22/05/2026
For the last two months, we faced an RPM fluctuation issue in the EXTR.B Plast Control System (Germany) of our LLDPE film-making machine. During this period, we carried out extensive troubleshooting and systematically checked every possible point to identify the root cause.
Our troubleshooting activities included:
✅ Checking all cables and connection points
✅ Inspecting and interchanging PCB boards
✅ Testing the IOC and IOX control boards
✅ Verifying load cells and related control systems
✅ Replacing components one by one for comparison and verification.
Despite all these efforts, the problem remained unresolved. We then procured and installed a new load cell, expecting the issue to be eliminated. However, the RPM fluctuation became even more severe.
After ruling out all other possibilities, we considered that the newly supplied load cell itself might be defective. To verify this assumption, we replaced it with another load cell. Immediately, the machine returned to normal operation and the RPM became stable.
This experience reinforced an important lesson: a new spare part is not always guaranteed to be fault-free. Even brand-new components should be thoroughly tested and verified during the troubleshooting process.
Finally, we successfully identified the root cause and resolved the issue. Special thanks to everyone who provided online technical support, guidance, and cooperation throughout this challenging journey.
Every problem is an opportunity to learn. Persistence, teamwork, and systematic troubleshooting are the keys to success. 💪🔧
