English Instruction Manual for Crystal Mud Filling Machine
I. Product Overview
Purpose
This crystal mud filling machine is a device specifically designed to accurately fill crystal mud into various containers such as plastic boxes, glass bottles, etc. It is applicable to crystal mud with different viscosities and compositions and can meet the filling requirements of crystal mud manufacturers or handicraft production sites.
Working Principle
The machine drives components such as pistons, pumps, or valves through a power system (such as an electric motor or a pneumatic device) to convey the crystal mud from the storage container (hopper or cylinder) to the filling head. The design of the filling head can precisely control the flow rate of the crystal mud, enabling it to be filled into the target containers according to the preset filling volume. Some filling machines are also equipped with advanced control systems that can automatically adjust the filling parameters according to different container sizes and filling requirements.
II. Product Specifications
Filling Volume Range
List in detail the minimum and maximum filling volumes that the machine can handle. For example, the minimum filling volume is 5 ml, and the maximum filling volume is 500 ml. At the same time, explain the way to adjust the filling volume, whether it is through a manual knob, an electronic control screen, or other means.
Filling Speed
Specify the filling speed of the machine under different conditions. For example, when filling with a single head, the maximum filling speed can reach [X] containers per minute; when filling with multiple heads, the speed will change accordingly with the increase in the number of heads.
Applicable Container Sizes
Enumerate the diameter and height ranges of the containers that the machine can be adapted to. For example, the container diameter range is from 30 mm to 100 mm, and the height range is from 50 mm to 200 mm. The applicability to containers with special shapes can also be mentioned.
Power
Indicate the rated power of the equipment. For example, if it is an electric motor-driven machine, the motor power is [X] kilowatts (kW). If it is a pneumatic device, specify the required air pressure range, for example, the air pressure range is 0.4 - 0.6 MPa.
Dimensions
Provide the length, width, and height dimensions of the machine, such as length [L] centimeters (cm), width [W] centimeters (cm), and height [H] centimeters (cm), so that users can reasonably plan the space when installing and placing the equipment.
Weight
Give the net weight and gross weight of the equipment. For example, the net weight is [X] kilograms (kg), and the gross weight (including packaging) is [X + Y] kilograms (kg), which is important for handling and transporting the equipment.
III. Component Introduction
Hopper/Cylinder
This is the part where the crystal mud is stored. Describe its material (such as stainless steel with good corrosion resistance), capacity size, and feeding method (such as manual addition or automatic feeding through pipes).
Power System
If it is motor-driven, introduce the type of motor (such as three-phase asynchronous motor), power, rotational speed, and other parameters. If it is a pneumatic system, explain the specifications of the air pump, the location and operation method of the air pressure adjustment device.
Filling Heads
Introduce the number and material of the filling heads (usually stainless steel or food-grade plastic). Emphasize the precision control components of the filling heads, such as precision valves or piston devices, and explain how they achieve accurate filling.
Control System
Describe the control method, whether it is by simple mechanical buttons, PLC (Programmable Logic Controller) control, or touch screen control. Explain in detail the functions of each button, knob, and display screen on the control interface, such as start/stop buttons, filling volume adjustment knobs, speed adjustment buttons, etc.
Conveying Pipes
Introduce the material of the pipes (such as food-grade silicone tubes or stainless steel tubes), the connection method of the pipes (such as quick connectors or flange connections), and the cleaning and maintenance methods of the pipes, because crystal mud is prone to residue and clogging in the pipes.
IV. Installation Instructions
Site Requirements
Describe the site conditions required for the installation of the equipment, such as a flat and dry ground, good ventilation, and the temperature and humidity range of the surrounding environment (for example, the temperature range is 5 - 40 °C, and the relative humidity does not exceed 80%).
Installation Steps
Detailed installation steps:
First, place the equipment at the selected location. Use a level to check whether the equipment is placed horizontally. If necessary, adjust the anchor bolts at the bottom of the equipment to make it level.
