The common causes of increased wire ends in winding machines can be divided into four categories: abnormal equipment structure, deviation of process parameters, problems with the wire itself, and operational errors, which require targeted investigation and rectification.
1, Abnormal equipment structure
1. Wear or installation deviation of wire wheel: After the wear of the guide wheel groove, the wire is prone to jump out of the groove, or the installation position of the guide wheel is offset, resulting in unstable wiring trajectory, and the wire is repeatedly scraped off, forming additional wire ends; Failure of tensioner damping can cause significant fluctuations in wire tension, and loose sections of wire are prone to stacking and knotting, resulting in excess wire ends after cutting.
2. Fault in wire breakage detection device: Under normal working conditions, the wire breakage will trigger a shutdown signal. If the detection device fails, the machine will continue to operate, and subsequent wire feeding will form two independent wire segments, generating multiple additional wire ends.
3. Cable laying mechanism or wire feeding mechanism jamming: Cable laying guide rod jamming can cause the wire arrangement to be misaligned and scraped off by the mechanism; The slippage of the wire feeding wheel and inaccurate step spacing of the wire feeding motor can result in the actual wire feeding length not matching the program settings, resulting in excess wire segments.
2, Process parameter deviation
1. Improper setting of winding tension: Insufficient tension can cause the wire to loosen and stack, resulting in knots and broken wires during the winding process; If the tension is too high, the wire is prone to breakage, and additional wire ends are directly formed at the fracture.
2. Incorrect input of winding parameters: The number of turns and step distance parameters in the program are set incorrectly, resulting in premature shutdown before the winding reaches the set value, or failure to break the wire in a timely manner after exceeding the winding limit, resulting in excess wire ends.
3. Mismatch between wire spacing and wire diameter: If the wire spacing is too small, it will squeeze the wire and cause it to break. If the spacing is too large, the wire arrangement will be loose and stacked, resulting in excess wire ends during subsequent cutting.
3, The problem with the wire itself
1. Uneven outer diameter or surface defects of the wire: Local areas of the wire that are too thin are prone to breakage, and burrs and protrusions on the surface can be scraped off by guide wheels and cable laying mechanisms, resulting in additional broken ends.
2. Batch performance differences: There are differences in the ductility and hardness of different batches of wire. The original tension setting is suitable for old batches of wire, while new batches of wire are prone to breakage or loose accumulation, resulting in excess wire ends.
4, Operational error
1. Improper threading operation: The wire is not fully inserted into the wire feeding wheel and guide wheel slot, and during the winding process, the wire jumps out of the slot to form a breakpoint, which can easily leave excess wire ends when re threading later.
2. Irregular start stop operation: After stopping the machine midway, the stacked wires were not sorted, and when the equipment was restarted, the wires were misaligned and tangled, resulting in additional wire ends during subsequent winding; During the final stage, excess wires were not cut or repeated threading left residual wire ends.
