Daily Maintenance And Troubleshooting Guide for Winding Machines

The winding machine is an indispensable and important equipment in the manufacturing of products such as motors, transformers, and electronic coils. Its performance directly affects the winding accuracy, production efficiency, and product quality. In order to ensure the long-term and stable operation of the winding machine, reduce the failure rate, and increase the service life of the equipment, daily maintenance and timely troubleshooting are particularly important. This article will introduce you to the common maintenance methods and troubleshooting points of the winding machine, helping the factory to achieve efficient and reliable production management.

Daily maintenance points

1. Clean and maintain to prevent dust accumulation

The winding machine is prone to accumulate copper chips, dust or oil after long-term operation, especially in the bobbin, wire wheel, and cable arrangement system. The key components should be blown and wiped every day to keep the equipment clean and prevent jamming or guide rail wear.

2. Lubrication system refueling regularly

If the equipment has moving parts such as guide rails, screw rods, bearings, etc., lubricating oil or butter should be added regularly to keep it running smoothly. It is recommended to check once a week or month to prevent mechanical wear or poor movement due to insufficient lubrication.

3. Check the electrical wiring and component status

Before starting the machine every day, check whether the power cord is loose and whether the electric control cabinet has any abnormal smell or overheating. Regularly check the operating status of electrical components such as sensors, PLC modules, and drivers, and replace aging components in time to prevent failures.

4. Regularly calibrate the winding tension and counter

Whether the tension system is stable will directly affect the tightness of the coil; the accuracy of the counting system is related to the consistency of the number of coil turns. The operator should regularly perform tension tests and counter reset calibration according to the product model to ensure the product qualification rate.

Common faults and troubleshooting guide

1. The coil wiring is not neat or jumper

Reason: foreign objects are stuck in the wiring system, the wiring rod is worn, and the servo motor encoder is faulty.

Troubleshooting: Check whether the wiring rod is bent, clean up foreign objects, and test whether the wiring motor is running normally.

2. The wire is broken or the tension is unstable

Reason: Improper setting of the tensioner, poor quality of the wire itself, and too fast winding speed

Troubleshooting: Adjust the tension of the tensioner spring, check whether the wire core is knotted or damaged, and reduce the initial winding speed to observe whether it improves.

3. The equipment cannot be started or stops midway

Reason: The emergency stop button is not reset, the travel switch is not reset, the power supply is abnormal, or the PLC program fails.

Troubleshooting: Reset all switches, check the power supply voltage, observe the control panel error code and handle it according to the manual.

4. The touch screen or control panel is unresponsive

Reason: Operating system failure, loose cable, static interference.

Troubleshooting: Restart the system, check the communication cable connection, and avoid the equipment from being close to the high-frequency electromagnetic interference source.

Conclusion

As a precision equipment, the winding machine can only operate stably and reduce the failure rate if it is properly maintained. Establishing a standardized inspection system, operating procedures and fault records is an important basis for realizing intelligent manufacturing. Regular training of operators is also the key to preventing misoperation and improving maintenance efficiency.