#J3000 - J4000 Troubleshooting Slitting Front Page July 2016
Javelinthe leading edge in converting technology for the Paper Film and Foil industriesModel: J3000 – J4000 seriesAUTOMATIC SINGLE KNIFESLITTERALL J3000 & J4000 MODELSJ4000 SERIESJULY 2016TROUBLESHOOTING HANDBOOKSLITTINGPROBLEMSJavelin Machinery (Australia)A.C.N. 005 543 411 ABN 18 005 543 411Email: sales@javmach.com.auWebsite: www.javelinmachinery.com.auHEAD OFFICEPO Box 805, Glen Waverley Vic 3150 AustraliaPhone: 61 3 8786 3614
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000IMPORTANT NOTESINGLE KNIFE SLITTINGThe principle on which this type of slitting is based, depends onthe knife being able to displace the roll width being slit.Materials which are too dense or have been wound too tightlymay be unsuitable to slit by this method.In this case either the roll must be rewound to a lesser tension orthe material cut on a machine known as a slit/rewinder.Knife parameters are crucial in successful Single Knife Slitting(Refer Knife Selection Section)As widths being slit increase so must the secondary or back bevelon the knife in order to balance the forces and achieve a straightcut.Failure to pay attention to choosing a knife with the correct bevelwill result in the knife chipping or in an extreme case shatter.An Operation & Maintenance Manual was supplied with machine,all operators should study and understand manual beforeoperating machineJavelin Machinery (Australia)1 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000OPERATOR SAFETYPLEASE NOTE FOLLOWING BEFORE COMMENCING OPERATION:Safety should be a constant concern of everyone around any type of machinery.While more than normal precautions were taken in the manufacture of this machine,everyone connected with its operation should be made fully aware of the HighVoltages, High Speed Motion and Sharp, Rotating Automatically ActuatedCutting Tools involved.To prevent injury, the suggestions below should be followed:1. KEEP CLEAR of cutting blade, rotating mandrel, chuck and material when themachine is in motion.2. ENSURE all GUARDS in position & safety systems operational before startingthe machine.3. DO NOT place your hands between the knife and rolls when loading orunloading. ENSURE knife is in its furthest back position.4. KEEP the area around the machine CLEAN and DRY proof surface or mats.Only the operator to work within area designated by hazard tape.5. ENSURE main isolator is switched OFF before any maintenance is carried out.6. USE suitable PROTECTIVE GLOVES when handling blades.7. Ensure KNIFE IS REMOVED OR KNIFE EDGE COVERED with the flexibleplastic cover provided when servicing or cleaning and when machine not in use.8. Request ASSISTANCE when CHANGING knives or LOADING heavy materialonto the mandrel.9. Ensure operators & maintenance personnel have read and understood theManual before operating or carrying out maintenance on this machine.Ensure only qualified electricians work on the electrical components of themachine. Operators must not open the electrical cabinet, motor drive cabinetor operator panel. In the case of an electrical malfunction qualified electricalpersonnel/contractor should be called.2 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000PRINCIPLES OF SINGLE KNIFE SLITTINGSlitting by the single knife method is basically the ability of a circular knife todisplace the slit roll as it enters the log.Single knife slitting is not a precise science. Slitting results are affected by anumber of factors including: the type of backing (i.e. Polyester/Cloth/Foam)evenness of adhesive coating,tension under which the log has been wound toknife diameterknife sharpness or dullnessair or room temperatureWhile Javelin can recommend settings for different products and widths, theoperator must be aware of the factors mentioned and make adjustmentsaccordingly. ALWAYS USE HIGH CHROME HIGH CARBON STEEL