Kongsberg C-series cutting machine troubleshooting guide

Chuck damage: When the handle slips or bounces beyond the standard, a special tool should be used to replace the chuck. Regularly clean the cone surface of the chuck and the inner cone of the spindle at least once a week.

4.4 The milling cutter cannot be removed from the chuck

Apply 7 bar air pressure, but press the 'Chuck Open' button to release it. At this time, a 12mm wrench and a 17mm wrench can be used in combination, with one person fixing the rotor and the other person counterclockwise loosening the clamp (note: it is strictly prohibited to rotate the rotor while the clamp is open). Remove the clamp and clean the internal debris.

Tool calibration and cutting quality deviation

5.1 Difficult to separate finished products and waste materials after cutting (unable to cut through)

Reason: Insufficient tool depth. Enter the 'Tool Height Calibration' wizard and add a negative offset (e.g. -0.3mm) to the tool. You can also temporarily increase the cutting depth in the depth setting of the homework layer.

Reason: Insufficient vacuum adsorption causes the material to lift during the cutting process. Optimize the vacuum zone or use Blow Back assistance.

5.2 Waste material still connected at the corner (continuous cutting)

Typical problem: The tool lag (Lag) is not set correctly. For rotating tools such as vibration tools and drag tools, the hysteresis value is equal to the radial distance from the tool tip to the center of the tool shaft. Common values: 6mm tool holder lags 3mm, 8mm tool holder lags 4mm. Enter the "Lag Settings" wizard and perform a "Lag test": the system will draw a square, measure the deviation between the actual incision and the theoretical position, and then automatically calculate the compensation value.

It can also be manually adjusted: increasing the hysteresis value can make the corner cut more.

5.3 Cutting line offset (the knife has lateral offset)

Center Offset: If the two lines cut by the tool in the forward and return directions do not coincide, the center offset needs to be adjusted. Use the "Center Offset Adjustment" wizard or manually test: cut a straight line, rotate the tool 180 ° and return along the same path, measure the deviation distance and fill in the dialog box.

Tool Offset: When there is a deviation between the laser point and the actual cutting position, use the "Tool Offset" wizard to correct it. The system will first make the tool cut a cross, then move the laser point to the center of the cross and automatically calculate the offset.

5.4 Cutting edge burrs, cardboard tearing

Rotation direction: Ensure that the tip of the tool is pointing tangential to the direction of motion. For a drag knife, if the tip of the knife is pointed incorrectly, it will be pushed away by the material, causing tearing. Manually adjust the 'Rotation Adjustment': Cut a line, observe the angle at which the knife enters the material, and fine tune the angle offset value until the knife cuts vertically.

Blade wear: Replace with a new blade. For V-groove knives, heavy-duty knives, etc., blunting the blade will significantly reduce quality.

Feeder and stacker crane malfunction (i-BF/i-MS)

6.1 "Fail to Pick Board" malfunction

Insufficient vacuum: Check whether the suction cup is aging, blocked, or has poor contact with the material pile. The set 'Low Vacuum Set Point' is too high (reference value: empty vacuum value+20). Enter 'Feeder Setting Screen 2', lower the setting value or temporarily set it to 0 to disable detection.

Suction cup not fully in contact: Add "Pick Sheet Additional Travel" (recommended 5-10mm) to allow the suction cup frame to penetrate deeper into the material pile. Be careful not to overtravel the compensator.

Air pressure: Confirm that the feeder air pressure is ≥ 6 bar.

6.2 "Plumger Sensor Stuck" malfunction

The plunger sensor (located at the first suction cup) is stuck. Check if the compensator can move freely up and down, and clean the distance between the sensor and the target gasket (which should be 0.5mm). If the sensor is damaged, replace it.

6.3 Frequent occurrence of 'Safety Bumper Fault'

Check whether the safety edge strips on both sides of the gantry are squeezed by material piles or loose cardboard. After the border is triggered, it needs to be manually reset (press the blue Fault Reset button). If the edge strip itself is damaged, it needs to be replaced.

Daily and Regular Maintenance Checklist

7.1 Daily

Clean the cutting pad and conveyor belt surface with a vacuum cleaner.

Check for debris inside the HPMU vacuum hood and clean the bristles.

Check the liquid level and temperature display of the cooler (normal 19-50 ℃).

7.2 Weekly

Cleaning the guide rail: Wipe the X1, X2, and Y guide rails and lightly apply Tellus R10 oil.

Clean the photoelectric sensor (DynaGuard transmitter/receiver): Wipe with mild soapy water and a soft cloth.

Check the automatic drainage function of the air pressure regulator. If the water cup does not drain automatically, remove and clean it.

7.3 Monthly

Refill the rack and gear with lubricating grease (through the oil nozzle).