Then, connect the power supply or air source. For the power connection, make the correct wiring according to the voltage and frequency requirements marked on the equipment nameplate, and ensure good grounding. For the air source connection, use a suitable air pipe to connect the air inlet of the equipment with the air source (such as an air compressor). Clean the air pipe before connection and adjust the air source pressure.
Next, install the filling heads and conveying pipes. Install the filling heads on the equipment in the correct direction and position, ensuring good sealing. Connect the conveying pipes between the hopper/cylinder and the filling heads, pay attention to the connection sequence and direction of the pipes, and check whether the connection parts are firm and without leakage.
Finally, conduct a preliminary inspection of the equipment, including checking whether each component is installed correctly, whether the electrical connections are normal, and whether the power system can start normally.
V. Operation Guide
Pre-startup Preparation
Check whether there are obstacles around the equipment to ensure the safety of the operators.
Check whether the raw materials of the crystal mud meet the requirements, such as viscosity and composition. Add the qualified crystal mud to the hopper/cylinder, and be careful not to overfill to avoid overflow.
Check whether the power supply or air source of the equipment has been correctly connected, and whether each control button and knob is in the initial state (such as the filling volume adjustment knob is in the minimum position, and the speed adjustment button is in the lower speed position).
Starting the Equipment
Press the start button, and the equipment will start. Observe whether the power system is operating normally, such as whether the motor is rotating normally and whether the pneumatic device has air leakage. Wait for the equipment to warm up (if there is a warming up requirement), and the warming up time is usually about [X] minutes.
Filling Operation
Place the empty containers at the designated position below the filling heads, ensuring that the containers are placed stably. Set the filling volume and filling speed through the control system, and then start filling. During the filling process, pay attention to observing the flow situation of the crystal mud. If there is an abnormality (such as a sudden change in flow rate, clogging, etc.), immediately stop filling and conduct an inspection.
Completion of Filling
After the containers are filled, remove the containers and replace them with new empty containers to continue filling. After a batch of containers are filled, if it is necessary to change the color or type of the crystal mud, first clean the remaining crystal mud in the hopper/cylinder, and then add new raw materials.
Shutdown Operation
After stopping the filling, let the equipment continue to run for a short period of time (such as 1 - 2 minutes) to empty the crystal mud in the conveying pipes to prevent residue. Then press the stop button to turn off the power supply or air source.
VI. Maintenance and Care
Daily Maintenance
Cleaning Work: After each use, promptly remove the residual crystal mud on the surface and inside of the filling machine. Wipe the equipment surface with a damp cloth or a special cleaner. Pay special attention to cleaning the parts that are prone to residue such as the inlet, outlet, and filling heads, but avoid the cleaner entering the electrical components or mechanical transmission parts.
Checking Components: During the production process, regularly patrol and observe the mechanical components. Check whether the rotation, elevation, and other movements are normal, whether there are any abnormal sounds or vibrations, and whether the screws are loose. At the same time, check the tightness of transmission parts such as belts and chains. If there is an abnormality, it should be adjusted or replaced in a timely manner.
Lubrication Maintenance: Regularly add an appropriate amount of lubricating oil to each lubrication point of the filling machine (such as bearings, bushes, gears, chains, etc.), and conduct a comprehensive lubrication inspection and supplement at least once a week to reduce friction and wear, reduce the operating noise of the equipment, and extend its service life.
Regular Maintenance
Pneumatic Component Inspection: Monthly, inspect the pneumatic components (such as cylinders, solenoid valves, and speed control valves). Check their quality and operational reliability through manual adjustment. Check whether the cylinders have air leakage and sticking phenomena, and the solenoid valves can be manually forced to operate to determine whether the electromagnetic coils are burned out and whether the valves are clogged.