KNIVES. CHROMECONTENT RETAINS THE KNIFE EDGE (DURABILITY) WHILE THE CARBONIS FOR HARDNESS. ENSURE KNIVES RUN TRUE – CHECK WITH A DIALINDICATOR. THE RULE IS TO USE THE SMALLEST DIAMETER KNIFE TOMINIMIZE RUNOUT AND GET BEST RESULTSCAUTION always use cut resistant gloves when handling knives ONLY PERSONNEL CERTIFIED TO SHARPEN AND BEVEL KNIVES SHOULDOPERATE KNIFE GRINDING FUNCTION3 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000TROUBLE SHOOTINGIMPORTANT NOTE: Condition of the log roll will affect quality of slit rolls.Read the page headed “Principles of Single Knife Slitting”.SLITTING PROBLEMS – PAPER & FILM TAPES*PROBLEM/EFFECTTape tears as itunwound.is Width varies from roll to roll. Wornorundersize mandrel sleeves Speed of knife entry unsuitablePoor fit of core to mandrel sleeve* Sometimes referredto as double cutting asthe knife makes twovery small cuts onentry into the tape.CAUSEKnifediameter unsuitableKnife running out of tolerance SLITTING PROBLEMSREINFORCED TAPESPROBLEM/EFFECTSlit roll “telescopes” after slitting –PAPER,REMEDIESAlways use smallestdiameter knife possibleCheck backing platesand knife surface areclean and re-sharpenknife and ensure it isrunning true.Replacemandrelsleeves/checkknife'stop' set correctlySlow down knife forwardspeedSpecify correct core I/Dto manufacturer or usealternate mandrel withspecialsizerubbersleeve (see Javelin)FILM,CAUSETension problem during loggingKnife edge unsuitable Unevencoatingof adhesive causes tightand loose sections inlog.CLOTHREMEDIESRewind log roll to moreeven tensionDullknivescancontributetothisproblem - sharpen knifeSlit up log separatingtight and loose sectionsand rewind each sectionto acceptable tensionusing J1000 Rewinder.SLITTING PROBLEMS – ALL ADHESIVE TAPESPROBLEM/EFFECT'Inside of cardboard core disintegrates' core collapsesmaking tape difficult toremove off Mandrel - usuallyoccurs when slitting narrowwidths. CAUSELubrication problem Knife edge dullWorn mandrel sleeve REMEDIESExcessive spray oncardboard cores whenslitting narrow widths.Restrict spray or useplastic cores (especiallyon narrow widths)Sharpen knifeReplace mandrel sleeve& check forward stop setcorrectly4 Page&
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000SLITTING PROBLEMS – COPPER ALUMINIUM FOILSPROBLEM/EFFECTSelf wound foil tapes, copper, aluminium, lead,tear when being unwoundafter slittingCAUSEKnife rolls edge over, causing tape to tearwhen unwoundREMEDIESInterlinefoilbeforeslitting to eliminate thisproblemSLITTING PROBLEMS – SINGLE SIDED FOAM SEALANTTAPESPROBLEM/EFFECTFoam tape with paper interliner leaves paper onadhesive side after slitting. CAUSEKnife edge dullInterliner breaks when slit roll is unwound.Toomuchlubricant spray that is absorbedby paper interliner. Knife rpm, mandrel rpm incorrect for product Poorqualityappearance.cutSoft “Open Cell Foam”Knife chews up foamand Knife RPM is too low or too high. Sprays not directed towards edge of knife Leading edge of material facing wrong way. Chuckrunningin reverse.Knife edge breaks down or becomes dull. Sprays not directed towards edge of knifeREMEDIESKnife edge must be keptsharpA table can be suppliedshowing rpm settings forboth knife & mandrelspeed.Use plastic liner orpaper siliconised onboth sides.Cut back on spray.Try silicon lubricant inlieu of detergent.Experiment with eitherlower or higher knifespeeds.Angle sprays at the knifebevel and in such a waythat the overspray isdirected towards thecentre of the knife.Flap or leading edge offoam must face awayfrom the operator.Run the chuck inforward direction.UseHighChromekniveswhichretainsharp edge longer andfor soft open cell foamsonly run chuck inreverse.Angle sprays at the knifebevel and in such a waythat the overspray isdirected towards thecentre of the knife.5 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000SLITTING PROBLEMS – DOUBLE SIDED FOAM MOUNTINGTAPESPROBLEM/EFFECTCAUSESticky edges