10%-15%. Use recycled cardboard (15% cheaper than new cardboard) for outer packaging, saving 4,500 yuan annually.

Eco-Friendly Alternatives: Replace traditional PE plastic film with corn starch-based biodegradable film (price 15% lower) and use water-based adhesives for carton sealing (instead of solvent-based adhesives). This not only reduces costs but also meets environmental requirements, avoiding 2,000 yuan in annual waste disposal fees.

5. Daily Maintenance Plan: How to Extend the Production Line Service Life to Over 8 Years?

(1) Core Production Component Maintenance

① Composite Roller Maintenance

Surface Care: After daily production, clean adhesive residues with a 30°-blade scraper and industrial alcohol. Inspect the surface for scratches: if scratches are ≤0.1mm, polish them with 1200-grit sandpaper along the roller rotation direction, then polish with a wool cloth to restore Ra ≤0.8μm. For scratches >0.1mm, mark the position and arrange for grinding repair during monthly shutdowns. After grinding, calibrate the roller parallelism with a feeler gauge (gap error ≤0.05mm).

Bearing and Pressure System: Every week, remove the bearing end cover and check the grease condition—if the grease is discolored or contains impurities, clean the bearing with kerosene, dry it, and refill with lithium-based grease (NLGI 2). Every month, test the pressure adjustment system by gradually increasing the pressure from 0 to 1.5MPa; if the pressure gauge pointer jams, disassemble the pressure relief valve, clean the valve core with diesel, and replace the O-ring (nitrile rubber).

Temperature-Pressure Calibration: Every quarter, simulate production conditions (150℃ heating, 1.2MPa pressure) and use an infrared thermal imager to detect the roller surface temperature distribution. Ensure the lateral temperature deviation is ≤±3℃; if local temperature is low, check the heating tube resistance (replace if infinite) and re-test.

② Cutting Unit Maintenance

Tool and Laser System: Before daily use, inspect the cutting tool edge—if there are burrs or small gaps (≤0.2mm), polish with 800-grit sandpaper. After tool replacement, use a dial indicator to measure the runout (≤0.03mm). Clean the laser emitter lens daily with a dedicated lens cloth and lens cleaner (e.g., Zeiss Lens Cleaner); check the laser line straightness—if deviation exceeds 0.1mm, adjust the emitter angle using the calibration screws.

Cutting Platform and Screw: Every week, use compressed air (0.4-0.6MPa) to blow metal scraps from the platform; check the platform flatness with a 2m straightedge (gap ≤0.1mm). If there is a depression, place a 0.05-0.1mm thick steel shim under the platform. Every month, apply molybdenum disulfide grease to the cutting tool holder’s ball screw; manually move the tool holder to ensure smooth movement—if there is resistance, disassemble the screw, clean it with acetone, and reapply grease.

(2) Vulnerable Functional Component Maintenance

① Conveying System

Belt/Chain Inspection: Daily, check the conveyor belt for damage (replace if area >10cm²) and edge wear (trim if >5mm). Adjust the driven roller to align the belt if it deviates. For chains, check the sag (≤5mm) and rotate each roller to ensure flexibility—replace links if rollers are stuck. Every two weeks, lubricate the chain with extreme-pressure gear oil (ISO VG 150) using an oiler.

Motor and Reducer: Every month, measure the conveyor motor’s three-phase current with a clamp meter (deviation ≤5%); if unbalanced, check the motor windings with a megohmmeter (insulation resistance ≥1MΩ). Every quarter, check the reducer oil level (within the oil gauge scale); if the oil is turbid, drain the old oil, flush the reducer with diesel, and refill with industrial gear oil (ISO VG 220). Run the reducer idle for 10 minutes to ensure lubrication.

② Pressurizing and Clamping Components

Hydraulic Clamping Device: Daily, check hydraulic pipelines for leaks (wipe joints with paper—no oil stains). If leaks occur, replace the sealing gasket (nitrile rubber). Every week, test the clamping force with a pressure sensor (0.5MPa); if insufficient, adjust the relief valve (0.05MPa per adjustment). Every month, clean the hydraulic oil tank, drain sediment, and replace the oil filter (10μm precision). Refill with anti-wear hydraulic oil (ISO VG 46) to the oil gauge line.

