In the production process of various electronic and electrical products, the circular 8-shaped continuous winding vertical winding machine plays a key role. Its efficient and precise winding capacity has greatly enhanced production efficiency and product quality. However, just like any mechanical equipment, the circular 8-shaped continuous winding vertical winding machine may encounter various malfunctions during long-term use, which can affect the normal operation of production. Yeyi Automation Technology (Suzhou) Co., LTD., as a high-tech enterprise that has been deeply engaged in the field of automatic winding equipment for many years, has a professional after-sales engineer team and has accumulated rich experience in fault diagnosis and resolution. Next, let's take a look at the common faults of the circular 8-shaped continuous winding vertical winding machine and the solutions provided by the after-sales engineers of Yeyi.
Yeyi Automation Technology (Suzhou) Co., Ltd. was established on July 21, 2015. It specializes in the research and development, production, processing, and sales of industrial automation equipment, electromechanical equipment, mechanical equipment, and electronic equipment, as well as the design, installation, maintenance, and import and export business of related products. The company adheres to the business philosophy of "people-oriented, technological innovation, and promoting industrial progress", and has gathered a group of professional technical talents with independent design and R&D capabilities. Many of these technicians have over seven years of working experience in the field of power equipment. In the research and development and manufacturing of winding equipment, Yeyi, relying on its profound technical background and continuous innovative spirit, has launched a series of high-performance products including circular 8-shaped continuous winding vertical winding machines, and provides customers with all-round high-quality after-sales service.
I. Motor failure
As the core power component of the circular 8-shaped continuous winding vertical winding machine, the motor has a relatively high frequency of faults. Common motor faults include motor overheating, inability to start, and abnormal noise during operation, etc.
When dealing with motor overheating issues, the after-sales engineers of Yeyi will first inspect the working environment of the motor to see if there is any poor ventilation, such as damaged cooling fans or accumulated debris around the motor that hinders heat dissipation. If the working environment is normal, the load condition of the motor will be further inspected, as prolonged overload operation can cause the motor to overheat. At this point, engineers will use professional tools to detect the motor current and determine whether it exceeds the rated current. If it is found that the problem is caused by excessive load, the transmission components of the equipment will be carefully inspected, such as whether the belt is too tight, whether the bearings are damaged, and whether the gear meshing is normal, etc., because problems with these components may all increase the motor load. In case of damage to the cooling fan, a new one will be replaced in a timely manner. For accumulated debris, clean up the surrounding environment of the motor. If there is a problem with the transmission components, the belt will be adjusted, damaged bearings replaced or gear meshing issues repaired to ensure the normal operation of the motor and prevent more serious malfunctions caused by overheating.
When the motor fails to start, the after-sales engineers of Yeyi will take measures from both the electrical system and the mechanical system. In terms of electrical aspects, first check whether the power supply is normal, including whether the power cord is loose or open-circuited, and whether the fuse has blown, etc. If the power supply is normal, the control circuit of the motor will be inspected, such as whether the relay and contactor are normally engaged, whether the control switch is damaged, and whether the parameters of the motor driver are set correctly, etc. In terms of mechanics, it is necessary to check whether the rotor of the motor is stuck, whether the coupling is loose or damaged, etc. After a step-by-step investigation to determine the cause of the fault, targeted repairs are carried out. For instance, if it is found that the relay is damaged, a relay of the same model will be replaced in a timely manner. If the parameters of the motor driver are incorrect, the correct parameters will be reset according to the equipment manual to restore the motor to normal start-up.
For the problem of abnormal noise generated when the motor is running, engineers will, based on their rich experience, initially determine the faulty part by listening to the sound. If the noise is sharp and shrill, it may be that the motor bearing is short of oil or severely worn. At this time, the bearing will be cleaned, oiled or replaced with a new one directly. If the noise is a dull "buzzing" sound, accompanied by motor heating, unstable speed and other conditions, it may be a short circuit or open circuit in the motor winding. Professional instruments such as multimeters and megohmmeters should be used to test the winding. After determining the faulty winding, it should be repaired or replaced.
