Operating Manual

for

MAXSON MDH Dual Knife/Rotary Cutter

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 Table of Contents

Section Description

1 Safety Guidelines and Procedures

 Company Responsibilities Concerning Safe Equipment Operation
 General Safety Rules
 Specific Safety Rules for MAXSON Sheeters

2 General Description of MAXSON MDH Dual Knife/Rotary Cutter

 Lead In Roll
 Slitter Rig
 Draw Drum Section
 Doctor Board Arrangement
 Dual Knife/Rotary Cutter
 Mechanical Transmission Components
 Electrical Drive System
 Operator Controls
 Safety Guarding

3 Lead in Roll and Slitter Rig

 General Description of Lead In Roll and Slitter Rig
 Setting the Position of the Lead In Roll
 Setting the Bottom Slitter Rings
 Replacing the Bottom Slitter Rings
 Setting the Top Slitter Blades
 Maintenance Schedule of Lead In Roll and Slitter Rig

4 Draw Drum Section

 General Description of Draw Drum Section
 Draw Drum Description
 Squeeze Roll Description
 Initial Inspection of Squeeze Roll
 Operation of Squeeze Roll
 Maintenance of Squeeze Roll
 Storage of Spare Squeeze Roll
 Maintenance Schedule of Draw Drum Section

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 Table of Contents (Continued)

Section Description

5 Doctor Board System

 General Description of Doctor Board System
 Setting the Position of the Before Knife Doctor Board
 Setting the Position of the After Knife Doctor Board
 Maintenance Schedule of Doctor Board System

6 Cutter Drive
 General Description of Cutter Drive System
 Mechanical Transmission Train
 Electrical Drive
 Maintenance Schedule of Cutter Drive

7 Installation, Adjustment, Care and Regrinding of Cross Cutting Knives

 Necessary Tools and Parts to Install Cross Cutting Knives
 Honing New Cross Cutting Knives
 Procedure for Removal of Cross Cutting Knives
 Procedure for Installation of Cross Cutting Knives
 Care and Maintenance of Cross Cutting Knives
 Regrinding of Cross Cutting Knives

8 Lubrication System
 General Description of the Lubrication System
 Oil Lubrication of Cutter Gears
 Lubrication of Cutter Bearings
 Maintenance of Lubrication Points

9 Pneumatic Controls
 General Description of Pneumatic Controls
 Cutter Compressed Air Supply
 Slitter Rig Air Controls
 Squeeze Roll Air Controls
 Maintenance of Cutter Pneumatic System

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 Table of Contents (Continued)

Section Description

10 Electrical Controls
 General Description of the Electrical Controls
 Cutter Electrical Control Supply
 Cutter Infeed Electrical Controls
 Main Operator Console
 Main Menu Screen
 Operator Menu Screen
 Production Menu Screen
 Set Up Menu Screen
 Motor Drive Status Screen
 Automatic Decurl Screen
 Description & Operation of Cut-to-Mark Feature
 Set-Up of Cut-to-Mark Feature
 Overview of the Cut-to-Mark Feature
 Cut-to-Mark Set-Up Screen

11 Safety Guarding
 General Description of Safety Guarding
 Location of Safety Interlocks and Emergency Stops

12 General Operating Instructions

 Set Up Procedure
 Threading Procedure
 Operating Procedure

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 Section 1

Safety Guide Lines and Procedures

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Customer Responsibilities Concerning Safe Equipment Operation

This manual outlines proper and safe operation and maintenance procedures to be followed
when working with the MAXSON Sheeter.

All personnel should read and become familiar with this manual before being allowed to
operate or make adjustments on this equipment.

All personnel must be made aware of the serious liability they will incur should they disable
any of the safety devices installed on the machine or fail to follow the proper procedures in
operating and maintaining the equipment.

It is the Customer’s legal responsibility to have and follow a Lock Out/Tag Out
procedure for servicing this equipment.

The equipment has been designed for high speed, continuous operation. The equipment is
subject to normal wear and by nature of its service can be subjected to heavy momentary over
loads. The over loads may occur because of jam ups caused when processing webs with
unmarked splices, tear outs, heavy curl, static problems, etc. The equipment must be
inspected periodically for components showing damage or undue wear. These parts must be
replaced immediately.