Pneumatic Components: Daily, drain condensed water from the pneumatic triple unit (filter, pressure reducer, oiler) and add 5-10ml of pneumatic oil to the oiler. Every week, clean the pneumatic cylinder rod with a lint-free cloth and apply a thin layer of silicone grease (heat-resistant up to 200℃). If the cylinder moves sluggishly, check the air pressure (≥0.6MPa) and clean the solenoid valve with compressed air.

(3) Electrical Control System Maintenance

① Power Supply and Control Circuit

Cabinet and Wiring: Every month, open the electrical cabinet and blow dust with compressed air (0.3MPa). Tighten all wiring terminals with a screwdriver (torque 2-3N・m) to prevent oxidation. Measure the insulation resistance between live wires and ground (≥1MΩ) with a megohmmeter. Every two weeks, inspect contactor and relay contacts—if burn marks cover >10% of the contact area, polish with 400-grit sandpaper; replace if pitting is severe.

PLC and Inverter: Every month, check the PLC and inverter cooling fans—if fans are noisy or stop, replace them immediately (e.g., Delta AFB0612HB). Back up the PLC program to a USB drive and record inverter parameters (acceleration time, frequency upper limit). Every quarter, use a thermal imager to detect the temperature of inverter components (≤60℃); if overheating, clean the heat sink with a brush.

② Sensors and Safety Devices

Sensor Calibration: Every month, calibrate the temperature sensor (K-type thermocouple) by inserting it into a standard constant temperature bath (150℃) and adjusting the temperature control instrument compensation value to ensure the error ≤±2℃. Calibrate the pressure sensor with a standard pressure gauge (deviation ≤±0.05MPa). Clean the laser positioning sensor lens every two weeks to avoid dust affecting accuracy.

Safety Protection Check: Daily, test the emergency stop button—pressing it should cut off all power; releasing it requires a reset to restart. Every week, test the safety light curtain by blocking it with a 50mm×50mm object—the equipment should stop and alarm within 0.5 seconds. Every month, measure the equipment ground resistance (≤4Ω); if exceeded, add a zinc-coated steel ground electrode (length 2.5m) and fill the surrounding soil with bentonite drag reducing agent.

(4) Auxiliary System Maintenance

① Cooling System

Water Cooling: Every week, check the cooling tank water level (add industrial pure water if low) and water quality—if turbid, drain the water, clean the tank with a brush, and refill. Every month, clean the cooling pipeline with a 5% citric acid solution (circulate for 2 hours) to remove scale, then flush with pure water. Check the cooling pump impeller for blockages—if worn, replace the impeller (stainless steel 304) and test the flow rate (8L/min).

Air Cooling: Every week, clean the cooling fan blades with a brush (remove dust); test the fan speed with a tachometer (1450r/min for 4-pole motors). Every month, lubricate the fan motor bearing with lithium-based grease (1g per bearing). If the fan vibrates (amplitude >0.1mm/s), check the motor anchor bolts and tighten if loose.

② Waste Recycling System

Waste Conveyor: Daily, clean residual waste from the conveyor belt with compressed air; check the belt joint for cracks—repair with special glue (e.g., 3M SCotch-Weld) if cracked. Every week, adjust the conveyor belt tension (sag ≤5mm) and lubricate the drive roller bearing.

Crusher: Every week, check the crusher blade gap (5-10mm); if worn, sharpen the blade with a grinding wheel (maintain a 30° edge angle). Every month, lubricate the crusher’s eccentric shaft bearing with calcium-based grease and clean the hopper to remove residual material. Test the crushing effect with waste—particle size should be 5-10mm; adjust the blade gap if too large.