Ii. Control System failure
The control system of the circular 8-shaped continuous vertical winding machine is responsible for precisely controlling key parameters such as the winding speed, number of turns, and tension. Once a fault occurs, it will seriously affect the winding quality and the stability of equipment operation. Common control system failures include incorrect parameter Settings, controller failures, and sensor failures, etc.
When encountering abnormal operation of the equipment due to incorrect parameter Settings, the after-sales engineers of Yeyi will first communicate with the operators to understand the recent adjustment of the equipment parameters. Then, refer to the equipment operation manual and carefully check the Settings of all parameters, such as winding speed, ribbon width, and turn count Settings, etc. If parameter errors are found, the parameters will be reset according to the correct process requirements and a trial run will be conducted to observe whether the equipment operation status returns to normal. Meanwhile, engineers will also explain in detail to the operators the principles and precautions of parameter Settings to prevent parameter errors due to misoperation again.
When a controller is suspected of malfunctioning, the after-sales engineers of Yeyi will use professional diagnostic tools to test the controller. For instance, use a programmer to read the programs and data inside the controller and check if there are any situations such as program loss or data errors. If any program issues are found, an attempt will be made to re-download the correct program. If it is confirmed that the controller hardware is damaged, such as faults in components like chips, capacitors, and resistors on the circuit board, component replacement or circuit board repair will be carried out based on the controller model and the type of faulty component. During the maintenance process, strictly follow the electronic maintenance process specifications to ensure the maintenance quality and restore the controller to normal operation.
Sensors are used in the circular 8-shaped vertical winding machine to monitor the operating status of the equipment in real time, such as position sensors to monitor the position of the ribbon pole and tension sensors to monitor the winding tension, etc. If the sensor malfunctions, it will lead to inaccurate control of the equipment and even prevent it from working properly. When detecting sensor faults, the after-sales engineers of Yeyi will use professional detection instruments to calibrate and test the sensors. For instance, for position sensors, the output signal of the sensor is observed to correspond to the actual position by moving the wiring pole. If the signal is abnormal, the installation position of the sensor is checked to see if it is loose or if the sensor probe is damaged, etc. For tension sensors, standard weights will be used for calibration to check whether the measurement accuracy of the sensor is within the normal range. If the sensor is found to be damaged, it will be replaced with a sensor of the same model in a timely manner, and recalibrated and debugged again to ensure that the sensor can accurately feedback the operating status of the equipment and provide reliable data support for the control system.
Iii. Winding quality issues
The quality of winding is directly related to the performance and reliability of the product. The possible quality problems that may occur during the winding process of the circular 8-shaped continuous vertical winding machine include loose winding, broken winding, inaccurate turns, etc.
Loose winding is usually caused by improper setting of winding tension or failure of the tension control system. When dealing with this issue, the after-sales engineers of Yeyi will first check whether the set value of the winding tension meets the process requirements. If it is set correctly, they will conduct a comprehensive inspection of the tension control system. This includes checking whether the tension sensor is working properly, whether the tension adjustment mechanism is flexible, and whether the actuating elements (such as electromagnetic clutches, motors, etc.) can accurately adjust the tension according to the instructions of the control system. If a malfunction of the tension sensor is detected, it will be replaced in a timely manner. If the tension adjustment mechanism gets stuck, it will be cleaned, lubricated or repaired. For issues with the actuating elements, repairs or replacements will be made based on specific circumstances to ensure stable tension during the winding process and prevent loose winding.
The problem of broken wires is relatively common during the winding process and may be caused by various reasons. The after-sales engineers of Yeyi will conduct a comprehensive inspection from multiple aspects. First, they will check whether there are any quality issues with the winding materials, such as whether there are scratches on the surface of the enameled wire and whether the wire diameter is uniform. If there are no issues with the materials, the wire-passing components of the equipment, such as the conductor wheel, tension wheel, and winding die, will be inspected for burrs, wear, or improper installation, as these can all cause the enameled wire to be scratched or broken during the winding process. At the same time, the winding speed will also be checked to see if it is too fast. If the speed is too fast, the tensile force that the enameled wire can bear may exceed its capacity, causing the wire to break. If it is found that the problem lies with the wire-passing components, the components with burrs will be ground, the severely worn components will be replaced or the installation positions of the components will be readjusted. For the issue of overly fast winding speed, the winding speed will be reasonably adjusted based on the material and diameter of the enameled wire to ensure the stability of the winding process and reduce the occurrence of wire breakage.
