The problem of multiple wire ends in the winding machine can be classified into four core reasons: abnormal equipment parameters, fixture failures, improper matching of wire technology, and non-standard operation. Targeted investigation and rectification are needed.
1, Abnormal device parameter settings
1. Misalignment of winding tension parameters: Insufficient tension can cause the wire to loosen and fall out of the groove, resulting in excess wire ends after displacement during the winding process; If the tension is too high, the wire will break and the fracture will directly form additional wire ends.
2. Deviation in winding stroke setting: The winding endpoint position is not accurately matched with the preset ending point, and there are still uncut wires left when the equipment is stopped, resulting in multiple wire ends during subsequent startup.
3. Failure of wire breakage detection function: The photoelectric and contact type wire breakage sensors fail or the trigger threshold is set incorrectly. After the wire breaks, the automatic wire cutting action is not triggered, and the remaining broken ends are subsequently wound and mixed into the process.
2, Fixture malfunction
1. Wear and deformation of winding threads and wire slots: After long-term use, pits and burrs appear on the surface of the winding threads or wire slots, causing the wire to get stuck and offset during the winding process, resulting in disordered winding paths and additional wire ends.
2. Loose and worn wire pressing wheel and guide wheel: The clearance between the guide wheel bearings is too large, which makes it difficult to stably pull the wire. When the wire bounces and shifts, it will repeatedly produce excess wire ends at the beginning and end; Insufficient clamping force of the wire pressing wheel can also cause wire slippage.
3. Failure of the wire cutting mechanism: The wire cutting edge is passivated, and the reset spring has insufficient elasticity, making it impossible to cut the wire at once. The remaining short ends will be carried into the next winding process, forming additional wire ends.
3, Improper matching of wire and process
1. Inconsistent wire specifications: The diameter of the wire exceeds the adaptation range of the winding machine, making it easy for thin wires to become tangled and stuck, and for thick wires to be difficult to be accurately pulled by the guide wheel, all of which can cause misalignment during winding and produce excess wire ends.
2. Abnormal surface condition of wire: Excessive tin coating and surface grease on the wire can change the friction between the wire and the guide wheel, resulting in unstable traction speed and winding deviation.
3. Batch differences in wire: The ductility and hardness of the same batch of wire fluctuate greatly, and local stress concentration during the winding process leads to wire breakage and the formation of broken ends.
4, Improper operation
1. Wiring operation error: When threading for the first time, the wire end was not firmly fixed on the winding shaft, causing the wire end to fall off during the initial winding process and requiring re threading, resulting in excess wire ends.
2. Incomplete replacement and cleaning of wires: When replacing wire batches, the residual old winding wire ends were not cleaned, and the old wire ends mixed into the new process to form additional wire ends.
3. Shutdown without wire cutting: After a single operation shutdown, if the wire is not cut, it will loosen and shift when restarted, forming additional starting wire ends.
When adjusting the parameters of the winding machine and repairing the fixtures, it is necessary to first shut down the machine and cut off the power. The operation should be carried out by personnel with equipment maintenance qualifications to avoid contact with the winding wire and electrical components in motion, and to prevent mechanical injury and electric shock risks.