6. Work Safety Specifications: How to Avoid Personal and Equipment Risks?

(1) Personal Protective Equipment (PPE) Requirements

Body Part	PPE Type	Standards & Specifications	Usage Notes
Head	Safety Helmet	GB 2811-2019, impact resistance ≥5000N	Adjust the chin strap to fit; hair must be tucked inside; replace if cracked
Eyes/Face	Anti-Impact Goggles	GB 14866-2006, anti-impact speed ≥120m/s	Wear when cutting/grinding; replace if lenses are scratched
Hands	Anti-Cut Gloves	EN 388 Level 5, cut resistance ≥20N	Use for metal handling; replace if holes appear
	Chemical-Resistant Gloves	Nitrile rubber, resistant to adhesives/thinners	Wear when handling chemicals; avoid contact with sharp objects
	Heat-Resistant Gloves	Aramid fiber, resistant to 200℃	Use for high-temperature parts; check for burns before use
Body	Anti-Static Work Clothes	Cotton blend, surface resistance ≤10¹¹Ω	No loose cuffs; button all fasteners; wash monthly
	Heat-Resistant Apron	Silicone-coated fabric, resistant to 300℃	Wear when operating heating units; avoid contact with moving parts
Feet	Safety Shoes	GB 21148-2020, toe impact ≥200J, puncture resistance ≥1100N	Check the steel toe for deformation monthly; replace if soles are worn

(2) Equipment Operation Taboos

① Mechanical Operation Prohibitions

Do not touch, wipe, or adjust moving components (composite rollers, cutting tools, chains) while the equipment is running. Even for foreign object removal, first press the emergency stop button and cut off power.

Do not remove safety devices (light curtains, guardrails, emergency stops). If a device is damaged, stop production immediately for repair—never start the equipment without protection.

Do not overload the equipment: do not exceed the rated daily output (e.g., 500㎡ for a medium-sized line) or the composite roller pressure (≤2.0MPa). Overload will cause permanent damage to motors and bearings.

Do not use metal tools (wrenches, screwdrivers) to block moving parts. In case of emergency, use the emergency stop button—never attempt "forced braking".

② Electrical Operation Prohibitions

Do not open the electrical cabinet or touch components (contactors, inverters) without cutting power. Even if the equipment is stopped, use a test pen to confirm no electricity before operation.

Do not modify electrical circuits or parameters (e.g., inverter acceleration time, PLC programs) without authorization. Adjustments must be made by certified electrical engineers and tested before mass production.

Do not operate switches, touchscreens, or plugs with wet hands. Clean water spills on the floor immediately to avoid short circuits. Do not stack flammable materials (adhesives, thinners) near the electrical cabinet.

③ Material Handling Prohibitions

Do not use unqualified materials: reject metal substrates with rust (area>5%) or core materials with moisture (Moisture content >5%). Unqualified materials cause equipment jamming and product defects.

Do not stack materials on the conveyor belt beyond limits: panels must not exceed the belt width, and stacking height ≤30cm. Overloading causes belt deviation or breakage.

Do not store chemicals randomly: adhesives and thinners must be kept in an explosion-proof warehouse (ventilated, temperature ≤25℃) with fire extinguishers and sand buckets. Seal containers after use to prevent volatilization.

(3) Emergency Response Procedures

① Personal Injury Handling

Mechanical Injury (Pinching/Cutting):

Press the emergency stop button immediately to cut power.

For pinching: Use a crowbar or jack to separate equipment parts slowly—do not pull the body forcefully.

For bleeding: Press the wound with a sterile gauze (press the proximal end of the artery for arterial bleeding). For deep wounds or heavy bleeding, wrap the wound with a sterile bandage and call 120 immediately.
Assign a dedicated person to protect the accident scene, record the time, equipment status, and operation process, and cooperate with the post-accident investigation.

Scalds (from High-Temperature Components/Molten Materials):

Quickly move the injured person away from the high-temperature area to avoid continuous heat exposure.

If clothing adheres to the scalded skin, do not peel it off forcefully—cut the surrounding clothing with scissors and retain the adhered part to prevent skin tearing.

Rinse the scalded area with flowing cold water (15-20℃) for 15-20 minutes to lower the skin temperature. For large-area scalds or scalds on the face/eyes, do not rinse—cover the area with a clean sterile gauze and seek medical attention immediately.

Apply scald ointment for minor scalds (no broken blisters). For severe scalds (broken blisters, skin carbonization), wrap the wound with a non-adherent sterile dressing and send the injured person to the hospital immediately; avoid pressing the wound during transportation.

