📞:+86 13381527768
📫:export@zaxmedical.com
📞:+86 13381527768
📫:export@zaxmedical.com
Fully automatic ECG electrode assembly equipment integrates dispensing, die-cutting, conductive buckle testing and waste removal modules. Long-term high-speed operation will trigger various process failures, lower electrode yield and lead to unexpected production shutdown. We classify all frequent malfunctions into three major categories with targeted inspection and maintenance solutions for factory operators.
This type of fault directly affects finished electrode appearance and quality. Typical issues include uneven hydrogel coating, molding deformation and rough die-cut edges.
Main root causes: Unstable dispensing pressure, worn cutting molds and unbalanced coil tension. If the tension roller is not calibrated regularly, substrate shifting will lead to gel deviation during coating.
Maintenance tips: Clean glue residue on dispensing rollers daily; Replace aging cutting molds regularly; Recalibrate feeding tension every week to keep consistent substrate positioning.
Many factories face batch unqualified conductivity test results caused by detection system faults, instead of raw material quality problems.
Core reasons: Dust accumulation on photoelectric sensors and displacement of conductive buckle positioning jigs, which cause the machine to misjudge normal electrodes as defective goods.
Solutions: Wipe detection sensors with clean cloth daily; Lock positioning fixtures tightly after mold replacement to guarantee stable testing accuracy.
Three high-frequency conveying faults: Coil breakage, substrate shortage alarm failure and waste material jamming inside the peeling module.
When photoelectric sensors are covered by residual gel, the alarm system cannot trigger warnings when raw materials run out, resulting in long-time idle running and raw material waste. Sticky waste film will block the automatic waste discharge structure.
Quick fixes: Clean all sensor surfaces every shift; Adjust waste roller pressure properly to avoid residual adhesive adhesion.
Hidden long-term faults include slow multi-spec mold switching, abnormal running noise and disordered control parameters after long-hour load operation.
Lack of lubrication on transmission rails, overloaded servo motors and aging internal circuits will cause unstable production speed fluctuation. Outdated control programs also slow down substrate switching response.
Preventive maintenance: Add lubricating oil to guide rails periodically; Update machine control program quarterly; Arrange full circuit inspection for equipment over 2 years old.
To reduce downtime loss, medical manufacturers need to build standardized daily inspection workflow: Check die cutting dimension, clean detection sensors and replace vulnerable parts on schedule. Timely remote after-sales consultation is recommended once unknown abnormal alarms pop up, to avoid small faults expanding into heavy shutdown losses.