Pneumatic Friction Welding Baler
B19, B25 Series Pneumatic Tool
Operations, Components and Security Guide
1. Safety Instructions
General Safety Rules
- Adhere to a "safety-foremost" principle.
- Read the manual carefully before operation.
- Do not dismantle safety parts.
- Do not tear or damage labels or marks on the product.
- Keep hands and body parts away from the packaging belt and tool during operation.
Application
This tool is designed for binding articles with PET packaging belts. Applicable belt widths are 13, 16, 19, 25mm. Do not use the packaging belt for lifting.
Correct Dressing
Wear safety glasses, earmuffs, protective gloves, helmet, protective footwear, and long-sleeved shirts. Ensure clothing is fastened and does not get caught by the machine.
Gas Source
Use an air supply pipe resistant to pressure and oil. Use a special quick union for the air pipe. Air pressure should not exceed 100psi/7bar. Use only clean compressed air.
Ventilation
Ensure proper ventilation, as indoor air can be polluted by lubricating oil.
Vibration
Prolonged exposure to excessive vibration is harmful. Adhere to operation specifications conforming to ISO5349.
Noise
Wear earmuffs if noise levels exceed 85dB(A). Earmuffs are recommended even below this level.
Safety Glasses
Wear safety glasses to protect against potential blindness from sudden packaging belt breaks.
Moving Part
Avoid touching moving parts, such as the take-up pulley, while it is rotating, as they can trap gloves or body parts.
Maintenance
Perform daily maintenance. Check regularly and remove dust. Tighten screws. Turn off the gas source before replacing parts.
Hazard While Cutting
The blade holder contains a sharp blade that can cause injury. Always wear safety gloves.
2. Principle of Friction Fusion
This tool is a friction fusion packaging machine where lapped thermoplastic packaging belts are fused by heat generated from friction motion.
Compressed air pushes a piston within the air cylinder. A rocking pin connected to the piston moves a vibrating bar downwards, pressing the lapped belt. An eccentric shaft in the pneumatic motor drives the vibrating bar in a rapid reciprocal motion, causing friction between the belt parts.
Diagram Description: Friction Fusion Mechanism
The diagram shows the main components: Body, Piston spring, Rear cover, Small rotor, Vibration motor, Blade holder, Blade pin, Take-up pulley, Tightening toothed plate, Body cover, Rocking pin, Piston, Eccentric shaft, Ball bearing, Vibrating bar, Base, and Fusion toothed plate.
3. Specification and Parts
Specifications
- Mode: B19, B25
- Tension Force: 3,500N (at 0.63Mpa air pressure)
- Max. Allowable Working Pressure: 0.8Mpa
- Required Working Pressure: 0.5~0.7Mpa (72-100psi)
- Weight: 3.65kg
- Total Length: 300mm
- Width: 149.5mm
- Height: 173mm
- Packaging Belt Material: PET
- Packaging Belt Width: 13mm~19mm
- Packaging Belt Thickness: 0.5~1.5mm
- Fusion Time: 2~5s
Parts Overview
Key parts include the Tightener (3,500N) and the Cutting device (Heavy cutting device for 0.5-1.5mm belts, Friction cutting device for 0.5-0.7mm belts). The tool supports suspension at various positions.
4. Gas Source Instruction
Requirement of Air Pressure
Required air pressure for B19, B25 is 72-100psi (5.0-7.0 bar).
Installation of Gas Source
Install filter, pressure regulating valve, and lubricator assembly close to the pneumatic tool. The air hose minimum inner diameter should be 6.0mm (1/4 inch). Use quick unions on both ends of the air supply pipe.
Moisture Filtration
A drain valve must be mounted at the bottom of the air supply circuit's bypass to drain moisture daily.
Lubrication
The pneumatic motor requires proper lubrication. The lubricator should be kept full and regulated to deliver approximately one drop every 2 minutes.
Diagram Description: Gas Source Connection
The diagram illustrates the connection of air pressure quick unions to the air supply pipe, leading to a filter, pressure regulator, and lubricator assembly, with a drain valve shown.
5. Operation Instruction
5.1 How to Bind
- Bundle the article with the packaging belt.
- Hold the lapped part with the left hand, leaving about 300mm tail.
- Pull the remaining part out with the right hand.
5.2 Place Packaging Belt
Hold the handle and tightener with the right hand to ensure maximum opening between the take-up pulley and tightening toothed plate. Insert both upper and lower parts of the packaging belt into the machine. Ensure the lapped part is separated by the blade holder's blade. Release the tightener to clip the belt.
5.3 Tighten the Packaging Belt
Press the tightening button (right side) with the thumb of the right hand until the belt is sufficiently tight.
5.4 Vibration and Cutting
Press the fusion button (red) with the thumb of the right hand until the belt is fused and cut off. Note: Continue pressing the button until the vibration timer stops automatically.
5.5 Take Down the Machine
Press the handle and tightener firmly with the right hand. Press the rewinding button with the little finger of the right hand to release the belt from the take-up pulley. Press the handle and tightener again, then remove the tool from the packaging belt. Ensure the belt is released before removing the machine.
6. Specification Adjustment
Width of Packaging Belt
Panel: The panel can be removed and replaced based on the packaging belt dimensions and installation method.
Location Hook: The location hook of the blade holder can be reassembled by removing the spring pin. A small compression spring is located within the hook.
Reassembly (Belt Width)
Choose a hole on the blade holder according to the packaging belt dimension: external hole for 19mm, medium for 16mm, and internal for 13mm belts.
