Electronics factory warehouse appeared \" cigarette boxes flying car \", 3 days to solve the problem of static electricity slope recordings

Last week in Shenzhen, an electronics factory warehouse, I saw the smoke box from the conveyor line "take off" - the slope of the smoke box more and more slippery faster and faster, hit the front of the baffle directly bounced half a metre high! Warehouse Supervisor Zhang anxious to beat his legs: "This month have crashed more than 200 boxes, and workers were hit by static electricity do not dare to touch the equipment!"In fact, the core of this type of problem is hidden in the 3% Slope Adjustment and Static Prevention and ControlThe first is that the two pain points are not the same as those in the other. Today, we will combine real-world cases to dismantle the solution techniques for these two major pain points.

I. Slope out of control? 3% Gold Slope real-world instruction

Guess what? The culprit of the smoke box "flying car" isSlope exceeds the standard.. The original conveyor line slope even up to 8%, speeding impact force is three times the normal value! We did a test on site:

1. ​Slope Ruler Measurement Method: Attach a protractor to the side of the conveyor frame and measure the angle of inclination ≈ 4.5° (corresponding to a slope of 7.81 TP3T).
2. ​Calculation of the correction value: Target 3% slope = height difference ÷ length × 100% → 3cm height drop per metre
3. ​hands-on conditioning::
   • ​Ground Bolt: Raise the tail of the machine by turning it anti-clockwise with a spanner (1cm per 2 turns)
   • ​laser positioning: Hand-held laser level to mark the 3% slope line on the bracket (green line aligned to meet standard)
   • ​Anti-slip verification: Tested by placing a fully loaded smoke box, the sliding speed was reduced from 1.2m/s to 0.4m/s, stopping steadily in front of the baffles

​Key details: Be sure to do it after the slope adjustmentFull load emergency stop test--Suddenly release the load at the highest point of the conveyor line and observe if it slides down at an even rate. If there is a stutter, it needs to be fine-tuned to the 2.8%-3.2% range.

Second, static electricity beat people? Three moves to end the "crackling monster"

Lao Zhang said that the workers were electrocuted and their "hair stood on end", the essence of which is thatRoller friction + dry environmentSneakiness. We broke the game this way:
https://example.com/anti-static-roller.jpg
Anti-static roller structure (drawing on patent CN202010288094)

1. ​Material upgrades::
   • Replace the plain steel rollers withCarbon Steel Conductive Roller(Surface resistance ≤ 10⁶Ω)
   • bracket stickerAluminium foil tapeGrounding with copper wire (grounding resistance <4Ω)
2. ​Rehabilitation of the environment::
   • Warehouse Entrance Fittingionic fan(Neutralisation of static electricity on cargo surfaces)
   • critical area releaseMobile HumidifierHumidity stable at 45%-55%
3. ​Maintenance God Operation::
   • dailyAnti-static WipesWipe rollers (contains propylene glycol content, does not collect dust)
   • Monthly sprayAntistatic coatingSpraying: Spray gun 20cm away from the drum to form a nano-scale conductive film.

After the transformation take static tester a test - equipment surface voltage from 15kV plummeted to 0.3kV, workers dare to operate with bare hands!

Third, the dust kill: to the rollers wear "protective clothing"

Electronic factories are most afraid of dust jamming the rollers. Before we had to stop work every week to clear the dust, we used two tricks to cure it:

1. ​Enclosed flow strip design::
   • Roller ends withNylon Seals(Temperature resistance -20℃~120℃)
   • Support plate opengutterV-groove: 45° inclined, dust automatically slides off without accumulating
2. ​Static Dust Black Technology::
   • Hang 30cm above the conveyor lineElectrostatic Dust Collector Plate(connected to 12V DC)
   • Dust is adsorbed by electrode when passing through, dust collection efficiency＞92%

Measured data of a factory in Tianjin: after transformationRoller jamming rate down 89%420 maintenance man-hours saved annually!

IV. Routine maintenance: the golden rule for saving time and effort

​Maintenance is not about fixing things when they break, it's about "slowing down" the equipment.. Teach you these tricks:

1. ​Slope Monthly Physical Examination::
   • Measure the slope with the mobile phone app "Level Master" (qualified within an error of ±0.2°).
   • focus onheader (computing): Sudden change of slope at the interface of conveyor section ≤ 0.5%
2. ​Static electricity prevention and control four must check::
   

   checklist	norm	artifact
   earth resistance	<4Ω	multimeter
   Roller surface resistance	10⁴~10⁶Ω	Surface resistance meter
   Environmental humidity	45%-65%	thermohygrometer
   Dust Collector Voltage	12V±0.5V	DC Voltmeter

3. ​Lubrication and Dust Control Package::
   • Quarterly coatingFood grade silicone grease(-40°C does not solidify)
   • For dust removalFlat Nozzle Vacuum Cleaner: suction head against the roller seam pan, dust box water filter anti backblow

​My Experience::
After ten years of doing conveyor line modifications, I foundThe 90%'s faults are planted in the slope and static electricityOn. 3% slope is not a dead rule - like a seafood warehouse in Qingdao changed to 2.5% slope (anti low temperature icing slippage), Beijing Precision Electronics Factory mentioned 3.5% (anti-chip box inertia forward impulse), the key or(idiom) use different methods depending on the product (e.g. product quality).
I'm more optimistic about the future.Intelligent MaintenanceThe mobile phone APP prompts "it's time to change the No.3 position roller"; the slope monitor network alarm, 10 times faster than manual inspection. After all, let the equipment "can talk", is really worry-free!