Electrical System Maintenance: Regularly inspect the electrical system of the filling machine, including wires, cables, plugs, sockets, switches, relays, etc. Check whether there are any damages, aging, loosening, etc. to ensure that the electrical connections are firm and reliable, without any safety hazards such as electric leakage and short circuit. At the same time, clean the dust and debris inside the electrical control cabinet to prevent them from affecting the heat dissipation and normal operation of the electrical components.
Pipeline and Valve Inspection: Regularly inspect the parts such as pipelines and valves that are in contact with the crystal mud. Check whether there are any wear, corrosion, leakage, etc. problems. If there is a leakage, replace the sealing parts in a time; for severely worn pipelines and valves, they should be replaced to ensure the normal progress of the filling process and the accuracy of material metering.
Long-term Shutdown Maintenance
Emptying the Materials: If the filling machine is to be stopped for a long time, the crystal mud materials in the pipes must be emptied to prevent the materials from drying up, caking in the pipes and clogging the pipes, which may affect the next use.
Cleaning and Protection: After a comprehensive cleaning of the filling machine, apply an appropriate amount of anti-rust oil or protective agent on the surface of the equipment to prevent the equipment from rusting and corroding. At the same time, cover the equipment with a dust cover to avoid dust, debris and other things from entering the inside of the equipment.
VII. Troubleshooting
Inaccurate Filling Volume
Causes of Malfunction:
Throttle Valve Problems: The speed throttle valve and the filling interval throttle valve are closed, resulting in unstable material flow and thus affecting the filling volume.
Foreign Objects in Control Valve: There are foreign objects in the quick-install three-way control valve, or there is air in the hose between the quick-install three-way control valve and the filling head, which obstructs or destabilizes the material flow.
Damaged Sealing Ring: A damaged sealing ring will cause material leakage, affecting the accuracy of the filling volume.
Problems with the Filling Nozzle Spool: The spool of the filling nozzle is stuck or opens with a delay, resulting in poor material outflow and insufficient filling volume.
Too Fast Filling Speed: If the filling speed is too fast, the material doesn't have enough time to accurately fill the container, which also leads to inaccurate filling volume.
Solutions:
Check and adjust the throttle valves to ensure they are in an appropriate open state so that the material can flow out stably.
Clean the foreign objects in the quick-install three-way control valve and at the same time expel the air in the hose. This can be achieved through multiple filling operations or by using a special air exhaust tool.
Replace the damaged sealing ring to ensure good sealing and prevent material leakage.
Reinstall the spool of the filling nozzle to ensure its correct position. If it opens with a delay, adjust the throttle valve of the thin cylinder to control the opening speed of the spool.
Appropriately adjust the pulse width modulation valve of the filling speed to reduce the filling speed so that the material can fully and accurately fill the container.
Material Leakage
Causes of Malfunction:
Installation Problems of Filling Head: The filling head is not installed properly, and there may be looseness or poor sealing, resulting in material leakage from the filling head.
Damage to the Filling Nozzle: The opening of the filling nozzle is taken out, the opening is trimmed to make its diameter meet the requirements, and the plane of the opening is gently smoothed on the wet sandpaper, but be careful not to over-polish and enlarge the opening.
Replacement of the Damaged Ball Valve: Replace the damaged ball valve to restore the normal control of the material by the filling head.
Timely Replacement of the Damaged O-ring: Replace the damaged O-ring in a timely manner to prevent material leakage from the rear end of the material cylinder.
The Filling Machine Fails to Start
Causes of Malfunction:
Power Supply Problems: Problems with the power switch, blown fuses, no output from the switching power supply, etc., result in the filling machine being unable to obtain a normal power supply.
Emergency Stop Button Not Reset: The emergency stop button has not been reset after being pressed, leaving the filling machine in a stopped state and unable to start.
Loose Communication Cables: The communication cables between the touch screen and the PLC are loose, resulting in poor signal transmission and affecting the start of the filling machine.
