INTRODUCTION

The ATFXU machine is designed for highly reliable production. However, like any mechanical system, these machines can encounter issues that disrupt their operation. One such challenge is the failure of the kicker to fold the back minor flap, a situation that can halt production and necessitate swift resolution.

POSSIBLE CAUSES

The kicker's failure to activate the back minor flap can stem from multiple sources, including insufficient air pressure within the machine or interruptions in the taping sequence. When faced with such challenges, a systematic approach is essential. In many cases, a simple machine reset can work wonders, restoring the kicker's functionality and preventing production bottlenecks. Understanding these root causes is the first step toward ensuring the reliable operation of tape sealing machinery.

GENERAL TROUBLESHOOTING TIPS
1) Identify- Carefully analyze the issue, Take videos to capture fast-occurring events. 

2) Isolate- Test only one function at a time. Instead of running a box through the machine which will fire off multiple processes, only trigger LS0 with a stick or measuring tape.  

3) Repair and retest- Multiple factors affect the kicking process. Sometimes, the biggest offender is easy to spot. Frequently, several small, overlapping conditions will contribute to complexity of the solution. 

TROUBLESHOOT STEPS

To address the issue of the kicker failing to fold the back minor flap, we have outlined a series of precise troubleshooting steps:

• Does the kicker activate at all? If it doesn't...
  •  The electrical trigger signal may not be functioning, or the air supply is shutoff.
    • Check Air Supply. Air regulator should maintain the recommended pressure range of 4-6 bar (`50-75psi)
    • Manually activate the Kicker solenoid valve by pressing the blue button on the solenoid
      • The kicker should activate if it has air. Replace the solenoid valve if it doesn't fire the cylinder. If it does fire the cylinder, then the problem is electrical-related...
    • Verify the relay R11, which fires off when LS0 is released. The green LED will indicate when the kicker should activate.
      • If the green LED never lights, determine if the relay is bad or if the switch/wiring is damaged.
        • Swap the relay R11 with another known-good relay.
          • If the 'swapped-in' relay in socket R11 fires the solenoid valve, then the original relay needs to be replaced.
          • If the 'swapped-in' relay in socket R11 still does not turn on, then the limit switch LS0 and associated wiring needs to be inspected for damage or improper connections.
        • Further testing with a DMM voltmeter may be required.
    • Verify electrical voltage and continuity at wire#20,24, 34,36, and 50, with respect to N24.
• ...If the kicker does activate automatically - Is kicker motion correct and consistent? The motion of the kicker should be quick to close the flap, with a slow, controlled retraction on reset. 
  • Air Flow issues can cause erratic kicking. 
    • Check the air pressure setting and supply for air starvation issues. 
    • Inspect the airlines and fittings for damage or kinks.
    • Adjusting the flow control valves should produce a noticeable reduction in cylinder speed. If the flow control valve does not affect the speed, the fitting may need to be replaced.
• Does the kicker make excessive noise, banging, or leaks air?
  • Verify air pressure setting.
  • Adjust the air cushion.
  • If the kicker strikes the front of the plow, adjust the cylinder rod extension.
  • If the kicker assembly is loose or rattling, check the mounting hardware for loose, missing, or sheared bolts.
  • Identify location of leak and tighten or replace air fittings and/or airline.

• If the Kicker functions 'normally', but inconsistently tucks in the rear flap- try running a box through to identify if the machine is adjusted correctly.
• Is the air supply sufficient? Check Air Supply. Air regulator should maintain the recommended pressure range of 4-6 bar (`50-75psi)
• Is the machine height adjusted correctly?
  • Too high can reduce the accuracy kick.
  • Too low can cause jamming and interrupt the kicker timing.
• Is the machine width adjusted correctly? 
  
  • Too narrow can stall the box and interrupt the kicker timing.
  • Do the lid lifters Pinch or cause the box to stall, adjust if necessary.
• Is the kicker activated too early/too late?
  • The position of LS0 may need to adjusted. 

TROUBLESHOOTING CHECKLIST

• Air-related Pneumatic Components
  • Air pressure
  • Air Flow
  • Components
    • Regulator
    • Solenoid 
    • Airlines 
    • Flow control valves
    • Air cylinder
      • Cushion
      • Rod extension
• Electrical-related components
  • Sensor- LS0
  • Relay - R11
  • Solenoid - "SV3"
  • Wiring: #20, 24, 34, 36, and 50, with respect to N24.
• Mechanical
  • Secure Mounting brackets
  • Secure Mounting Hardware
  • Machine Adjustments

CONCLUSION

When confronted with the challenge of a kicker failing to fold the back minor flap in a ATFXU machine, a structured troubleshooting approach can be the difference between an expensive service call and a quick resolution. By proactively addressing air pressure, conducting thorough air regulator examinations, performing machine resets, and inspecting relays, you can mitigate disruptions and enhance the performance of your tape sealing machinery. In doing so, you contribute to the efficiency and improve the production flow.