This line originally used mechanical transmission to synchronize the cutter roller with the feed mechanism. Changing specifications required swapping gears and re-setting the tool, taking about 30 minutes per changeover. The upgrade aims to move synchronization into the controller, replacing mechanical linkages with electronic cam control.
The first step in retrofitting is empirical testing. Use an encoder to record the positional relationship between the feed shaft and the knife roller over one cycle, converting the original mechanical transmission ratio into a cam profile. Empirical data is more reliable than drawings because mechanical clearances have shifted from the original design due to long-term operation.
The second step is phase compensation. Since the cut position is affected by material stretching, the phase must be fine-tuned in real time based on color mark feedback. During debugging, first run with a fixed compensation value to verify functionality, then integrate the color mark signal for dynamic correction to avoid introducing too many variables at once.
After the upgrade, changeovers are performed by switching cam tables in the recipe; mechanical adjustments are now limited to tension only. Note that electronic cams are more sensitive to encoder signal quality—improper shielding or grounding can cause cut jitter.