INTRODUCTION

The BestPack AS machine is an adjustable, automatic carton sealer designed for industrial, agricultural packaging with pressure-sensitive tape. AS has been successfully integrated into the automated production of many industries. This article will explain  the initial machine setup process and basic troubleshooting. It will discuss basic mechanical adjustments, air pressure, and sensor alignment.   

UNBOXING and OBSERVATION

Unbox carefully. With Two-person team, lift and remove the tri-wall corrugated lid.  

Follow the Instructions in manual for proper lifting points using a forklift. Remove the machine from the pallet. 

Check overall condition; note any obvious defects in paint and frame caused from shipping damage. Remove Parts and tape head from pallet. Remove machine from Pallet.  Set conveyor height and level. Set casters or Bolt/anchor if required.  Connect air and power.  Flip over adjustment handles. Thread tape and Install the Tape Heads.

AIR SETTINGS

The main regulator controls the air pressure for the pneumatic Kicker. Changing the air setting will affect the kicker operation.   The recommended air pressure range is 65 psi to 70 psi. NOTE: Maintaining the air pressure within this range will help prolong the lifespan of the machine’s pneumatic components.

MECHANICAL ADJUSTMENTS

1.  Place the box in the sealing area and adjust height and width.
2.  Set the top compression rollers to press lightly against the sides of the box.
3. Adjust the Folding horns. Start the machine to push the box out.
4. Readjust the width if the belts are too loose and the box is slipping.
5. Stop the machine and Move to the entrance.
6. Set the entrance photo eye in line with the drive pulley on the side drive.
7. Start the machine and run the box through.
8. Check Kicker timing and motion.
   * Adjust timing with position of PH1 entry Photo Eye.
   * Adjust motion with flow control valves and air cushions to minimize banging.
   * If the kicker doesn’t actuate, verify the air is ON and the Entry PE is properly aligned with its reflector.
9. Check flap folding is smooth- the flaps shouldn’t tear.
   * Smaller flaps fold later. Folding horns should be closer to the center.
   * Larger Flaps fold earlier. Folding horns should be further apart.
   * Folding horns should be equally spaced with relation to the centerline of the machine.
10. Check tape application and Sealing.
    * If the box stalls, readjust height and width if necessary.
    * Adjust tape tension and main spring.
    • Three internal threads should be visible on the mandrel nut.
    • Main spring tension should be set to about half the length of the threaded bolt.
      • Less tension for softer corrugated
      • More tension for higher belt speed for improved rear tab.

FAULT TROUBLESHOOOTING

If the machine faults out, Check display for the type of Fault. The are two general types of faults: jams and tape faults.

• Generally, observing where the box stops can indicate the fault without looking at the screen
  • Tape faults occur by the tape head.
  • Jams occur at obstruction points.
    • Kicking.
    • Flap-folding.
    • Tape Sealing.
    • Nuisance jams or carton spacing errors occur at entry.

Tape Faults can be broken down into No-Cut and No-Tape issues.

• No-Cut means that the machine detected tape dispensing after it should have cut.
  • No-Cut faults should be caught as the box is leaving.
    • The Box would be situated slightly after the tape head, 
  • If fault is correct,
    •  Check tape threading.
    • Clean the blade.
    • Adjust the tape head:
      •  tape tension,
      •  main spring,
      • or blade mounting.
  • If the fault is Nuisance or incorrect,
    •  Verify the associated sensor is correctly positioned after the knife harness.
    • Verify the wipe delay, by enabling the function on the HMI.
• No-Tape means that the machine detected that no tape was dispensed.
  • No tape faults should be caught earlier before tape application is completed.
    • The Box would be situated directly above/below the tape head, when the fault is generated.
  • If fault is correct:
    • Fix the tape, renew the roll.
    • Verify tape threading.
    • Adjust the tape head.
  • If the fault is Nuisance or incorrect:
    • Verify the associated sensor is aimed correctly at the encoder on the one-way roller.
    • Verify the tape head is correctly mounted in the tape head cavity.
    • Adjust the sensitivity of the associated No Tape sensor. The Amber LED indicator on the sensor should pulse as tape is dispensed
    • Verify electrical signals with a voltmeter.

Jam faults Can be broken down into Box jam and Carton spacing Error

• Box jams are triggered when a box takes too long to exit the machine.
  • Check sensor alignment on PH1, PH2, PH3
    • Machine Clear Function
      •  If the machine is started with a box inside blocking a sensor, the machine will clear the box before tape monitoring is enabled. This is done to start the machine from a clear state and make it easier to recover from a fault. Once the machine is clear, the upstream conveyor will feed and the Green light will turn on. Machine functions and tape monitoring will begin on the following boxes.
      • If a sensor is out of  alignment, the same delayed start behavior will be observed. The machine will attempt to clear a photo eye when starting.  So pressing the start button will turn the belts on, the green light turns on several seconds later and the upstream starts feeding even though there is no box in the machine. However, several seconds after that, when a box does enter, an alarm will be generated because one of the photo eyes is out of alignment.
  • Verify height and width adjustments
  • Verify belt tension
  • Verify Top compression rollers are not blocking the box.
  • Verify tape heads are seated correctly.
• Carton Spacing Error- A Carton Spacing Error is generated when boxes enter too close together or carton spacing is insufficient to allow the tape head to cycle properly. The tape head requires about 12 inches between cartons to cut the tape properly. If boxes are fed too close together, the machine will not be able to detect the No-Cut tape fault condition as the following box resets the counts for the previous box. A simple PLC timer is used on PH1 entry sensor. If sensor changes states too quickly, a fault is generated. The sensor must remain off after toggling for the duration of the timer. 250ms is typically sufficient spacing (14”) with standard belt speed. The Carton Spacing Timer can be adjusted on the HMI. The timer sets the carton spacing by delaying the upstream conveyor the given duration after the entry PH1 state toggles LOW.

• Nuisance carton spacing Errors
  • Check PH1 for alignment and signal stability
    • Adjust Sensitivity
    • Secure loose or wobbly brackets
  • Verify smooth and consistent carton feeding. If a light box hits a side drive while entering it may bounce out, triggering two quick pulses on PH1 which will look like two boxes came in very close together
    • Ensure the machine is centered to conveyor
    • Use guide rails to ensure boxes are centered or properly justified
    • Use grip tape on rollers to ensure smooth entry transition.