Fault Diagnosis and Troubleshooting of Pharmaceutical Cartoning Machines
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This article aims to comprehensively introduce common faults of pharmaceutical cartoning machines and their diagnosis and troubleshooting methods. By deeply analyzing possible faults in mechanical components, electrical systems, material conveying, and operational stability, it provides practical technical references for equipment maintenance personnel and engineering technicians in pharmaceutical enterprises, ensuring the efficient and stable operation of pharmaceutical cartoning machines and guaranteeing the continuity and quality of drug packaging production.
I. Introduction
Pharmaceutical cartoning machines play a crucial role in modern drug packaging production. They can automatically load drugs into cartons and complete a series of packaging processes, greatly improving production efficiency and the consistency of packaging quality. However, like any mechanical equipment, pharmaceutical cartoning machines will inevitably encounter various faults during operation. Timely and accurate diagnosis and troubleshooting of these faults are of great significance for maintaining the normal order of drug production, reducing production costs, and ensuring drug quality and safety.
II. Fault Diagnosis and Troubleshooting of Mechanical Components
(A) Faults in Carton Picking and Conveying
Fault Phenomena
The carton picking is not smooth, with cases of missed picking or inaccurate picking positions.
The cartons get jammed or deviated during the conveying process, preventing them from entering the cartoning station normally.
Diagnosis Methods
Check whether the vacuum suction cups are damaged or clogged, and examine whether the suction force of the suction cups is sufficient. A vacuum gauge can be used to measure the vacuum degree of the suction cups.
Troubleshooting Measures
If the suction cups are damaged, replace them promptly. If the suction cups are clogged, clean the suction cups and their connecting pipes to ensure smooth air passage.
Remove foreign objects from the carton conveying track and adjust the flatness and width of the track to match the carton size well. In case of severe deformation of the track, it may be necessary to repair or replace the track.
Adjust the parameters of the carton pushing mechanism, such as the stroke and speed of the cylinder, to ensure stable and reliable pushing actions. If the position of the pushing rod is inaccurate, recalibrate its position.
(B) Faults in Drug Pushing and Loading
Fault Phenomena
The drugs are not pushed into place, and some drugs cannot be accurately dropped into the cartons.
The drugs are damaged during the loading process.
Diagnosis Methods
Inspect the mechanical structure of the drug pushing device, including components such as the pushing plate and guide rail for wear or deformation. Check whether the operation of the pushing motor or cylinder is normal, without jamming or insufficient force.
Observe whether there is blockage or a narrow section in the drug loading channel and check for residual drugs or foreign objects in the channel.
Evaluate the size matching between the drugs and the cartons to determine if there are difficulties in loading due to oversized or undersized drugs.
Troubleshooting Measures
Repair or replace worn or deformed parts of the pushing device's mechanical structure. Adjust the parameters of the pushing motor or cylinder, such as torque and pressure, to ensure sufficient and stable pushing force.
Clean the residual drugs and foreign objects in the drug loading channel and appropriately widen or repair the narrow sections to ensure smooth passage.
If there is a size mismatch between the drugs and the cartons, negotiate with the drug production department or carton supplier to adjust the size specifications of the drugs or cartons for better compatibility.
III. Fault Diagnosis and Troubleshooting of Electrical Systems
(A) Control System Faults
Fault Phenomena
The cartoning machine fails to start normally after power-on, and the control system does not respond.
Program errors or system crashes occur during operation.
Diagnosis Methods
Check the hardware devices of the control system, such as the PLC (Programmable Logic Controller), touch screen, and industrial computer, for any fault indicator lights. Examine whether the connection cables between the hardware devices are loose or damaged.
Analyze the software program of the control system to check for error alarm messages and determine if there are logical errors or data loss. Comparison and analysis can be carried out with the backup program.
Troubleshooting Measures
Repair power line faults and replace blown fuses to ensure stable power supply. If the power voltage is abnormal, check the power supply equipment or adjust the output voltage of the power transformer.