and Knife bevel unsuitablegenerallypoorquality appearanceREMEDIESExperiment with driving the knife keepingthe RPM low and also a lowerChuck/mandrel speed. When driving theknife ensure that the chuck switch is inthe forward mode. Do not allow the knifeto overheat. An indication of too muchheat is the slit roll will have sticky sides.In this case lower knife RPM or switch offthe knife drive and allow the knife torotate freely. Using the knife brake mayalso help.Sprays not directed Angle sprays at the knife bevel in such atowards edge of knife.way that the overspray is directedtowards the centre of the knife.Leadingedgeofmaterial facing wrongway.Chuckrunninginreverse.Slit rolls have a Liner has moved offstepped appearance tape.Double cutting on Knife edge too sharp.plastic liner.Flap or leading edge of foam must faceaway from the operator.Run the chuck in forward direction.Warm tape prior to slitting in temperaturecontrolled cabinet.Round off cutting edge of knife.SLITTING PROBLEMS – ALL TAPESPROBLEM/EFFECTAdhesive smearing on sides of rolls.CAUSEKnifethickness unsuitable. Knifeunsuitable. Knifeproblem. Knife or chuck RPM unsuitableWrong choice of bevel.Knifebevel unsuitableKnife entry speedunsuitable Concave or convex roll at beginning and end of logroll width of roll varies from I/D to O/D.edge lubrication REMEDIESTry using thinner blade forbetter displacement i.e. 1/16thin lieu of 1/8”.Depends on product beingslit. Knife edges that are verysharp can sometimes causethis problem -round off knifeedge.Insufficient spray directed atknife bevel and upwardstowards centre of blade.Reduce knife or mandrelRPM.See knife selection chart.Problem can be reducedwithout changing knife for firstand last cut by slowing downknife entry speed.6 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000SLITTING PROBLEMS – SIGN VINYLS & INTERLINEDMATERIALSPROBLEM/EFFECTWidth varies from outsidediametertoinsidediameter of slit roll atchuck end of log roll.CAUSEREMEDIESAs these materials are not Bond end of log roll with fastbondedtogetherwith drying resin (Hot melt glue).adhesive, the layers moveaway unevenly as knifepenetrates rollSLITTING PROBLEMS – TEFLONS (PTFE)PROBLEM/EFFECTCAUSESoft adhesive coated No back bevel on knife.tapes such as Teflon areleft with raised ridge onone side of roll. REMEDIESGrind No. 2 diagram backbevel on knife to minimiseproblem.Use 1/16” thick knife.SLITTING PROBLEMS – TIGHTLY WOUND, HIGH DENSITYADHESIVE TAPESPROBLEM/EFFECTKnife-edge shatters. CAUSEKnife bevel too sharp. Very thick/hard cores. Knife depthcorrectly andmandrel.Trying to cut awith no backknife. not set hits steelwide width bevel onREMEDIESRegrind and round offknife edge.Use cores with thinnerwall.Adjust forward stop andcheck knife spindle notdamaged.Use a knife with suitableback bevel (see knifeselection chart)SLITTING PROBLEMS – FABRICS(see also trouble shooting for Signs Vinyls – Interlined Adhesive Tapes – Fabrics)PROBLEM/EFFECTSmall strands on outer edge of large diameter materials ofa type used to manufacturevertical blinds.CAUSELoosely wound log roll Knife RPM too slow Increase knife RPMspeed. Chuck RPM too highDull knife edge Decrease RPM Re-sharpen (must bekept sharp).Use High Chromesteel knife.Increaseforwardspeed.Re-sharpen With softer fabrics the sides of the roll can exhibit afibrous web of strands of material which have to be cut through before the roll canbe unwound.Knife forward speed to slowBurrs on knife edge Not enough Back Bevel REMEDIESWrap log roll in stretchfilm. Rewind log roll.Increase back bevel7 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000SLITTING PROBLEMS - HOT STAMP FOILPROBLEM/EFFECTEdge of knife shatters CAUSEFoil wound too tight Insufficientfriction. Knife too sharpknife brake REMEDIESRewindtosoftertensionTighten brake so knifeturns only when cuttingthrough core.Slightly round cuttingedge of knifeTROUBLE SHOOTING – SAW