Electric Shocks:

Cut off the power supply immediately (e.g., turn off the main switch in the distribution box, unplug the power cord). If direct power cutoff is not possible, use insulating tools (dry wooden sticks, insulating gloves) to separate the injured person from the power source—never touch the injured person with bare hands.

Move the injured person to a well-ventilated, dry area. Check their consciousness, breathing, and heartbeat: if unconscious, not breathing, or without a heartbeat, perform cardiopulmonary resuscitation (CPR) immediately and call 120.

If the injured person has electrical burns, treat the wounds according to the scald handling procedure—cover with a sterile gauze to prevent infection.

Inspect the electrical system for faults (e.g., line leakage, poor grounding). Only restart the equipment after repairing the fault and passing the inspection by a certified electrical engineer.

② Equipment Fault Emergency Handling

Equipment Fires (Electrical Short Circuits/Adhesive Combustion):

Cut off the equipment’s main power, air supply, and close the valves of flammable chemical containers to prevent fire spread.

For small fires (e.g., smoke from the electrical cabinet, local adhesive combustion), use a dry powder fire extinguisher (water-based extinguishers are prohibited for electrical fires) or fire sand to put out the fire. Stand upwind during extinguishing to avoid inhaling toxic fumes.

If the fire is uncontrollable, call 119 immediately and organize personnel to evacuate along the safe passage (do not use elevators). Confirm the number of evacuees at the assembly point to ensure no one is left behind.

After the fire is extinguished, conduct a comprehensive inspection of the equipment: replace burned electrical components (contactors, cables), clean fire residues, and test the equipment’s operation after repairs—only restart production if all functions are normal.

Equipment Jamming (Material Blockage/Component Seizure):

Press the emergency stop button to cut off power and prevent motor burnout due to overload.

Identify the cause of jamming:

1. If caused by material blockage (e.g., oversized panels, agglomerated core materials), remove the local protective cover of the equipment and use plastic tools to clear the blocked materials—never start the equipment to "force through" the blockage.
2. If caused by component seizure (e.g., composite roller bearing damage, conveyor chain breakage), disassemble the faulty components, replace damaged parts (bearings, chains), and recheck the fit gap of related components (e.g., composite roller parallelism, conveyor belt tension) after reassembly.
   
   

Clean residual materials and impurities inside the equipment, test the equipment with no load for 5 minutes, and confirm no jamming before resuming production.

③ Chemical Leakage Emergency Handling (Adhesives/Thinners)

Stop the Leak Source: Immediately stop the adhesive delivery pump and close the container valve to prevent further leakage. If the valve is damaged, plug the leak with a rubber stopper (compatible with the chemical) temporarily.

Evacuate and Isolate: Evacuate personnel within a 5-meter radius of the leakage area, set up warning signs, and prohibit unrelated personnel from entering. Prohibit open flames, smoking, or the use of electrical equipment in the leakage area to prevent explosions or combustion caused by volatile chemical vapors.

Contain and Clean:

For small leaks: Cover the area with oil-absorbing cotton/activated carbon to absorb the chemical; collect used absorbents into a sealed, labeled hazardous waste container.

For large leaks: First build a sand cofferdam to prevent chemical spread to sewers; then use a non-sparking pump (to avoid ignition) to transfer the leaked chemical to a dedicated collection container

Post-Cleanup: Rinse the leakage area with water (if the chemical is acidic/alkaline, neutralize with a weak acid/alkaline solution first, then rinse). Ventilate the area until no chemical odor remains before resuming work. Dispose of the hazardous waste in accordance with local environmental regulations—never dump it arbitrarily.

(4) Special Scenario Protection

① Cutting Link Protection

Dust Control: Install a bag-type dust collector above the cutting unit (air volume ≥2000m³/h) to collect metal dust. The dust concentration in the workshop should be ≤10mg/m³ (meeting GBZ 2.1-2019 standards). Operators must wear N95-grade dust masks (filter efficiency ≥95%) and replace the masks daily or immediately if they become damp/clogged.

Noise Reduction: Install a sound insulation cover around the cutting unit (noise reduction ≥20dB) to reduce the noise level from 95dB to ≤75dB. Operators must wear anti-noise earplugs (noise reduction ≥25dB) or earmuffs (noise reduction ≥30dB); the cumulative daily wearing time should not exceed 8 hours to prevent noise-induced hearing loss.

