Coating Machine Maintenance and Care Knowledge 2: Conveyor Belt Maintenance and

Coating Machine Maintenance and Care Guide 2: Conveyor Belt Maintenance and 1. Ensure the coating equipment is installed horizontally and properly grounded. Always use an independent residual-current device (RCD) for safe operation. 2. Keep the coating machine clean by using a compressed air blower to remove dust, thread remnants, and other debris from both the inside and outside of the machine casing before starting up each day. 3. Never place hard objects (such as scissors, pens, rulers, or tools) on the workbench or external cover plates, as they could be accidentally fed into the conveyor belt and cause damage. 4. When starting the machine, first turn on the power supply. Set the temperature initially between 50°C and 60°C—never exceed 80°C. (Only after the upper and lower belts are fully separated should you gradually adjust the speed for smooth conveyor belt operation.)

Introduction and Classification of Coating Machines

The coating machine is primarily used in the surface-coating process for materials like films and paper. It applies a layer of specialized adhesive, coating, or ink—among other functional materials—to a continuous roll of substrate, followed by drying and rewinding. Equipped with a dedicated, multi-functional coating head, the machine enables various types of surface coating applications. Additionally, both the unwind and rewind sections feature fully automatic film-joining mechanisms that operate at full speed, while PLC-programmed tension control ensures precise, closed-loop regulation throughout the process. Among the oldest coating technologies, the brush-type coating machine was first introduced in the 1850s for producing coated wallpaper using porcelain-based coatings. Brush-type coating heads come in three distinct designs: round-brush heads, blanket-roll heads, and blanket-sleeve heads. Figure 1 illustrates this setup.

Causes of Wrinkling in Electrode Sheets During Coater Operation and Countermeasures

1. Overall installation accuracy is low, with the centerlines of individual components deviating from the machine’s designed centerline—or even forming an angle with it—leading to severe wrinkling of the foil strip. The installation centers must be adjusted accordingly. 2. Excessive parallelism errors between the rollers can cause the foil strip to wrinkle. It’s crucial to carefully inspect whether the issue stems from vertical or horizontal planes being out of alignment, and then make the necessary adjustments. 3. If the roller surfaces exhibit excessive roughness—lacking smoothness and showing noticeable machining marks—it can also result in foil strip wrinkling. In such cases, the manufacturer should be contacted for replacement. 4. Ensure that the backing roll and all intermediate rolls are free from foreign contaminants. Additionally, avoid overusing water or isopropyl alcohol during cleaning; regular inspections are essential to catch any issues promptly.

Phenomena and Causes of Poor Coating Gap

1. **Web Breaks** (1) **Material Factors**: Slurry composition, viscosity, solids content, and slurry (surface) tension. (2) **Equipment Factors**: Coating-backup roller gap; coating roller speed when the backup roller expands; diameter of the backup roller; material used for the backup roller surface; potential deformation of the backup roller; alignment between the backup roller and coating roller; misalignment between the backup roller and the front roller in the oven; as well as operational tension levels. (3) **Operational Factors**: Parameters for adjusting the web at the start and end sections. 2. **Non-Parallel Start/End Sections** (1) **Material Factors**: Uneven tensile forces acting on both edges of the substrate. (2) **Equipment Factors**: Misalignment between the horizontal planes of the backup roller and coating roller; uneven expansion of the backup roller from side to side; lack of coaxial alignment on the backup roller’s surface; and misalignment between the backup roller and the traction roller—specifically, horizontal discrepancies.

