When the winding machine is working, excess wire ends need to be investigated one by one from five core dimensions: wire supply system, tension control mechanism, process parameters, equipment wear parts, and operation and environment.
1, Troubleshooting of the supply line system
(1) Wire laying and wire wheel assembly
1. After shutting down and locking the equipment, check whether the wire wheel is worn out with grooves or stuck in rotation, which may cause jumping and deviation during wire transportation.
2. Check if the brake mechanism of the pay off disc has failed, and if the wire has become loose and piled up, causing it to accidentally throw out and form excess wire ends.
(2) Wire feeding roller group
1. After shutting down the power and locking the equipment, check whether the rubber pressure wheel of the wire feeding wheel is worn and thinning, and whether the surface is adhered with wire debris, which causes the wire feeding to slip and the length of the wire feeding to be unstable.
2. Check if the clamping gap adjustment of the wire feeding wheel is improper. If the wire is too loose, it may cause wire feeding delay, and if it is too tight, it may cause wire breakage.
(3) Storage line organization
1. After shutting down the power and locking the equipment, check if the tension rod of the storage rack is offset and reset, or if the reset spring has insufficient elasticity, causing the storage capacity to lose control and the wires to pile up and be cut off, resulting in excess wire ends.
2, Investigation of tension control mechanism
(1) Tension regulator
1. Check whether the spring of the mechanical tension regulator is fatigued or deformed, and whether the tension weight is offset or displaced, which causes excessive fluctuations in the tension of the wire. When loosening the wire, the wire will be stacked and cut off, resulting in wire ends.
2. The electromagnetic tensioner needs to confirm whether the output current parameters drift, causing unstable tension.
(2) Tension detection sensor
1. For closed-loop controlled winding machines, after shutting down and cutting off the power, check whether the sensor is contaminated by dust or calibrated for deviation, which cannot timely feedback tension changes, resulting in excessive wire feeding and the formation of excess wire ends.
3, Process parameter investigation
(1) CNC winding parameters
1. Check if the single wire feeding step size setting of the CNC system is incorrect, resulting in a mismatch between the wire feeding amount and the winding requirements, and excess wire being cut off to form wire ends.
2. Check if the winding speed and acceleration settings are too high, and if the wire inertia causes the wire feeding volume to lose control; Is the deceleration parameter for wire winding reversing unreasonable? The wire is cut off after being stacked in the reversing section.
(2) Tangent mechanism parameters
1. Check if the cutting position of the tangent knife is offset, as it cannot cut the wire at once, resulting in residual wire ends.
2. After stopping the machine and cutting off the power, check whether the cutting edge of the cutting knife is worn, whether the gap is too large, and whether the cutting is not smooth, which may cause the wire to pull and break.
4, Equipment wear and tear parts inspection
(1) Winding spindle and fixture
1. After shutting down the machine and cutting off the power, check if the main shaft bearings of the winding are worn, causing radial runout, and if the position of the wire is offset during winding, resulting in overlapping or tangled wires, and then cut off to form wire ends.
2. Check if the fixture is loose when clamping the workpiece. When the workpiece rotates, the wire may shift, resulting in excess wire ends.
(2) Cable laying mechanism
1. After shutting down the machine and cutting off the power, check if the wire guide rod is worn and if the gap between the lead screws is too large, which may cause the wire trajectory to deviate and the wires to not be neatly arranged, resulting in stacking and cutting.
2. Check if the synchronous drive belt between the cable motor and the winding spindle is slipping and if the speed matching is abnormal.
5, Operation and environmental investigation
(1) Wire quality inspection
1. Check if there are any factory joints in the wire, if the diameter fluctuates beyond the tolerance range, and if the unqualified wire is cut off during winding to form additional wire ends.
2. Check whether the wire storage is damp, oxidized, hardened, and prone to breakage and wire ends due to decreased toughness.
(2) Operation and environmental maintenance
1. Confirm whether the operator did not thread the wire according to the specifications, resulting in the wire being misaligned and stuck between the guide wheels.
2. Clean up the dust in the work environment to avoid sensor and roller jamming that may affect the stability of the wire feeding.
