INTRODUCTION

The efficient operation of every component is essential to ensure the seamless packaging of products. One vital element on the ATFXU machine is the lid lifters, responsible for separate the top lid from the bottom of the box. However, when this critical component encounters issues, it can lead to disruptions in the production process. need picture

The lid lifter process is central to the operation of the ATFXU machine. Diagnosing the issues with the lid lifter system can be difficult because the machine executes several tasks almost simultaneously, so if one step is off, it may show up as failure to fold or failure to cut. Understanding the correct sequence of operations is important in diagnosing the cause of the problem. 

This is the ideal sequence of events in the ATFXU Process:
1) Fold the Major Flaps Out.

2) Lift the Lid. Shake, if necessary, to break friction resistance of a stuck lid.  Lid should rest on the Lid-support rails. 

3) Kick or tuck in the rear minor.

4) Fold the majors in.

5) Apply tape to Seal.

However, there are a number of issues that can occur during lid-Lifting that can cause delays or obstruct other processes, which will lead to torn flaps, crushed boxes, or failure of the tape head to cut the tape. 

POSSIBLE CAUSES

A lid lifter that isn't operational may indicate factors such as inadequate air pressure, mispositioned PH3 sensors, or a disengaged lifter switch. Improperly adjusted lifters frequently cause jams, torn flaps, and taping problems. Checking and addressing these elements can restore the lifter's functionality.

TROUBLESHOOT STEPS

Now that we have identified potential causes, let's delve into the steps you can take to troubleshoot and resolve these issues.

1. 1. Check the Air Regulator's Pressure:

      • Check the Air Setting. The regulator should maintain the recommended pressure range of 4-6 bar (~50-75psi)
      • Monitor Air Supply for air starvation while in operation. |
        
        

   2. Verify PH3 Sensor Status: To address mispositioned or malfunctioning PH3 sensor, close the doors and reset the machine.
      

      • Confirm that the PH3 sensor's red dot light is visible (powered-on). 

      • The sensor also has power and signal LED indicators on the body of the sensor which can be used to verify operation by placing a box over the senor and noting the state change.  This indicator is a clear sign that the sensor is functioning correctly.

      • The sensor should be securely mounted in the middle of the slot towards the exit. After resetting the machine, run a new box through the system to verify that the lid lifter now detects, and lifts lids as expected.
      • If the power indicator is not lit, try adjusting the sensitivity.
      • Check the electrical connections for loose screw terminals.
      • Check the sensor cable for nicks, cuts or abrasions.
      • Use a DMM voltmeter to verify supply voltage to the sensor.
      • Replace if necessary. 

   3. , Verify lid lifter solenoid valve. 

      • Manually actuate the valve by pushing the blue button on the valve body

      • Use a DMM voltmeter to verify voltage the solenoid.
        
        
   4. If the solenoid valve works mechanically, Verify R12 Relay which fires the lid lifter solenoid valve. 
      • The Green LED indicator on the relay should light as a box goes through.
      • If the LED does not light, swap the relay a neighboring relay that is functioning to verify it is the relay not the wiring or socket.
      • Check the electrical connections for loose screw terminals.
      • Use a DMM voltmeter to verify electrical to the relay.
   5. If R12 is functioning, verify timers T3 and T4. T3 is frequency of oscillation and T4 is the shaking reset. 
      • Verify that T3 and T4 are set correctly (2 @ 0.1sec and 2.5 @ 1sec respectively). If T4 is too long, it might not reset correctly.
      • Run a Box Through the machine and verify the timers power up and fire off.
      • If the timers do not power up, swap the timer with a neighboring timer that is functioning to verify it is the timer not the wiring or socket.
      • Only swap or change one thing at a time. 
      • Check the electrical connections for loose screw terminals.
      • Use a DMM voltmeter to verify electrical voltage to the timer.
        
        
   6. If the timers are functioning, verify PH4 Sensor

      • The sensor also has power and signal LED indicators on the body of the sensor which can be used to verify operation by placing a box over the senor and noting the state change.  This indicator is a clear sign that the sensor is functioning correctly.

      • The sensor should be securely mounted in the middle of the slot towards the exit. After resetting the machine, run a new box through the system to verify that the lid lifter now detects, and lifts lids as expected.
      • if the power indicator is not lit, try adjusting the sensitivity.
      • Check the sensor cable for nicks, cuts or abrasions.
      • Check the electrical connections for loose screw terminals.
      • Use a DMM voltmeter to verify supply voltage to the sensor.
      • Replace if necessary. 
   7. If PH4 is working, verify lifter disable switch.
      • Verify position of the switch
      • Check the electrical connections for loose screw terminals.
      • Use a DMM voltmeter to verify supply voltage to the sensor.
        
        
   8.  If the electrical components, check the air cylinder. 
      • Shut the air off, and manually move kicker in and out. the kicker should move smoothly.
      • Check for mechanical binding and interferene. 
      • Check for loose or missing mounting hardware. 
        
        
   9. If the kicker does not move freely or it feels like a vacuum or excessive restriction, check flow control valves. 
      • Check the flow control setting is not completely closed.
      • If the valve was recently replaced, it will need to be adjusted.
        • Close the valve completely (CW)
        • Open the valve four complete turns (CCW)
          
          
   10.  If the flow control valves are functioning and set correctly, check the airlines for kinks, cuts, and damage. 
       
   11. If the electrical and pneumatic components, appear to be in good working order, verify that the lid lifters are mechanically adjusted correctly.
       • Mechanical adjustments should be performed equally to both lid lifters to prevent binding. the Lifters are mechanically linked together, is if one side is heavily adjusted and other isn't the system as a whole will perform poorly. 
       • Adjust the prop angle so that the lifters fire nearly parallel with a slight negative camber.
       • Adjust Lid lighter spring tension, so that the lifters very gently press against the sides of the box.
       • Adjust the lifter's height to be slightly (3-5mm) below the score line of the box when it is collapsed. 

TROUBLESHOOTING CHECKLIST

• Electrical- Controls
  • PH3 Sensor - trigger
  • R12 Relay
  • T3 and T4 Timers
  • PH4 Sensor- reset.
  • SV5 Solenoid Valve
  • Lifter Disable Switch
• Pneumatics 
  • Air Regulator
  • Cylinders
  • Flow control valves
  • Airlines
• Mechanical-Lid Lifter
  • Adjustment

CONCLUSION

By understanding the possible causes and following the troubleshooting steps outlined in this article, you can swiftly diagnose and rectify issues with the lid lifters. Regular maintenance and attention to these critical components will ensure that your equipment continues to operate efficiently, minimizing downtime and maximizing productivity in the folding and sealing process.