Tool Replacement Safety: When replacing cutting tools, fix the tool holder with a locking pin to prevent accidental rotation. Use a dedicated wrench to loosen/tighten the tool bolts—never hold the tool edge with hands. After installation, manually rotate the tool holder to check for interference with other components before starting the equipment.

② Heating Link Protection

High-Temperature Isolation: Install a guardrail (height ≥1.2m) around the heating unit and post a "High Temperature Hazard—No Unauthorized Entry" warning sign. The heating chamber door must be equipped with an interlock device: if the door is not closed tightly, the heating system will automatically shut down to prevent high-temperature gas leakage.

Heat Radiation Protection: Wrap the outer surface of the heating unit with high-temperature-resistant insulation material (aluminum silicate fiber, thickness 50mm) to reduce the surface temperature to ≤50℃. Operators working near the heating unit must wear heat-resistant aprons (silicone-coated, resistant to 300℃) and heat-resistant gloves; each continuous operation should not exceed 30 minutes to avoid heat exhaustion.

Waste Gas Treatment: If volatile organic compounds (VOCs) are generated during heating (e.g., adhesive volatilization), install an activated carbon adsorption device (adsorption efficiency ≥90%) to treat the waste gas before discharging it. Operators must wear gas masks with organic vapor filter cartridges (replace every 30 days or if an odor is detected).

③ Composite Link Protection

Pressure Safety: Install a pressure relief valve in the composite pressure system (set pressure 1.1 times the rated working pressure). When adjusting the pressure, increase it gradually (0.1MPa per adjustment) and observe the pressure gauge stability—never increase the pressure abruptly to avoid equipment damage.

Interlock Control: Set up interlock control between the composite unit and the conveying unit: if the conveying unit stops unexpectedly, the composite unit will immediately stop heating and pressurizing to prevent panels from being overheated/deformed in the composite roller. Test the interlock function once a week to ensure timely response.

Panel Handling: Composite panels have a surface temperature of 80-100℃ after compounding—use special fixtures with heat-resistant handles (e.g., aluminum alloy clamps) to transfer the panels. Place the panels on a dedicated cooling platform (covered with a heat-resistant rubber pad) and cool them to ≤40℃ before subsequent processing to avoid scalds or panel deformation.

7. Special Working Condition Adaptation: How to Ensure Production Under Low-Temperature, High-Humidity, and High-Dust Environments?

(1) Low-Temperature Environment Adaptation (≤5℃)

① Equipment Preheating and Insulation

Full-Machine Preheating: Before starting production in winter, preheat the electrical system (control cabinet, inverter) for 30 minutes, then preheat the heating unit to 50-60℃ for 1 hour. Start the power system (conveyor motor, hydraulic pump) for 30 minutes of no-load operation to raise the component temperature to ≥15℃—this prevents increased lubricating oil viscosity (which causes motor overload) and cooling water freezing.

Key Component Insulation: Wrap the composite roller with an electric heating mat (power 500W/m, temperature set to 20-30℃) and insulate the hydraulic oil tank with a rock wool layer (thickness 50mm). Add antifreeze (ethylene glycol, concentration 30%) to the cooling water to lower the freezing point to -15℃, avoiding pipeline freezing and cracking.

Workshop Heating: Install a hot air stove in the workshop to maintain the temperature at 10-15℃. For large workshops, build local insulation sheds (using color steel plates and rock wool) around the production line to reduce heat loss—focus on insulating the electrical control cabinet and heating unit areas.

② Material Pretreatment

Metal Substrates: Store substrates in a constant-temperature warehouse (15-20℃) to prevent surface condensation. If the substrate temperature is ≤5℃, preheat it in an oven (40-50℃) for 2 hours before production—this ensures good adhesion between the adhesive and substrate (avoiding bubbles caused by moisture).

Core Materials: For polyethylene/rock wool core materials, store them in a dehumidified warehouse (relative humidity ≤50%). Use a moisture meter to check the moisture content before use: polyethylene ≤0.5%, rock wool ≤3%. If moisture exceeds the standard, dry the core materials in an oven (60-80℃) for 4-6 hours.

