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As an important equipment for the production of electronic components, the operating stability and efficiency of fully automatic winding machines directly affect product quality and production costs. However, in actual use, various faults are inevitable, affecting production progress. This article will introduce common faults of fully automatic winding machines and their troubleshooting methods to help operators quickly solve problems and ensure smooth production.
1.1 Uneven and loose winding
Reason:
Improper tension setting, too small will cause loose winding, too large will cause wire breakage or wire deformation.
The winding speed is too fast, and the wire has no time to be neatly arranged.
The winding wheel and guide wheel are worn or dirty, affecting the smooth operation of the wire.
The wire itself is of poor quality, with problems such as uneven thickness and burrs.
Troubleshooting method:
Adjust the appropriate tension according to the wire specifications and winding requirements.
Appropriately reduce the winding speed to ensure that the wire is neatly arranged.
Clean and replace worn winding wheels and guide wheels regularly.
Select qualified wires and perform necessary pretreatment.
1.2 Winding misalignment and overlap
Reason:
The winding program is set incorrectly, such as the starting point, winding width, number of winding layers and other parameters are improperly set.
The position of the winding wheel and guide wheel is offset, resulting in deviation of the wire running track.
The wire tension is unstable, resulting in deviation during the winding process.
Troubleshooting method:
Carefully check and modify the winding program to ensure that all parameters are set correctly.
Adjust the position of the winding wheel and guide wheel to ensure that the wire running track is accurate.
Check the tension system to ensure that the tension is stable and reliable.
1.3 Wire breakage
Reason:
The wire tension is too large, resulting in the wire being broken.
The wire quality is poor, there are defects or insufficient strength.
The winding wheel and guide wheel have burrs or wear, scratching the wire.
Abnormal conditions such as wire jamming and wire entanglement occur during the winding process.
Troubleshooting methods:
Adjust the appropriate tension to avoid excessive or insufficient tension.
Select qualified wire materials and conduct necessary tests.
Clean and replace worn winding wheels and guide wheels regularly.
Check the winding path to eliminate abnormal conditions such as wire jamming and wire entanglement.
2.1 Abnormal operation of the equipment and loud noise
Reason:
Mechanical parts are worn, loose or lack lubrication.
The transmission belt is loose or worn.
The motor bearing is damaged.
Troubleshooting methods:
Maintain the equipment regularly, check and tighten loose parts, and add lubricating oil.
Adjust or replace loose transmission belts.
Replace damaged motor bearings.
2.2 The equipment cannot be started or stops suddenly during operation
Reason:
Power failure, such as power failure, unstable voltage, etc.
The motor is overloaded or damaged.
Control system failure, such as program error, sensor failure, etc.
Troubleshooting:
Check the power connection to ensure normal power supply.
Check the motor load, eliminate overload, and replace the motor if necessary.
Check the control system to eliminate program errors, sensor failure and other faults.
2.3 The winding shaft jumps or shakes
Reason:
The winding shaft bearing is worn or damaged.
The winding shaft is not installed horizontally or loosely.
Troubleshooting:
Replace the worn or damaged winding shaft bearing.
Adjust the level of the winding shaft and tighten the mounting screws.
3.1 The display screen has no display or displays abnormally
Reason:
Power failure, such as power failure, unstable voltage, etc.
The display screen connection cable is loose or damaged.
The display screen itself is faulty.
Troubleshooting:
Check the power connection to ensure normal power supply.
Check the display screen connection cable and replace it if necessary.
Contact a professional for repair or replacement of the display screen.
3.2 Button failure or abnormal function
Reason:
Poor contact or damage of the button.
Control panel failure.
Troubleshooting:
Clean the button contacts and replace the button if necessary.
Contact professionals for repair or replacement of the control panel.
3.3 Sensor failure
Reason:
The sensor is dirty or damaged.
The sensor connection line is loose or damaged.
Troubleshooting:
Clean the sensor and replace it if necessary.
Check the sensor connection line and replace it if necessary.
4.1 Equipment alarm
Reason:
Abnormal conditions occur during the operation of the equipment, such as overload, overheating, disconnection, etc.
Troubleshooting:
Find and eliminate the corresponding faults according to the alarm information.
4.2 Low production efficiency
Reason:
Equipment aging and performance degradation.
Unskilled operators and low operating efficiency.
Irrational production process and bottlenecks.
Troubleshooting method:
Perform necessary maintenance and upgrades on the equipment.
Strengthen the training of operators to improve their proficiency.
Optimize the production process and improve overall efficiency.
In order to reduce the occurrence of automatic winding machine failures and extend the service life of the equipment, daily maintenance should be done:
Clean the equipment regularly to keep it clean and tidy.
Check the various parts of the equipment regularly to find and eliminate hidden dangers in time.
Lubricate and maintain the equipment regularly to ensure smooth operation of the equipment.
Keep good equipment operation records for fault analysis and handling.
Common faults of automatic winding machines are varied, and operators need to have certain professional knowledge and skills to quickly and accurately troubleshoot and ensure smooth production. At the same time, doing a good job of daily maintenance can effectively reduce the occurrence of faults and extend the service life of the equipment.