Distance (a) between Tightening Pulley and Tightening Toothed Plate
This distance should be adjusted based on the belt thickness. It should be no less than the belt thickness. The default setting is 1.0mm more than the belt thickness. Adjustments involve adding gaskets (0.2mm thick) under the tightening toothed plate or between the body and blade.
Distance (b) between Vibrating Bar and Fusion Toothed Plate
Measure this distance with a feeler gauge. Press the fusion button for at least 2 seconds to move the piston and vibrating bar downwards. If the belt thickness is less than 0.6mm, insert a 0.2mm gasket. Do not insert too many gaskets, as this can damage the machine.
7. Disassembly
The following outlines the disassembly method for daily maintenance and part replacement. Complex motor body parts should be serviced by a professional.
Base
Disconnect hoses from the air pipe plug. Remove screws from the bottom of the base to detach it from the motor body.
Take-up Pulley and Tightening Toothed Plate
Unlock the connection pin shaft, remove the nut and gasket, then pull the front side plate to separate and remove the take-up pulley.
Connection Pin Shaft
Disassemble the motor body, base spring, and base by pulling out the connection pin shaft.
Cutting Device
Remove screws to disassemble the blade holder. Disassemble the blade and blade pin. Check and replace the blade if blunt. Remove the blade pin and bearings.
Vibration Motor
Remove screws from the rear cover and knock the shaft end of the small rotor. Disassemble bearing liner, ball bearing, and gasket from the body.
Body Cover and Piston
Remove screws from the top of the body cover. Remove the rocking pin. Use an air duster gun to remove the piston and piston spring from the body.
Vibrating Bar
Remove the vibrating bar from the bottom of the body.
8. Reassembly
The reassembly process generally follows the reverse of the disassembly steps.
Vibrating Bar
Insert the vibrating bar into the body, ensuring correct orientation. Assemble ball bearings onto the blade pin and then onto the vibrating bar.
Piston
Insert piston spring, lubricate and assemble the O-ring into the piston, then insert into the body. Ensure the rocking pin faces forward. Assemble the rocking pin into the piston and vibrating bar. Assemble the body cover with its O-rings and fasten with screws.
Vibration Motor
Assemble gasket, bearings, and bushing onto the small rotor. Insert the pneumatic motor into the body and assemble the ball bearing. Secure the rear cover with screws.
Cutting Device
Assemble the blade onto the blade pin and into the blade holder, securing with screws.
Connection Pin Shaft
Assemble the base torsion spring, motor body, and connection pin shaft. Assemble the take-up pulley onto the turbine shaft. Insert the front side plate assembly and secure the connection pin shaft with the nut and gasket.
Base
Fix the motor body onto the assembled base using the connection pin shaft and secure with screws.
Air Supply Hose
Insert air hoses with springs into the pipe joint on the valve body.
9. Failure and Trouble-shooting
Common Failures
| Phenomenon | Causes | Trouble-shooting |
|---|---|---|
| Motor body can't start | 1. Foreign material in motor. 2. Motor needs lubrication. | 1. Send for repair. 2. Add lubricating oil to motor. 3. Press inverting button, then entering button. |
| Tightening pulley presses the upper packaging belt | 1. Distance between pulleys too wide. 2. Tension force too strong for belt thickness. 3. Take-up pulley blocked by dust/residue. 4. Teeth of take-up pulley blunt. | 1. Increase gasket. 2. Clean take-up pulley teeth. 3. Replace take-up pulley. |
| Packaging machine moves forward or can't clamp the end of packaging belt | 1. Take-up toothed plate blocked by residue. 2. Teeth on take-up toothed plate blunt. 3. Tension too strong. | 1. Clean take-up toothed plate. 2. Replace take-up toothed plate. 3. Adjust tension. |
Cautions During Tension Operation
After tying the article, hold the overlapping part by hand to pull out excess belt. Ensure the overlapping part is aligned in the machine.
Fusion Operation Failures
| Phenomenon | Causes | Trouble-shooting |
|---|---|---|
| Incomplete fusion or no fusion | 1. Insufficient air pressure. 2. Small air pipe ID. 3. Fusion teeth blocked or worn. 4. Vibration motor needs lubrication. | 1. Adjust air pressure. 2. Use larger ID air pipe. 3. Clean or replace teeth/bar. 4. Lubricate motor. |
| Packaging belt excessively fused or broken | 1. Insufficient belt thickness. 2. Fusion time too long. 3. Short cooling time. | 1. Use correct belt thickness. 2. Reduce fusion time. 3. Ensure 3s cooling time. |
| Machine can't move off after fusion | 1. Take-up pulley can't reverse. 2. Vibrating bar fails to rise. | 1. Press rewind button. 2. Hold tightener handle to connect with exhaust valve. |
Cautions During Fusion
Sound fusion ensures a smooth joint, but excessive fusion can weaken the belt. Allow 3 seconds after fusion for the joint to set.
10. Part List
A comprehensive list of spare parts is provided, detailing part numbers, figure references, part names, and quantities. This list is extensive and includes numerous components for the B19 and B25 series pneumatic tools. Due to the extensive nature of this list, it is summarized here.
11. Assembly Drawing
An assembly drawing illustrates the complete breakdown of the pneumatic tool, showing all components and their interconnections. This diagram serves as a visual reference for part placement and assembly. Due to its complexity, a detailed textual description of the entire diagram is not feasible here.