Adhesives: Add a low-temperature thinner (5%-8% of the adhesive volume, e.g., ethylene glycol monobutyl ether) to reduce the adhesive viscosity to 1500-2500mPa·s (measured at 25℃). Store the adhesive in a constant-temperature warehouse (15-20℃) and stir it for 30 minutes before use to ensure uniform composition.

③ Production Parameter Optimization

Heating: Increase the heating temperature by 10-15℃ compared to normal temperatures (e.g., from 130℃ to 140-145℃ for aluminum-polyethylene panels) and extend the heating time by 20%-30% (e.g., from 5 minutes to 6-6.5 minutes). Use segmented heating (preheat: 120℃ → main heat: 145℃ → insulation: 135℃) to ensure uniform temperature distribution.

Pressure and Speed: Increase the composite pressure by 0.1-0.2MPa (e.g., from 1.0MPa to 1.1-1.2MPa) to enhance bonding between the substrate and core material. Reduce the conveyor speed by 10%-15% (e.g., from 8m/min to 7-7.2m/min) to give the adhesive sufficient curing time.

Cooling: Adopt progressive cooling—first cool the panels naturally in the workshop for 30 minutes, then use air cooling (air speed 3m/s) to lower the temperature to ≤50℃. Direct water cooling is prohibited to avoid panel warping due to large temperature differences.

(2) High-Humidity Environment Adaptation (Relative Humidity ≥85%)

① Electrical System Moisture Prevention

Control Cabinet Protection: Install a semiconductor dehumidifier (dehumidification capacity ≥100ml/day) in the electrical control cabinet to maintain the internal relative humidity ≤60%. Place a moisture-proof pad (rubber material, thickness 5mm) under the cabinet to prevent ground moisture seepage. Open the cabinet door for 30 minutes weekly for ventilation and wipe off condensation on components with a dry lint-free cloth.

Motor and Wiring: Apply waterproof sealant (silicone sealant) to the motor junction box to prevent moisture from entering the windings. Measure the motor winding insulation resistance monthly (≥1MΩ); if the resistance decreases, dry the motor with a hot air gun (temperature ≤80℃) to avoid short circuits. Wrap the sensor wiring connections with waterproof tape (e.g., 3M Scotch 33+ tape) to prevent signal interference caused by moisture.

Sensor Selection: Use waterproof sensors with a protection class of ≥IP65 (e.g., Omron E8F2 pressure sensors, K-type thermocouples with waterproof sheaths). Clean the sensor probes every two weeks with alcohol to remove condensation and ensure accurate measurements.

② Material Moisture Prevention

Metal Substrates: Store substrates on pallets ≥30cm above the ground, cover them with plastic film, and place desiccants (calcium chloride, 1kg per 10㎡) around the storage area. If the substrate surface rusts, polish the rusted area with 1200-grit sandpaper and apply a thin layer of anti-rust oil (e.g., WD-40 Specialist Long-Term Corrosion Inhibitor) to prevent further rusting.

Core Materials: Inorganic core materials (rock wool, glass wool) must be sealed in moisture-proof packaging; open packages must be used within 24 hours. Unused core materials should be sealed with plastic film and stored in a dehumidified warehouse. For organic core materials (polyethylene), bake them in an oven (50℃) for 1 hour before use to remove absorbed moisture.

Adhesives: Store adhesives in a cool, dry warehouse (temperature 15-25℃, relative humidity ≤50%). After opening the adhesive container, seal it tightly after each use. If the adhesive stratifies due to moisture, stir it thoroughly for ≥15 minutes; if it cannot return to a uniform state, discard it to avoid affecting bonding quality.

③ Production Process Adjustment

Coating: Increase the adhesive coating amount by 10%-15% (e.g., from 80g/㎡ to 88-92g/㎡ for aluminum-polyethylene panels) to compensate for the slow drying speed in high humidity. Add a pre-drying step before compounding: heat the coated substrate to 60-70℃ for 10-15 minutes to remove moisture from the adhesive layer and prevent bubbles.

