From Tuning to Maintenance: A Rubber Laser Marking Case Study
The book centers on optimizing the entire rubber laser marking process, explaining in detail how to improve marking efficiency and product quality, from setting up equipment and matching parameters to routine maintenance.The book shares actual case studies to help readers resolve common problems such as unstable laser power and blurry marking, helping users reduce maintenance costs and prolong equipment life.
Why is it necessary to optimize the entire process?
Many factories that were just beginning to use laser marking thought that "as long as it works, that's fine." But they discovered that either the marking wasn't clear enough and the customers returned the goods, or the equipment broke down all the time.The real problem was that the process hadn ’ t been smoothed out. The parameters were set at random, and maintenance was all about “ hitting one ’ s head against the wall, ” with the result that the end cost was actually higher.
Last year, we helped a company that makes shoe soles to optimize its production process and discovered that in the testing phase alone we could save 15 % in material waste, and the failure rate of equipment fell by half.The key to this method is four words: "Don't be afraid of trouble.
The test period: from "flipping over" to stable production.
First, you have to find the right material.
Rubber is not a monolithic material, and the hardness and amount of latex in it can make a world of difference in how it responds to a laser.For example, EPDM rubber requires more power, and silicone rubber can easily be burned.He suggested that they first do a test on scrap material to measure the depth of the laser burns at different power levels. This would be much more reliable than relying on the manufacturer's "standard specs.
Environmental factors shouldn't be ignored.
In the summer, the temperature in the laser chamber rises, and the efficiency of the cooling system falls, which can cause power fluctuations.One customer once had his bid spoiled in the afternoon, because he had not had air conditioning installed.Later, we added a temperature control system to the equipment room, and the consistency of the markings increased by 40 %.
The secret of saving money is in daily maintenance.
Cleanliness is more important than you think.
If the laser lens gets covered with rubber dust, it's like having myopia and not cleaning your glasses. The light is deflected and the energy is scattered.Wiping the lens with a dust-free cloth and a special cleaning agent once a week can reduce the power loss problem by 80 %.One person tried using alcohol-soaked cotton balls, but ended up with the coating peeling off.
Calibration is serious business.
Don't wait until the marks are off before checking the light path.It is suggested that the focal point be calibrated once a month, and the accuracy of the marking tested with a calibration plate.One factory insisted on quarterly calibrations, and as a result did not need to replace the galvanometer for two years, saving tens of thousands of dollars in repair costs.
How do you deal with problems?
The yellowed label was handled in this way.
If the rubber is light in color and turns yellow, don't immediately adjust the power.Most of the time the problem is that the auxiliary gas (such as compressed air) contains too much moisture, which causes oxidation at high temperatures.Installing a three-stage filter dryer will solve the problem at a much lower cost than replacing the laser.
Don't panic if your bid is suddenly cut.
If the lines are discontinuous, check the ground connection first. Static electricity may cause the laser to drift off course.Once we spent three hours on site and finally discovered that a ground wire had become loose. We tightened the screw and everything returned to normal.
This method looks simple, but the key is persistence.Just as a car needs regular maintenance, laser equipment needs "three parts use, seven parts upkeep.First you have to get the calibration right, and then you have to do the day-to-day maintenance properly. Then you'll see that the production costs are more and more stable and customer complaints are fewer and fewer.