CUTTINGPROBLEM/EFFECTSaw tooth knife stalls during cutting cycle. For best results run knife inreverse.CAUSESaw teeth dull Insufficient Lubricant. Saw RPM too high Mandrel RPM too high or too low.REMEDIESRe-sharpenMaximumlubricantspray to keep saw fromoverheating.Directspray onto saw .Set at approximately150 – 200 RPM.TROUBLE SHOOTING – KNIFE GRINDINGPROBLEM/EFFECTKnife vibrates when being ground leaving scallopededge on knife.Usuallyoccurs with large diameter knives. CAUSELooseknifebearingsspindle backing plate bent or no longer concaveloose grinding wheel on grinder motor shaft REMEDIESSlightly raise or lowerknife RPMTighten knife spindlebearingsreplace backing platetighten grinding wheel8 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000SLITTING TECHNIQUESSLITTING INTERLINED MATERIALSAny interlined material especially large diameters need to be glued with a hot melt glueat the chuck end only, to prevent the centre of the log roll slipping away whilst it is beingcut.When slitting non-adhesive products such as Polyester, Polyimide Film and Electrical,insulation papers, a much shorter main bevel is needed on the knife to prevent thecutting edge chipping, this bevel is called a number 2 bevel and can be ground on theKnife Grinder.Note: When slitting copper, lead or aluminium foil whether or not coated with apressure sensitive adhesive, an interlining paper is essential to achieve qualityslit rolls.SAW CUTTINGSome products which are extremely dense and cannot be slit by the normaldisplacement blade method can be slit by an alternative system using a saw tooth knife.To successfully sawcut materials such as heatshrink packaging film, polyethyleneprotective film and similar products. Javelin can be consulted for slitting instructions forspecific products.9 Page
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000KNIFE SELECTION always use cut resistant gloves when handling knives KNIFE BEVELS When slitting narrow widths only a primary bevel is requiredbut with wider widths a back bevel is needed to balance the forces on eitherside of the knife so that it will cut straight through the roll without deflecting(See note re bevels below)CAUTION: Knife may be damaged or shatter if insufficient back bevel on knifewhen slitting wide widths. Trying to slit a roll to a wide width from a tightly woundlog roll, using a knife with insufficient back bevel, risks chipping or shattering the knife.Diagram No.12345Slitting rangeUp to 22 mm (7/8”)25.4 mm (1”) - 38 mm (1½”)40 mm (1 5/8”) - 96mm (4”)Over 100mm (4”)Any width (very hard materials)Dense materials that will not displaceKnife requirementsNo Back Bevel0.5 mm (1/64”) Back Bevel1.5 mm (1/16”) Back BevelEqual Bevel both sides of knifeTightly wound denser rolls will require test slitting to determinethe best knife bevel & edge for product Additional angle onprimary bevelMust be rewound to a lesser tensionTHE ABOVE DIMENSIONS ARE A GUIDE ONLY AND WILL VARY ACCORDING TO THE DENSITY OF THE MATERIAL TO BE SLIT.**With interlined materials it may be necessary to glue end of log roll to prevent centre of roll moving out, alsoif tightly wound a Diagram 3 bevel may be required. (Ensure log roll is pushed up against chuck face or spacerroll)Diagram 1:Knife with noback bevelDiagram 2:Knife with 0.5mm(1/64”)back bevelDiagram 3:Knife with 1.5mm(1/16”)back bevelDiagram 4:Knife with equalbevel both sidesDiagram 5:Knife with reinforcededge (No. 2 angle)(refer to manual fordetails)No. 1 angleNo. 