Compounding: Raise the composite temperature by 5-10℃ (e.g., from 130℃ to 135-140℃) and extend the dwell time by 10-15 seconds (e.g., from 20 seconds to 30-35 seconds) to ensure the adhesive fully cures. After compounding, use a hair dryer (low wind speed, 40-50℃) to dry the panel surface and prevent water spots.

Quality Inspection: Increase the frequency of post-production inspections—check for bubbles, delamination, and flatness every 30 minutes. For panels with minor defects (e.g., small surface bubbles), dry them in an oven (50-60℃) for 2 hours and re-inspect; discard severely defective panels to avoid affecting subsequent processes.

(3) High-Dust Environment Adaptation

① Equipment Dust Prevention

Sealing and Shielding: Install dust covers on the electrical control cabinet, motor, and composite roller bearing seats—choose covers with a rubber sealing edge to prevent dust entry. Install dust curtains (PVC material, height 2m) around the cutting and conveying areas to isolate the dust source. Add dust-proof caps to the air inlet of the pneumatic system and replace the air filter element (10μm precision) weekly.

Regular Cleaning: Formulate a daily cleaning schedule:

After production, use compressed air (0.4-0.6MPa) to blow dust from the cutting platform, composite roller surface, and conveyor belt.

Wipe the electrical control cabinet, sensor probes, and laser positioning emitter with a dust-free cloth daily.

Clean the workshop floor with a vacuum cleaner (equipped with a HEPA filter) to avoid dust accumulation and secondary pollution.

Component Protection: For moving components such as the cutting tool holder’s ball screw and conveyor chain, apply a dust-proof grease (e.g., Mobil Polyrex EM) to form a protective film. Check the grease condition weekly and replenish if it becomes contaminated with dust.

② Material and Process Adaptation

Material Storage: Store metal substrates and core materials in sealed warehouses or covered with dust-proof cloths. Before putting materials into the production line, clean the surface with low-pressure compressed air (0.2-0.3MPa) to remove dust—this prevents dust from mixing with the adhesive and affecting bonding strength. For core materials prone to dust absorption (e.g., rock wool), use vacuum packaging and open it only at the feeding port of the production line to minimize dust contact.

Process Optimization: Reduce the cutting speed by 10%-15% (e.g., from 8m/min to 7-7.2m/min) to reduce dust generation caused by high-speed friction between the tool and material. Increase the flow rate of the cooling lubricant (by 20%-30%) during cutting to suppress dust dispersion and cool the tool at the same time. After compounding, wipe the panel surface with a clean lint-free cloth to remove surface dust—this improves the product’s appearance quality and avoids dust-induced paint defects in subsequent processes.

③ Personnel Protection Enhancement

Respiratory Protection: Provide operators with N95-grade dust masks (or powered air-purifying respirators for high-dust areas) and require them to replace the filter cartridges every 3 days (or immediately if breathing resistance increases significantly). Conduct monthly training on correct mask wearing to ensure a tight seal between the mask and the face—this reduces dust inhalation by over 90%.

Body Protection: Equip operators with dust-proof work clothes (with hoods) and anti-static shoes. The work clothes should be washed weekly with a high-pressure water gun to remove accumulated dust; damaged clothes (e.g., with holes) must be replaced immediately to prevent dust from entering the clothing and irritating the skin.

Health Monitoring: Arrange annual occupational health examinations for operators in high-dust areas, focusing on lung function and chest X-rays. Establish health records for each operator to track long-term health changes and adjust job positions in a timely manner if abnormal conditions are found (e.g., decreased lung function).

8. Conclusion: Core Practical Insights for the Metal Composite Panel Production Line Series

The stable and efficient operation of the Metal Composite Panel Production Line Series relies on systematic control of the entire production chain—from pre-startup inspection to post-production maintenance, from fault handling to special environment adaptation. The following summarizes the core practical points of this guide to help enterprises and operators translate technical details into practical benefits:

(1) Lay a Solid Foundation with Pre-Startup Inspection and Parameter Adjustment

Pre-startup inspection is the "first line of defense" for production safety and product quality. Focus on three key dimensions: mechanical precision (composite roller parallelism ≤0.05mm, cutting tool coaxiality ≤0.03mm), electrical stability (insulation resistance ≥1MΩ, ground resistance ≤4Ω), and material qualification (adhesive viscosity 1500-2500mPa·s, core material moisture content ≤5%). When adjusting parameters, adapt to material characteristics: thin panels (≤3mm) require higher conveyor speeds (7-8m/min) and lower pressure (0.8-1.0MPa), while thick panels (>8mm) need segmented heating (180-200℃) and extended dwell time (30-40 seconds). This targeted adjustment ensures the product qualification rate remains above 98%.