Inaccurate turns may be caused by counting errors in the control system or slippage during the winding process of the equipment. The after-sales engineers of Yeyi will first check whether the relevant parameter Settings of the turn count in the control system are correct, such as whether the pulse equivalent setting matches the actual transmission ratio of the equipment. If the parameter Settings are correct, it will be checked whether the transmission connection between the winding shaft and the motor is reliable, and whether there are situations such as belt slippage and loose couplings. At the same time, the encoder of the equipment will also be inspected, as the encoder is used to measure the number of turns of the winding shaft. If the encoder malfunctions, it will also lead to inaccurate turns counting. If any problems with the transmission connection are found, the belt will be tensioned, repaired or the coupling replaced. In case of encoder failure, a new encoder will be replaced in a timely manner, and recalibration and debugging will be carried out again to ensure the accuracy of the turn count and meet the winding process requirements of the product.
Iv. Mechanical Transmission failure
The mechanical transmission components of the circular 8-shaped continuous winding vertical winding machine are numerous. After long-term operation, faults such as wear and loosening may occur, affecting the normal operation of the equipment. Common mechanical transmission faults include belt slippage, loose chains, gear wear, etc.
Belt slippage can prevent the motor's power from being effectively transmitted to components such as the winding shaft, causing unstable equipment operation speed or even failure to work normally. When the after-sales engineer of Yeyi discovers the problem of belt slippage, they will first check the tension of the belt and adjust the tension force of the belt by regulating the tensioner pulley. If the belt tension is normal but there is still slippage, the surface of the belt will be checked for oil stains, wear and other conditions. If there is oil stain on the belt, a special cleaner will be used to clean it, remove the oil stain and restore the friction between the belt and the pulley. If the belt is severely worn, a new one will be replaced. At the same time, the surface condition of the pulleys will also be inspected. If there is any wear or deformation, they will be repaired or replaced to ensure the reliability of the belt drive.
Loose chains can cause problems such as chain jumping and increased noise during the operation of the equipment. In severe cases, it may even lead to chain detachment. When dealing with the problem of loose chains, the after-sales engineers of Yeyi will first check whether the tensioning device of the chain is working properly and adjust the tension of the chain by regulating the tensioning device. If the tensioning device fails to effectively adjust the tension of the chain, it may be that the chain has elongated or worn out after long-term use. At this point, based on the actual condition of the chain, the decision will be made to shorten the chain or replace it with a new one. After installing a new chain or adjusting it, the equipment will be tested to ensure that the chain runs smoothly without any problems such as jumping or falling off.
Gear wear can affect the transmission accuracy and stability of the equipment, leading to phenomena such as jamming and increased noise during the winding process. When the after-sales engineers of Yeyi detect the problem of gear wear, they will first conduct an appearance inspection of the gears to observe whether there is any wear, peeling, cracking or other conditions on the gear tooth surface. Then, professional measuring tools are used to measure parameters such as the tooth thickness and pitch of the gears, and compare them with the standard values to determine the degree of gear wear. For slightly worn gears, they can be treated by grinding or repairing the tooth surfaces, etc. For gears that are severely worn, new ones will be replaced. When replacing gears, installation will be carried out strictly in accordance with the equipment assembly requirements to ensure the meshing accuracy of gears and reduce the impact of gear transmission problems on equipment operation and winding quality.
The after-sales engineer team of Yeyi Automation Technology (Suzhou) Co., LTD., with professional technical knowledge, rich practical experience and a responsible attitude towards customers, can quickly and accurately diagnose various common faults of circular 8-shaped continuous winding vertical winding machines, and adopt effective solutions to ensure that the equipment returns to normal operation as soon as possible, providing strong support for customers' production. During daily use, users should also enhance the maintenance and upkeep of the equipment, regularly inspect the operation of each component of the equipment, promptly identify and solve potential problems, so as to extend the service life of the equipment, improve production efficiency and product quality.
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