2 angle1 - 2mm (1/16” - 3/32”)NOTE: A rounded edge is preferred for most adhesive tapes. Some exceptions wouldbe, for example, foam sealant & paper tapes which require a sharp edge. Toosharp an edge can result in edge breaking down (chipping). Edge should beslightly rounded with Shielded oil stone to prevent this occurring.KNIFE DIAMETER The rule is to use the smallest diameter knife possible to minimise any run out. Using a dial indicator, check theknife for excessive run out.KNIFE BEVELS.The primary bevel on each knife has a long bevel at 8º with a smaller bevel at the outer edge of the knife at 11º tostrengthen knife edge. All Javelin grinders are factory set to 11º and care must be taken for this not to change. We recommend knivesbe either ground on your machine or returned to Javelin in order to maintain 11º bevel. Knives sent to contractors may result in bevelangle being changed with resultant slitting problems. To ensure knives are sharpened to the edge we suggest running a thin markaround the outer edge with a black pental pen. This mark will disappear once the knife has been sharpened to the edge.NOTE:It is imperative records be kept for specific materials so the operator knows which knife to choose each time a particular productis to be slit. Ref: Operator Reference Sheets in the Manual.10 P a g e
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000KNIFE STORAGEThe knife is the most important item on your machine.Knives should be kept in a purpose built cabinet and knifeedge protected with protective strip. always use approved protective gloves when handling knives Operators should read the guidelines for knife selection, preparation andmaintenance carefully.ROUNDING KNIFE EDGEOperator MUST wear cut proof gloves when performing this function.Turn off power at main isolating switch and using a Shielded Oil Stone (see Fig 3.3.1) holdthe stone flat against knife ege and slowly rotate the knife with the other gloved hand. Thiswill have the effect of dulling the sharp edge. Polish knife edge with Scotch Bright IMPORTANT NOTEIf knife is slightly chipped youwill need to retun it to JAVELINfor repair. The knife grinder onthis machine is not intended forheavy grinding.Fig 3.3.111 P a g e
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000SLITTING TOLERANCESTo achieve tolerances within .1mm or 4 thou you need to check the following:1. Use the smallest diameter knife possible the bigger the knife diameter the morechance of run-out. Check our knife selection chart for a knife bevel to suit the widthyou wish to cut. As an example, you cannot hope to hold tolerances slitting narrowwidths with a knife with a back bevel.2. Check the knife spindle, knife and backing plate for run-out using a dial indicator, asdescribed below, where accuracy to .1mm ( /- 4 thou) is required.3. With some products such as film tapes, you can use the knife brake so that the knifeis locked and will not turn. By this method you eliminate any possibility of knife runout. However, you will need to stop slitting occasionally and rotate the knife so as toprevent a flat spot occurring on one section of the knife-edge.Other factors that can affect tolerance are the index counter and encoder and in veryrare cases the clutch brake. An encoder problem is usually indicated by significantvariations in width from roll to roll although the index counter will still read correctly.Always check for any loose wires to the encoder or index counter. A clutch brakeproblem is usually indicated by erratic tolerances displayed on the P1. When checkingfor a problem with the unit always first check the correct voltage is going to the clutchbrake.Remember that any burrs on the knife, backing plate, washer and even the locking nutare enough to prevent tight tolerances being held.Knives should always be fitted on the machine so that the engraved parallel lines facethe mandrel and the engraved word “top” is uppermost. The knife must always besharpened on the integrated knife sharpener mounted on the machine. Javelin knivesare bevelled at 11º and any alteration to that angle will cause problems. We stronglyadvise against sending knives out for sharpening. Even when you receive new knivesfrom Javelin they must be finally sharpened true on your machine.Remember also that the mandrel must be aligned properly (see