A poker card die-cutting machine is the most important equipment in the production of poker, smart cards, game cards, and paper cards. It ensures the products are made correctly and quickly. It has the main features of accurate feeding, automatic collection, and automatic waste removal and is widely used by poker production enterprises all over the world. For overseas customers who want to produce poker cards in large quantities and produce good poker cards, how to use scientific methods to make the production efficiency of poker card die-cutting machines higher is directly related to the reduction of production costs and the improvement of market competitiveness. This article will combine the characteristics of the equipment, starting from the four elements of typesetting, pressure adjustment, speed and accuracy balance, and environmental control, to discuss how to optimize production. This will help companies produce more efficiently and stably.
The Art of Layout: How to Make the Most of Your Materials
Material costs are a very large part of the total cost of card production. The best way to reduce production costs is to make full use of materials, and scientific typesetting design is the best way to achieve this. The poker die-cutting machine can die-cut books, filter paper, etc. This provides more options for optimizing typesetting, but the specific plan needs to be formulated according to different materials and product specifications.
First, the layout should follow the principle of "close fit and staggered arrangement." Using computer-aided typesetting software, cards of different sizes (such as standard playing cards and customized game cards) can be combined, as long as the edge blanking standard of the product is met and large areas of blank space are avoided. For example, small and large cards can be arranged side by side on the same substrate, and the edge space can be used to fill the blank. This increases the yield of material per unit area. The cutting range and feeding precision of the poker die-cutting machine should also be considered. When typesetting, sufficient running space should be reserved for the paper feeding mechanism of the equipment to avoid paper jams or die-cutting errors due to tight typesetting.
Second, the correctness of the typesetting and material specifications must be ensured. The thickness and width of the base material used for different card products, such as coated paper, PVC, ABS, etc., are different. Before typesetting, the material specification parameters should be clarified and changed according to the characteristics of the equipment's wooden light mold. The equipment's wooden lightweight mold can be changed in only 2-3 minutes. This means it can quickly adapt to the mold requirements of different typesetting schemes. Enterprises can plan different layout schemes in advance according to the mass production tasks. It can also continuously produce different products by quickly changing the mold, which further improves the material utilization rate and production efficiency.
In addition, the optimization function of the typesetting software can be used to make the typesetting more scientific. At present, the more popular typesetting software can automatically optimize typesetting and track material loss. It can also automatically generate the best typesetting scheme according to the quantity and specifications of the products. Enterprises can make full use of this tool to compare the material loss rate of different layout schemes and select the best scheme for production. For standard products with large batches, fixed typesetting templates can reduce repetitive design work and speed up production preparation.
The science of stress regulation: What happens when stress is too little or too much?
The most important technical link in the manufacture of poker die-cutting machines is pressure control. This directly affects the quality of the product and the service life of the machine. The equipment comes with a 7.5 kW automatic servo system to ensure the pressure is set correctly. However, the law of scientific adjustment must be followed to avoid production problems caused by too light or too heavy pressure.
If the pressure is too small, the die-cutting will not be thorough, which will cause problems such as burrs on the edge of the card and an unclear outline. The next step is manual trimming, which not only increases labor costs but also reduces production speed. At the same time, if the die-cutting is not correct, it may cause the waste to be unable to be removed smoothly. The waste material will build up in the die-cutting mechanism, causing the equipment to jam and production to stop. To solve this problem, slowly increase the pressure as the substrate thickness and hardness increase until the cards are completely punched out. At the same time, make sure that the waste material can be easily separated from the substrate.
Excessive pressure can be counterproductive. It will accelerate the wear of the mold, shorten the life of the wooden light mold, and increase the cost of replacing the mold. It will also cause the transmission mechanism, frame, and other parts of the equipment to bear excessive pressure, accelerate aging, and reduce the service life of the equipment. In addition, excessive pressure can also cause deformation of the substrate, especially flexible materials such as PVC, which are prone to problems such as card warping and dimensional deviation, reducing the product qualification rate.
The scientific method of adjusting the pressure should follow the principle of "gradual progress and precise matching." First, set the initial pressure according to the thickness of the product and the nature of the substrate. Use the pressure recommendation value in the equipment operation manual. 2. Check the die-cutting effect by trial production of a small number of products. If there is a burr, slowly increase the pressure. If the substrate is bent, reduce the pressure as needed. Finally, the real-time feedback function of the 7.5 kW servo system is used to pay attention to the pressure change curve at all times to ensure that the pressure is stable within the best range. For mass production, the equipment's memory function can save the pressure settings of different products. These settings can be directly called up the next time the product is run, allowing for faster adjustments.
Find the best balance between speed and accuracy.