(2) Minimize Downtime with Rapid Troubleshooting

Most production failures can be resolved within 10 minutes with clear troubleshooting logic:

For composite quality issues (bubbles, delamination), prioritize checking adhesive coating amount, heating temperature, and material cleanliness—adjust coating pressure by 0.1-0.2MPa or increase heating temperature by 5-10℃ to quickly restore quality.

For equipment operation faults (conveyor jamming, cutting deviation), focus on mechanical wear and positioning accuracy—clean foreign objects in the conveyor track or calibrate laser positioning (deviation ≤0.1mm) to resume production.

For electrical system failures (black screen, motor non-startup), first check power supply and safety components—reset tripped switches, replace blown fuses, or test emergency stop functions to eliminate risks.

By mastering these 'quick fixes,' enterprises can reduce annual downtime by over 300 hours and avoid raw material waste of more than 500㎡.

(3) Reduce Costs Through Systematic Optimization

Cost control should cover the entire production process, with three key breakthrough points:

Raw material waste reduction: Use nesting software to increase substrate utilization to over 95%, splice scrap ≥100mm for small parts, and recover metal scrap (aluminum recovery rate ≥90%)—this cuts raw material costs by 15%-20%.

Energy efficiency improvement: Adopt segmented heating and waste heat recovery to save 15-20kWh of electricity per hour; replace resistance heating tubes with electromagnetic ones to reduce energy consumption by 25%-30%; equip motors with frequency converters to avoid no-load energy waste.

Auxiliary material saving: Implement quantitative lubrication to reduce grease consumption by 30%-40%; recycle cooling emulsion (service life extended to 3-4 months); use reusable plastic turnover boxes instead of disposable cartons—these measures save over 50,000 yuan in annual auxiliary material costs.

(4) Extend Equipment Life with Targeted Maintenance

A scientific maintenance plan can extend the production line’s service life to over 8 years. Focus on four systems:

Core production components: Clean composite rollers daily, calibrate parallelism quarterly, and polish tool edges every 4 hours of operation.

Vulnerable parts: Replace conveyor belts every 6-8 months, change hydraulic oil every 3 months, and inspect pneumatic seals weekly.

Electrical system: Clean the control cabinet monthly, calibrate sensors quarterly, and test safety devices daily (emergency stop, light curtain).

Auxiliary systems: Drain cooling water tank sediment weekly, clean crusher blades monthly, and replace air compressor filters every 3 months.

By avoiding "over-maintenance" and "under-maintenance," enterprises can reduce annual maintenance costs by 25% while ensuring equipment reliability.

(5) Ensure Safety and Stability in Special Environments

Harsh environments (low temperature, high humidity, high dust) require customized solutions:

Low-temperature (≤5℃): Preheat equipment for 1-1.5 hours, insulate key components (composite rollers, hydraulic tanks), and preheat substrates to >15℃—this prevents equipment jamming and adhesive curing failure.

High-humidity (≥85%): Install dehumidifiers in control cabinets, use waterproof sensors (IP65), and increase adhesive coating amount by 10%-15%—this avoids electrical short circuits and composite layer bubbles.

High-dust: Add dust covers to equipment, clean daily with compressed air, and provide N95 masks for operators—this reduces equipment wear and protects personnel health.

In summary, the Metal Composite Panel Production Line Series is not just a set of mechanical equipment, but a systematic project integrating "operation, maintenance, cost control, and safety management." By implementing the practical points outlined in this guide, enterprises can achieve a balance between production efficiency, product quality, and cost optimization, while building a safe and sustainable production model. In future operations, it is also important to continuously collect production data (output, energy consumption, waste rate), analyze optimization space, and adjust strategies according to changes in product types and market demands—this is the key to maintaining long-term competitiveness in the metal composite panel industry.