section Knife Pedestalalignment in the manual) and the fit of the rubber sleeve to the I/D of the core of yourmaterial must be a close fit.The material must be gripped firmly on the expanding mandrel and up against the faceof the chuck so there can be no sideways movement. If you are using a spacer rollbetween the chuck and material to be cut make sure it has straight edges and that it isapproximately the same diameter as the material to be cut.When measuring slit rolls with a dial Vernier do not allow the jaws of the Vernier toclose against the cardboard or plastic core as this can give you a false reading.If you follow the above points closely you will be able to slit tape to close tolerances12 P a g e
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000a. CHECKING FOR BACKING PLATE RUNOUT:BACKING PLATES THAT HAVE BEEN DROPPED ONTO A HARD SURFACE MAY BE OUT OFSPECIFICATION AND WILL NEED TO BE REPLACED.i) Run a smooth flat file across the face of the backing plate and washer toensure there are no burrs.ii) Check spindle face for burrs or grit.iii) Fit backing plate and washer and check for runout with dial indicator (SeeNote).iv) Runout should not be more than .08mm (.003”). If runout exceeds tolerance,mark backing plate in 2 positions and one position on spindle with markingpen.v) Rotate backing plate to position 2 and re check if runout is excessive.14NOTE: Checkbacking plate oninside by fittinglarge backingplate/smallbacking plateand nut, thenplacing dialvernier on edgeof backing plateas shown inpicture.backing plate2spindle32DIAL INDICATORb. CHECKING FOR KNIFE RUNOUTPlace dial indicator on knife face (1 at top-Picture A) and rotate knife to 2 (PictureB). A runout of not more than .08mm (.003”) is permissible.AB13 P a g e
JAVELIN MACHINERY (AUSTRALIA)Troubleshooting Slitting ProblemsJ3000/J4000Table of ContentsSINGLE KNIFE SLITTING . 1OPERATOR SAFETY. 2PRINCIPLES OF SINGLE KNIFE SLITTING. 3TROUBLE SHOOTING - SLITTING PROBLEMS. 4SLITTING PROBLEMS – PAPER & FILM TAPES. 4SLITTING PROBLEMS – PAPER, FILM, CLOTH & REINFORCED TAPES . 4SLITTING PROBLEMS – ALL ADHESIVE TAPES . 4SLITTING PROBLEMS – COPPER ALUMINIUM FOILS. 5SLITTING PROBLEMS – SINGLE SIDED FOAM SEALANT TAPES . 5SLITTING PROBLEMS – DOUBLE SIDED FOAM MOUNTING TAPES . 6SLITTING PROBLEMS – ALL TAPES . 6SLITTING PROBLEMS – SIGN VINYLS & INTERLINED MATERIALS . 7SLITTING PROBLEMS – TEFLONS (PTFE) . 7SLITTING PROBLEMS – TIGHTLY WOUND, HIGH DENSITY ADHESIVE TAPES . 7SLITTING PROBLEMS – FABRICS. 7SLITTING PROBLEMS - HOT STAMP FOIL . 8TROUBLE SHOOTING – SAW CUTTING . 8TROUBLE SHOOTING – KNIFE GRINDING. 8SLITTING TECHNIQUES . 9SLITTING INTERLINED MATERIALS. 9SAW CUTTING . 9KNIFE SELECTION. 10KNIFE STORAGE. 11ROUNDING KNIFE EDGE. 11SLITTING TOLERANCES . 12a. CHECKING FOR BACKING PLATE RUNOUT: . 13b. CHECKING FOR KNIFE RUNOUT . 1314 P a g e
Knife chews up foam Knife edge breaks down or becomes dull. . heat is the slit roll will have sticky sides. In this case lower knife RPM or switch off the knife drive and allow the knife to rotate freely. Using the knife brake may . Round off cutting edge of knife. SLITTING PROBLEMS – ALL TAPES
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2. PORT-O-SLITTER OPERATION—SLITTING A. Loosen the SET SCREWS on the LOWER SLITTING KNIFE and slide the KNIFE into the cutting position by aligning the cutting edge of the KNIFE with the desired measurement on the TAPE MEASURE. Tighten the SET SCREW. IMPORTANT: Tighten all SET SCREWS against the FLATS of the SHAFTS only.
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troubleshooting on actual industrial components. Troubleshooting skills include testing an indicator lamp, manual switch, control relay, motor contactor, overload relay, and many more! Introduction to Troubleshooting 2. Systems Troubleshooting 3. VFD Troubleshooting 4. SACA Test / Study Guide
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