For hardware devices with fault indicator lights, perform fault diagnosis and repair according to the equipment manual. Re-plug the connection cables to ensure a firm connection. If the hardware device is damaged, replace it promptly.
Modify and optimize the software program based on the error alarm messages and backup program to fix logical errors and data loss. If necessary, contact the control system software supplier or professional technicians for technical support.
(B) Sensor Faults
Fault Phenomena
The carton detection sensor malfunctions, resulting in incorrect carton counting or the inability to detect the carton position normally.
The drug detection sensor fails, causing inaccurate drug loading quantity or misjudgment of the presence of drugs.
Diagnosis Methods
Check the installation position of the sensor to ensure it is correct and not loose or displaced. Wipe the sensing head of the sensor with a clean cloth to remove dust or dirt.
Measure the output signal of the sensor to determine if it is normal. Tools such as an oscilloscope or multimeter can be used for detection. Compare the output signal of the sensor during normal operation with that during a fault to judge whether the sensor is damaged.
Check whether the connection lines of the sensor are broken, short-circuited, or have poor contact. Examine whether the line connectors are oxidized or corroded.
Troubleshooting Measures
Readjust the installation position of the sensor to ensure accurate detection of the target object. If the fault persists after cleaning the sensing head, the sensor may need to be replaced.
If the sensor output signal is abnormal, repair it according to the type and cause of the signal abnormality. For a damaged sensor, replace it with the same model in a timely manner and connect the lines correctly. Repair broken, short-circuited, or poor-contact connection lines and handle oxidized or corroded connectors by methods such as grinding and cleaning before reconnecting.
IV. Fault Diagnosis and Troubleshooting of Material Conveying
(A) Carton Feeding Faults
Fault Phenomena
The supply of cartons in the carton hopper is not timely, resulting in a shortage of cartons.
The cartons get jammed or piled up in the hopper and cannot enter the conveying track smoothly.
Diagnosis Methods
Check the structural design of the carton hopper to determine if there are dead corners or narrow sections where cartons can get stuck. Observe the arrangement of cartons in the hopper to ensure they are neat and orderly.
Evaluate the quality and size consistency of the cartons to determine if there are feeding problems due to deformed or dimensionally deviated cartons.
Troubleshooting Measures
Optimize the structure of the carton hopper to eliminate potential jamming points, such as adding guide plates and adjusting the hopper slope. Organize the arrangement of cartons in the hopper to facilitate conveying.
Repair or replace faulty components of the carton lifting or pushing mechanism and adjust the parameters of the motor or cylinder to ensure stable and reliable lifting and pushing actions.
Communicate with the carton supplier about cartons with unsatisfactory quality and size requirements and ask them to improve the production process to enhance carton quality and size consistency.
(B) Drug Feeding Faults
Fault Phenomena
The drug supply in the drug hopper is interrupted, resulting in an empty hopper.
The drugs clump or get blocked in the hopper and cannot flow out for feeding normally.
Diagnosis Methods
Check whether the material level sensor of the drug hopper works properly and can accurately detect the remaining amount of drugs. Examine whether the outlet of the hopper is blocked by foreign objects and check the working status of the outlet valve or vibrating feeder.
Analyze the physical properties of the drugs, such as whether they are prone to moisture absorption and caking and whether their fluidity is good. Check whether the humidity and temperature of the drug storage environment meet the requirements.
Observe the flow of drugs in the hopper to determine if there are bridging or rat-holing phenomena. Auxiliary judgment can be made by tapping the hopper wall or using a stirring device.
Troubleshooting Measures
Repair or replace the drug level sensor to ensure it can detect the drug remaining amount accurately and send signals in a timely manner. Clean the foreign objects at the outlet and repair or adjust the parameters of the outlet valve and vibrating feeder to ensure smooth drug outflow.
Improve the drug storage environment according to the physical properties of the drugs, such as controlling humidity and temperature to prevent drug caking. For drugs prone to caking, install a stirring device in the hopper or adopt fluidization technology to improve drug fluidity. If there are bridging or rat-holing phenomena, solve them by tapping the hopper wall, installing an arch-breaking device, or adjusting the hopper structure.