The Process Flow of the Coating Machine

The coating machine's process flow: The electrode substrate, mounted on the unwinding unit, is pulled out by rollers and, after automatic edge correction, enters the floating roller tension system. Once the unwind tension is adjusted, it moves into the coating head, where the electrode slurry is applied according to the preset program of the coating system. The wet-coated electrodes then proceed to an oven, where they are dried using hot air. After drying, the electrodes pass through another tension control system to fine-tune their tension while simultaneously regulating the winding speed—ensuring it stays synchronized with the coating speed. Finally, the electrodes are automatically corrected by the edge-tracking system to maintain proper alignment in the center, before being neatly wound up by the take-up mechanism. Unwinding → Splicing → Traction → Tension Control → Automatic Edge Correction → Coating → Drying → Automatic Edge Correction → Tension Control → Automatic Edge Correction → Winding The coated substrate (metal foil) is fed into the coating machine via the unwinding unit. At the splicing station, the leading and trailing edges of the substrate are joined to form a continuous strip, which is then conveyed by the traction system to the tension-adjusting and automatic edge-correction units. Here, the web path tension and position are precisely regulated before the material enters the actual coating section. During the coating process, the electrode slurry is applied in segments, with each segment precisely controlled for coating amount and blank length as pre-programmed. In cases of double-sided coating, the system automatically tracks both the first-side coating pattern and the corresponding blank lengths to ensure consistent application. Once coated, the wet electrodes are transferred to the drying system, where they undergo thorough drying at temperatures tailored to the coating speed and film thickness. After drying, the electrodes are further refined through tension adjustment and automatic edge correction before being wound up for subsequent processing steps. A key factor in maintaining the stability of the coating machine is critical—once a parameter is set correctly, it often needs to remain unchanged throughout an entire day. Any fluctuations or disturbances during the coating process can significantly impact battery performance. While machine stability is essential, the operator’s expertise and proficiency play an equally vital role. An exceptional operator not only masters the equipment operation but also understands how to perform routine maintenance effectively. Moreover, such an operator must be adept at identifying the root causes of any issues that arise during coating, pinpointing whether the problem stems from equipment settings, material quality, or operational practices—and, most importantly, knowing exactly how to address and resolve these challenges promptly.

Coating Machine Maintenance and Care Knowledge 2: Conveyor Belt Maintenance and

Coating Machine Maintenance and Care Guide 2: Conveyor Belt Maintenance and 1. Ensure the coating equipment is installed horizontally and properly grounded. Always use an independent residual-current device (RCD) for safe operation. 2. Keep the coating machine clean by using a compressed air blower to remove dust, thread remnants, and other debris from both the inside and outside of the machine casing before starting up each day. 3. Never place hard objects (such as scissors, pens, rulers, or tools) on the workbench or external cover plates, as they could be accidentally fed into the conveyor belt and cause damage. 4. When starting the machine, first turn on the power supply. Set the temperature initially between 50°C and 60°C—never exceed 80°C. (Only after the upper and lower belts are fully separated should you gradually adjust the speed for smooth conveyor belt operation.)

Tips for Coating Machine Maintenance

Coating machines require thorough maintenance in all aspects—this not only ensures safer operation but also reduces the likelihood of malfunctions, ultimately helping to extend the equipment's lifespan. Today, Benyue’s editor shares some handy tips on how to maintain your coating machine effectively, including specific methods for daily upkeep. To properly care for your coating machine on a daily basis, here’s what you should do: 1. Regularly inspect all the screws on the equipment to check for any signs of loosening. A clear understanding of these details will enable you to meet the appropriate maintenance requirements effectively.

What are the types and features of coating machines?

Coating operations are classified into in-machine and off-machine types, depending on the relationship between the coating machine and the papermaking machine. They are also divided into single-layer and double-layer coating processes based on the number of coating applications. In the in-machine method, a coating unit is integrated directly into the papermaking machine, allowing continuous paper production and coating without interruptions. In contrast, the off-machine approach involves separate coating and papermaking machines. The primary types of coating machines used for off-machine operations include roll coaters, air-knife coaters, and blade coaters. Among these, the roll coater applies coating material to the paper surface using a coated roller, making it the most commonly used type in in-machine coating systems. The amount of coating applied can be precisely adjusted by controlling the pressure between the metering rollers—increasing the pressure reduces the flow of coating material, thereby decreasing the coating thickness.