A tool for customized production: How does the film slitting machine meet the flexible production needs of multiple specifications and small batches?

The film slitting machine is essentially a precision equipment that cuts wide and large coils of master film into multiple rolls of narrow or small diameter finished coils through sharp blades rotating at high speed. Its core value is to transform mass-produced standardized master rolls into personalized and diversified specifications required by the market.

Here are some key tools that meet the needs of flexible production:

1. Fast specification changeover - "change knives like a god"

This is the primary condition for achieving flexible production. While traditional equipment can take hours to change specifications, modern high-end slitting machines dramatically reduce downtime with the following technologies:

• Automatic sleeve inflatable shaft system: when changing the coil, there is no need to disassemble the entire shaft effortlessly, just remove the sleeve after deflating, and then replace it with the sleeve of the required width and inflate, and the change time is shortened from hours to minutes.

• Multi-tool holder and automatic tool adjustment system:

◦ Multi-tool holder design: Allows several sets of commonly used slitting widths to be preset.

◦ Servo motor-driven automatic tool adjustment system: The operator only needs to input the target width and quantity on the HMI (human-machine interface), and the servo motor can drive the tool holder to move to the predetermined position accurately and quickly, with an accuracy of ±0.1mm or even higher. This completely avoids errors and time-consuming errors in manual measurement and adjustment.

• Modular design: core components such as the retraction shaft and unwinding shaft adopt a quick-locking device for quick replacement.

Effect: Minimizes "changeover time" on the line, making it economically feasible to produce small batch orders.

2. Extremely high slitting accuracy and stability - "not a fraction of a cent"

Small batch orders often mean higher quality requirements and lower fault tolerance rates. The slitting machine ensures the quality of each roll with precision technology:

• High-precision correction system: CCD or ultrasonic sensors are used to monitor the film edge or printing line in real time, and the servo system automatically fine-tunes to ensure that the coil is always in the correct position during the slitting process. This is essential for patterned and circuitry (e.g., lithium battery electrodes) to ensure pattern consistency across each roll.

• Constant tension control system: the whole process from unwinding, traction to winding, through magnetic powder clutch, vector frequency converter or servo motor for precise tension control. Stable tension is the basis to ensure that the winding is neat, wrinkle-free, and tensile deformation, which directly determines the quality of the finished roll.

• Advanced blade technology: Using manual/automatic fine-tuning circular knives, ultrasonic knives, etc., can achieve clean and flat cutting, reduce burrs and dust, especially suitable for optical films, electronic films, etc. that require high cleanliness.

Results: Ensure that even very small batches of orders meet high-quality, high-quality product standards consistent with high-volume production, reducing waste and rework.

3. Broad material adaptability - "one machine for multiple purposes"

Flexible production lines need to be able to handle a wide range of materials. Modern slitting machines adapt to different properties with adjustable configurations Films:

• Flexible tension control range: can handle a wide range of materials from extremely thin (e.g., 2μm ultra-thin capacitive films), easily stretched (e.g., PE, PP) to thick, rigid (e.g., PET, PI).

• Different unwinding methods: Center winding, surface winding or gap winding can be used to adapt to the tension and flatness requirements of different materials (e.g., preventing adhesive products from sticking).

• Specialized options: can be equipped with anti-static systems, dust removal systems, online defect detection systems, etc., to meet the production needs of special materials (such as MLCC release film, high-end tapes).

Effect: A production line can easily switch to produce orders of multiple different materials in one day, which greatly improves the utilization rate of equipment and the factory's ability to receive orders.

4. Intelligent and Data-Based Control - "Knowing in Your Heart"

This is the brain that enables efficient and flexible production.

• PLC + HMI control system: preset and store a large number of recipes. Every time a new specification order is received, only the corresponding recipe needs to be called, and all parameters (such as width, tension, speed, tool position) are automatically set and started with one button, which greatly simplifies the operation and eliminates human error.

• Data Logging and Traceability: The system can record the production data of each work order (such as length, speed, alarm information), provide data support for quality traceability and production efficiency analysis, and continuously optimize the production process.

Effect: Reduce dependence on operator experience, make production management more standardized and visual, and make decisions more data-based.

Summary: How to specifically meet the needs of "multiple specifications and small batches"

Let's say a factory receives three orders:

1. Order A: 0.05mm thick, 5mm wide special tape, length 5000 meters.

2. Order B: 0.1mm thick, 1000mm wide decorative film, length 800 meters.

3. Order C: 0.025mm thick, 10mm wide electronic release film, length 3000 meters.

Traditional mass production model: each order needs to change lines and debug, which consumes a lot of time and raw materials, and is almost unprofitable.

Flexible production mode with modern film slitting machines:

1. Select a suitable master roll (e.g. 1.2 m wide standard master roll).

2. For order A, select or create a new "Recipe A" in the system and enter the parameters. The automatic tool adjustment system accurately positions dozens of blades to 5mm intervals. Replace with a socket suitable for small roll diameters. Set high-precision, low-tension parameters. Complete production quickly.

3. When finished, the device pauses. The operator replaces the winding sleeve to a size suitable for a width of 1000mm.

4. Call "Recipe B" of order B, and the tool holder will automatically move to both ends (only need to cut the scrap edges on both sides or cut into two rolls), and set the corresponding tension parameters. Complete production quickly.

5. In the same way, quickly switch to the configuration of order C for production.

In the whole process, the changeover time is short, the material waste is minimal, and the product quality is stable, so that the factory can quickly respond to market changes, undertake diversified and personalized orders in a high-efficiency and low-cost way, and finally win an advantage in the fierce market competition.

Therefore, the film slitting machine is not just a simple "cutting" equipment, but an indispensable core tool for flexible and customized production in the field of high-end manufacturing.