V. Fault Diagnosis and Troubleshooting of Operational Stability
(A) Speed Matching Faults
Fault Phenomena
The speeds of various working components of the cartoning machine do not match, resulting in 不协调 between carton and drug loading, such as drugs overflowing the cartons or incomplete carton sealing.
Diagnosis Methods
Check the main transmission system of the cartoning machine, including the operation speed of components such as the motor, reducer, and transmission shaft. Use a tachometer to measure the rotational speeds of key parts and compare them with the speed parameters required by the equipment design.
Analyze the speed setting and adjustment mechanism in the control system for each working component. Check for any speed setting errors or unreasonable adjustment parameters. Examine whether the speed sensors work properly and whether their feedback signals are accurate.
Observe the actual operation of the carton conveying, drug pushing, and carton sealing working components to evaluate their action coordination and determine if there are obvious delays or advancements.
Troubleshooting Measures
Perform maintenance on the main transmission system, such as cleaning the motor cooling fan, checking the lubricating oil level of the reducer, and tightening the connection parts of the transmission shaft to ensure stable operation. If there are speed fluctuations or abnormalities, check the power supply of the motor and the parameters of the frequency converter and make corresponding adjustments or repairs.
Reset and optimize the speed parameters of each working component according to the actual operation of the equipment and process requirements. Check the installation position and working status of the speed sensors to ensure accurate feedback of speed signals for reliable speed regulation by the control system.
Improve the action coordination between working components by adjusting the transmission ratio between them and optimizing the action sequence in the control system to ensure accurate matching between carton and drug loading.
(B) Vibration and Noise Faults
Fault Phenomena
The cartoning machine generates excessive vibration and noise during operation, affecting the stability of the equipment and the working environment.
Diagnosis Methods
Check the mechanical structure components of the cartoning machine, such as the motor, reducer, transmission gears, and bearings, for looseness, wear, or imbalance. Use a vibration measuring instrument to measure the vibration amplitude and frequency of key parts to identify the vibration source.
Analyze the source of the noise, whether it is mechanical friction noise, air flow noise, or electrical noise. For mechanical friction noise, focus on checking the lubrication condition and fit clearance of the friction parts. For air flow noise, check for air leakage or unsmooth air flow in the air circuit system. For electrical noise, check the shielding and grounding of electrical equipment.
Troubleshooting Measures
Reinforce the installation foundation of the equipment, tighten the anchor bolts. If there is foundation settlement, repair it in a timely manner. Avoid resonance by adjusting the operating speed of the equipment or installing vibration damping pads and dampers between the equipment and the foundation.
Take corresponding measures according to the source of the noise. Improve the lubrication condition of friction parts and adjust the fit clearance to reduce mechanical friction noise. Repair air leakage points in the air circuit system and optimize the air flow path to reduce air flow noise. Strengthen the shielding and grounding measures of electrical equipment to reduce electrical noise affecting the equipment and the environment.
VI. Conclusion
Fault diagnosis and troubleshooting of pharmaceutical cartoning machines is a complex and crucial task that requires equipment maintenance personnel and engineering technicians to possess solid professional knowledge in mechanical, electrical, and other fields as well as rich practical experience. By deeply understanding and mastering common faults in mechanical components, electrical systems, material conveying, and operational stability, it is possible to quickly and accurately diagnose the causes of faults and take effective troubleshooting measures to ensure the efficient and stable operation of pharmaceutical cartoning machines. In daily work, it is also necessary to strengthen the maintenance of cartoning machines, establish a complete equipment file and fault record, and conduct regular inspections and preventive maintenance on the equipment. This can reduce the fault occurrence rate, improve the efficiency and quality of drug packaging production, and provide a strong guarantee for the development of pharmaceutical enterprises.
Susan Lin
Hei , I am Susan Lin, the sales manger of Yile Machinery and I have been working for cartoning machine and case packing machine more than 15years.I would like to share my experience in this field. I am specialist of our packaging machine ,if you interesting our machine ,we can discuss and exchange technology of machine ,also give you good solution .
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