Speed and precision are the two major problems encountered in the production process of the poker die-cutting machine. If you only care about speed, you will lose accuracy. If you only care about accuracy, you will lose production efficiency. To make production more efficient, a suitable balance point needs to be found between the two. The equipment has the characteristics of high punching precision, no burr, automatic servo drive, etc., which provides a strong technical foundation for balancing speed and precision.
First, the accuracy requirements of the product should be clarified, and a reasonable card-making speed should be set on this basis. Different types of card products have different requirements for accuracy. For example, smart cards require the embedding of electronic components such as chips, and the requirements for edge accuracy and dimensional tolerances are very high. In order to ensure the stability of die cutting, the production speed should be reduced to a suitable level. The precision requirements for ordinary playing cards are not high, and the speed can be appropriately increased as long as the precision is guaranteed. Through trial production, the company can explore the fastest speed for making different products, establish a speed parameter database, and facilitate the call when more production is carried out in the future.
2. The automatic servo system of the equipment is brought into full play, and the speed is more stable. The equipment is equipped with a 7.5 kW automatic servo system, which has a fast response speed and stable operation. It can also precisely control the synchronization of the feeding speed and the die-cutting frequency, which helps to reduce the accuracy error caused by the speed change. When the operator changes the production speed, the servo system will feed back the running data in real time. Operators can see how the die-cutting accuracy changes through the monitoring interface and modify the speed parameters in time to ensure that the accuracy always meets the requirements during the speed-up process.
In addition, planning the production process well and reducing non-production time can indirectly improve the effective production speed. For example, take advantage of the quick mold change feature of the equipment (2-3 minutes) to prepare the molds for different products in advance to reduce the production line switching time. Automatic classification and sorting, customized finished product collection (collection in order, collection by category), and other functions can also reduce the time for manual sorting of finished products, make the equipment operate efficiently, and achieve a balance between speed and accuracy.
The influence and control of temperature and humidity on the stability of die cutting
The die-cutting stability of the poker die-cutting machine not only depends on the performance of the machine but also depends on the temperature and humidity of the area where it is used. The temperature and humidity in production workshops vary greatly around the world. If not controlled, it will change the performance of the substrate, cause the equipment parts to fail, and then affect the quality of the product and the production process. In order to ensure the stability of die cutting, it is very important to scientifically control the temperature and humidity of the production environment while considering the technical characteristics of the equipment.
The influence of temperature on the die-cutting process mainly has two aspects: one is the substrate itself. For example, PVC, paper, and other substrates are easily deformed at high temperatures and become hard and brittle at low temperatures, which reduces the die-cutting accuracy. Second, the operation of equipment parts. High temperature will accelerate the aging of the equipment lubricating oil and reduce the accuracy of the transmission mechanism, and low temperature will slow down the response speed of the servo system. Therefore, the temperature of the production workshop should be maintained between 20 and 25 degrees Celsius. The temperature can be changed by central air conditioning and constant temperature equipment.
Don't forget the effect of humidity. When the humidity is high, the paper, cardboard, and other substrates are easy to absorb moisture, causing the paper edge to soften, and the burrs and adhesion are more likely to occur during die-cutting. When the humidity is low, the substrate is dry and brittle, and it is easy to generate static electricity, which affects the stability of automatic paper feeding and finished product paper collection. To solve this problem, the workshop humidity should be maintained between 45% and 60%. Humidifiers and dehumidifiers can be used to accomplish this. In addition, for large batches of substrates, they should be put into the workshop in advance for warm and humid treatment. This can ensure that the substrate adapts to the production environment and makes die-cutting more stable.
At the same time, as the equipment has the characteristics of integrated and customized overall solutions, enterprises can formulate their own environmental adaptability solutions according to their own production environment needs. For example, in areas with high humidity, the equipment can be adapted with moisture-proof components; in areas with low temperatures, the heating and insulation system of the equipment can be improved to make it more adaptable to the environment.
Conclusion: Maximize productivity with scientific optimization.
The poker die-cutting machine is the most important equipment for poker production. To improve the production efficiency of a poker die-cutting machine, many factors such as typesetting, pressure, speed accuracy, and environment need to be considered. At the same time, the unique functions of the machine should be fully utilized. Faster mold changes for light wood molds, the use of a 7.5 kW servo system to ensure accurate operation, and the use of integrated customized solutions to meet different production needs are all important steps to improve production efficiency.
For companies that manufacture and sell products worldwide, the practical tips shared in this article can help poker card die-cutting machines work better, produce more qualified products, and reduce production costs and equipment losses. With the continuous improvement of production technology, enterprises should pay close attention to the technical characteristics and improvement methods of equipment. At the same time, enterprises should also tap more production potential through scientific management and operation so as to maintain a leading position in the fierce market competition. It should be noted that only trained professionals can optimize and operate the equipment. This ensures that every change meets the equipment's operating standards and maximizes the equipment's core value.