The Customer is obliged to notify MAXSON AUTOMATIC MACHINERY COMPANY

immediately if during the operation of this equipment, a condition develops which causes the
Customer to believe a safety hazard exists.

In the event of an Operator injury associated with this machinery, the Customer is obliged to
notify MAXSON AUTOMATIC MACHINERY COMPANY of the incident.

MAXSON AUTOMATIC MACHINERY COMPANY will, after consultation with the

Customer’s management and operating personnel, take corrective action deemed necessary.

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 General Safety Rules

The most important factor in accident prevention is safe working practices. The following “Do’s” and
“Don’ts” are general rules that apply to any manufacturing machinery that converts rolls to sheets.
Safety Do’s
1. Be familiar with plant and machine safety rules and notes.
2. Be sure crewmembers are aware of all areas and operations that need extra safety measures.
3. Wear protective devices.
4. Correct or report any missing or inoperative safety devices.
5. Report bare wiring or exposed electrical circuits.
6. Keep the floor around the entire machine clean.
7. Keep aisles clear.
8. Report any injury to plant management and machine manufacturer.
9. Make sure injuries receive prompt medical treatment.
10. Be alert and use common sense.
11. Follow lock out/tag out procedures prior to working on the machine.
Safety Don’ts
1. Don’t remove or bypass safety devices.
2. Don’t wear jewelry or loose clothing near moving equipment.
3. Don’t fail to warn others of an intended action that may endanger them.
4. Don’t start a machine unless you are sure there is no danger to your fellow workers.
5. Don’t clean or lubricate moving parts of a machine that is running.
6. Don’t place tools on a machine that is running.
7. Don’t climb or crawl over machinery that is running.
8. Don’t allow horseplay in working area.
9. Don’t allow unauthorized persons to operate machinery.
10. Don’t leave unattended equipment in an unsafe condition.

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 Specific Safety Rules for MAXSON AUTOMATIC MACHINERY
COMPANY Sheeters

There are several specific safety rules for operating a MAXSON Sheeter:

1. Always follow the instructions and recommended procedures in this manual.

2. Never perform work on sheeter components without locking out/tagging out the main drive.

3. Never attempt to retrieve any object advancing into the sheeter with the web. Remove all trim
and waste only with the machine shut down and the main drive locked out/tagged out.

4. Never enter the machine area under rotating components.

5. Handle cross cutting blades and slitter knives with care. Even non-rotating knives can cause
severe injury.

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 Section 2

General Description

of the

MAXSON MDH Dual Knife/Rotary Cutter

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 Description of the MAXSON MDH Dual Knife Rotary Cutter

General Description of the Cutter

The MDH Cutter can include lead in rolls, a slitter rig, a draw roll section, a doctor board arrangement,
a dual knife/rotary cutter, mechanical transmission components, an electrical drive system, operator
controls and safety guarding mounted on a common steel weldment.

Due to the continual research for improvements and modernization of this equipment, it maybe found
that various portions of this manual differ slightly from your machine. If in any case where a problem
arises, or further information is required that is not covered by this text, please contact MAXSON
AUTOMATIC MACHINERY COMPANY’s Customer Service Department.

Lead In Roll
The cutter’s lead in roll insures smooth web flow into the cutter and establishes the correct depth for
slitter penetration at the infeed. The dead shaft roll is constructed of aluminum tubing and balanced
for vibration free performance. The roll’s mounting bracket can pivot to permit different flow paths.

Slitter Rig
The slitter rig consists of individual top slitters mounted on a dovetail bar across the width of the cutter
loaded against bottom slitter rings. The slitter rig allows the sheeting operation to trim a web to a
finished width or create several web streams across the sheeter prior to cutting to length.

The top slitters have individual height and side load adjustments, which are governed by pneumatic
adjustments. These adjustments provide a means for obtaining minimal dusting and edge distortion for
the material being cut. The lower rings are mounted on a rigid bottom slitter shaft and are driven
slightly faster than the line speed via a timing belt coupled to the draw roll.

