Setting overlap X7

Checklist setting overlap X7

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X7 – Setting overlap

1. The cutted blanks must be within the required tolerance (see tolerance requirement of Can Man/Soudronic). Cutting burrs should not be present. Measure at least all blanks of one complete sheet or more.
2. The corresponding setting values in the HMI should be checked and corrected if necessary.
3. The rounding of the can body must be correct: 

• A) The shape of the can body must be as circular as possible. 
• B) Both welding edges must be overlapped accordingly: Diameter 99 – 127 mm approx. 10 – 15 mm. 
• C) There should be no offset of the two front/rear corners to each other.

4. The overtravel of the can body over the welding center should be in accordance with Instruction manual (IM) must be set.
5. The grooves in the upper welding disc and lower welding roller must not be worn. If necessary, they should be regrooved (see IM).
6. The width of the copper wire profile should be set correctly. Measure the width on different positions.
7. The height of the lower welding roller should be adjusted above the theoretical welding center (center z-bar): This reduces the possibility of the two front edges being welded with too much overlap (see 17.)
8. The tin imprint after the lower welding roller and upper welding disc should be visible as centrally as possible on the copper wire.
9. The welding pressure should be between 42 – 50 daN, depending on the materialhardness/thickness and overlap. Check the correct melting of the two welding edges by means of a micrograph.
10. The complete z-bar should not be worn.
11. Setting of calibration crown (CC): 

• A) The basic setting must be made with the mandrel on the adjustment gauge. 
• B) The entire CC should be clean, all rollers must rotate smoothly.
• C) The adjustment of the CC should always be carried out in accordance with the IM.
• D) If necessary, it is helpful to adjust the preload of the individual pre-centering rolls according to your own experience and depending on the sheet format.
• E) If necessary, it is helpful to adjust the two upper ceramic diabolo rollers so that the upper end of the inner diabolo roller is slightly closer to the adjustment mandrel than the upper end of the outer diabolo roller. About as much as a blank thickness.

12. The height adjustment of the CC is to be adjusted by welding a can body. It can help if the CC is set to low, so that the shape of the welded can body is like "a pear". Basically must the seam-extrusion inside/outside be equal. It can be measured by a linen tester.
13. The adjustment of the overhead discharge conveyor should be made with the adjustment mandrel: The two belts should have approx. 0.5 mm air to the adjustment mandrel. It is important that the adjustment mandrel is pressed by hand from above onto the lower diabolo rollers/conveyor belt (after the main diabolo rollers).
14. The two welded body blank edges should not have an offset and must be adjusted accordingly.
15. The position of CC center in the welding direction should be set correctly: 1.5 – 0.5 mm in front of the center of the welding rollers leads to the best welding results. The correct position shall be determined by means of experiments (see 17).
16.  In order to adjust the outer gas-shoe correctly, the CC should be removed and mounted on the adjustment dummy. Then the shoe can be correctly positioned following the setting-mandrel. The distance between the mandrel and the inner surface of the shoe is 1 – 2 sheet thicknesses. The inner gas-shoe must be adjusted directly in the machine. Here as well a distance of 1 – 2 sheet thicknesses to the inside of the welded can body.
17. The width of the welded overlap follows the overlap of the Z-rail: Diameters 99 and 127 mm are usually welded with a «Z-rail 0.4 mm». The effectively measured overlap at the exit point of the two z-bar nosepieces measures 0.45 mm. This results in a welded overlap of 0.50 – 0.60 mm. In the best case, the adjustment of the welded overlap is carried out only with the setting described in point 15. In the second best case, it is a combination between screwing in / out the differential screw on the WZ (see also IM) and from point 15.