Solutions:
Check whether the power switch is normal. If it is damaged, replace it in a timely manner. Check whether the fuse is blowing. If it is blowing, replace it with a fuse of the same specification. Measure the upkeep voltage of the switching power supply to ensure normal power supply.
Check the state of the emergency stop button and reset it to release the filling machine from the stopped state.
Check the connection of the communication cables between the touch screen and the PLC. Reinsert the loose cables tightly to ensure normal signal transmission.
The Filling Machine Stops Suddenly During Operation
Causes of Malfunction:
Machine Malfunctions: Such as motor malfunctions, damage to transmission components, cylinder malfunctions, etc., which cause the filling machine to be unable to operate normally.
Overload Protection Triggered: The filling machine runs for a long time or has an excessive load, triggering the thermal overload protection and causing the equipment to stop automatically.
Insufficient Air Pressure: The air pressure required for the pneumatic components is insufficient, unable to ensure the normal operation of the filling machine, thus resulting in a shutdown.
Solutions:
Check machine components such as motors, transmission components, and cylinders to see if there are any damages or abnormalities. If there are problems, replace or repair the damaged components in a time.
Find out the reasons for triggering the overload protection, such as whether there is material blockage, excessive load, etc. After eliminating the faults, press the reset button to restart the filling machine.
Check the air pressure system to ensure that the air pressure valve is open and the air pressure meets the normal working requirements. If the air pressure is insufficient, adjust the air pressure valve to increase the air pressure.
Poor Material Flow During Filling
Causes of Malfunction:
Material Blockage: The material contains impurities or crystals, which cause blockages in the pipes, valves, or filling nozzles, affecting the normal flow of the material.
Pipe Problems: The pipes are bent, deformed, or have internal wear, increasing the resistance to material flow and slowing down the flow rate.
Pneumatic Component Malfunctions: Malfunctions of pneumatic components such as cylinders and solenoid valves, which are unable to normally push the material to flow.
Solutions:
Clean the impurities and crystals in the material and at the same time check the pipes, valves, and filling nozzles to remove the blockages and ensure the material can flow smoothly.
Check the installation of the pipes. If there are bends or deformations, adjust or replace the pipes in a time. For pipes with severe internal wear, they should be replaced.
Check the working state of the pneumatic components, such as whether the cylinders are leaking air, whether the solenoid valves are switching normally, etc. Repair or replace the faulty pneumatic components.
VIII. Safety Precautions
Electrical Safety
The equipment must be properly grounded to prevent electric shock accidents. Before performing any electrical maintenance or repair work, it is necessary to cut off the power supply first and ensure that the power switch is in the "off" state. At the same time, hang a "Under Maintenance" warning sign on the power switch. Non-professional electrical personnel are not allowed to disassemble or repair electrical equipment without permission.
Mechanical Safety
During the operation of the equipment, it is strictly prohibited to bring hands or other objects close to the rotating and transmission components (such as motor shafts, belts, chains, etc.) to avoid accidents such as pinching and entrapment. When the equipment is running, the operator should be vigilant and observe the running state of the equipment. If any abnormal situation (such as abnormal sounds, vibrations, etc.) is found, the equipment should be stopped immediately and inspected.
Operation Safety
Operators should receive professional training and be familiar with the operation process and safety precautions of the equipment before they can start working. When adding crystal mud raw materials, operate carefully to avoid splashing of the raw materials, especially onto the eyes or skin. If the crystal mud accidentally contacts the eyes or skin, immediately rinse with a large amount of clean water and seek medical attention in a timely manner.
Other Safety Matters
Keep the environment around the equipment clean and avoid piling up debris around the equipment to avoid affecting the normal operation of the equipment and the safety of the operators. The equipment may produce certain noises and vibrations during operation. Appropriate protective measures (such as wearing earplugs, installing shock-absorbing pads, etc.) should be taken to protect the hearing of the operators and the stability of the equipment.