Draw Drum Section

The draw drum section includes a rubber covered squeeze roll loaded against a driven draw drum.
Both rolls are dynamically balanced for vibration free performance. The web is nipped between these
two rolls and pulled into the cutter.

The draw drum is motor driven via high torque drive pulleys and timing belts. The surface speed of
the draw drum is the sheeter’s line speed. The squeeze roll’s rubber covering is usually chevron
grooved to minimize wrinkles as the web is drawn into the cutter. The squeeze roll is air loaded and
nip pressure is adjusted by means of individual pressure controls for each side located on the operator
control panel.

Description of the MAXSON MDH Cutter (Continued)

Doctor Board Arrangement

The doctor boards guide the web through the cutter. There is a” before knife” doctor board system
and an “after knife” doctor board.

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The before knife doctor board system is positioned between the draw drum and the dual knife rotary
cutter.

The after knife board is positioned between the cutting point and the high-speed tape section. It
provides smooth sheet flow into the tape delivery system.

Dual Knife/Rotary Cutter

The dual knife/rotary cutter design has both top and bottom blades mounted in rotating cylinders.
Knife holders secure each cross cutting blade within a machined helix slot. The dynamically balanced
knife cylinders are supported by anti-friction bearings at each end within common housings. The
knife cylinders are geared together on the drive side of the cutter with anti-backlash gears.

The lower fly knife is bolted by a series of screws onto the bottom revolver. The lower knife cylinder
is direct coupled to the knife motor.

The upper fly knife is bolted onto the cylinder. A series of wedges mount within the machined slot to
adjust the blade setting to insure a clean cut. The upper knife cylinder is coupled to the lower cylinder
with anti backlash gears on each end.

Mechanical Transmission Components

High torque timing belts, pulleys and take-ups are used to drive the draw drum and slitter rig. All of
the belt drives are engineered with generous drive factors to insure positive, non-slip drive even
under” low speed, high torque” conditions.

The knife revolvers are coupled together on the drive side by hardened gears.

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 Description of the MAXSON MDH Cutter (Continued)

Electrical Drive System

Within the cutter’s electrical system, two AC drives are used. Each drive package governs an AC
servomotor. The first motor is coupled to the knife revolver; the second drives the draw drum. Each
motor is outfitted with a high-resolution encoder that generates pulses during each revolution.

A microprocessor controls the motion of the two motors through the drives. The speed of the sheeter
is governed by the draw motor’s drive, which responds to the Operator’s adjustment of line speed.
The sheet length is governed by the knife revolver’s drive that is programmed, through the
microprocessor, to accelerate and decelerate during each revolution such that the peripheral speed of
the blades match the speed of the web at time of cut while achieving the preset length.

Digital signals from both motors’ encoders are sent to the microprocessor, which continually compares
the inputs during each revolution, correcting the knife motor speed accordingly. Precise sheet length
tolerances are consistently maintained, regardless of speed change or length.

A programmable logic controller governs the sheeter’s functions. Operator controls, safety interlocks
and emergency stops provide inputs and monitors and counters supply outputs.

Operator Controls
There are pneumatic and electrical Operator controls on the cutter. Pneumatic controls can include
slitters; squeeze roll, and doctor boards. Electrical controls include the main operator console that
includes several different view screens and an operator station at the cutter infeed.

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 Description of the MAXSON MDH Cutter (Continued)

Safety Guarding
The cutter is equipped with safety guarding featuring Lexan vision panels through which the cutting
action may be observed.

An emergency pull cord is mounted across the cutter infeed. Prior to the slitting rig, minimally
obtrusive finger guards protect the Operator from injury when feeding the web into the slitters.

Between the slitter rig and the draw drum section is an infeed guard that prevents the Operator from
accessing the pull roll area unless the guard is removed using hand tools. The cutter’s hinged, out feed
guard provides access to the knife revolver area. (Knife changes are normally made in this area.) It is
safety interlocked to the cutter drive.

The top cutter guard and the Operator side Lexan cutter guard are bolted in place and require hand
tools to remove.

The cutter is not to be run with the safety guarding disabled or out of position.

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