What Are The Common Faults of Inner Winding Machines?

The inner winding machine is the core equipment for winding coils in motor manufacturing and is widely used in motor, transformer and other industries. However, due to its complex working environment and high-intensity operation, the inner winding machine is prone to failure during use. This article will introduce the common faults of the inner winding machine and their causes to help readers better understand and prevent these problems.

1. Unstable winding tension

Unstable winding tension is one of the common faults of the inner winding machine, which is mainly manifested as uneven coil tightness or wire breakage. The reasons may include:

Failure of the tension adjustment device: aging or improper calibration of the tension controller causes fluctuations in wire tension.

Wire quality problems: The surface of the wire is not smooth or has defects, affecting the uniformity of tension.

Wear of the wire wheel: Long-term use causes the surface of the wire wheel to wear and the wire does not slide smoothly. Preventive measures include regular inspection of the tension device, selection of high-quality wire, and timely replacement of worn parts.

2. Abnormal motor operation

The motor system of the inner winding machine is responsible for driving the winding action. If the motor is abnormal, it may cause the equipment to shut down or the winding quality to decline. Common problems include:

Motor overheating: long-term high-load operation or poor heat dissipation causes the motor temperature to be too high.

Motor abnormal noise: abnormal noise caused by bearing wear or insufficient lubrication.

Start failure: poor circuit contact or internal short circuit of the motor. Solutions include strengthening motor heat dissipation, regularly lubricating bearings, and checking circuit connections.

3. Control system failure

Modern internal winding machines mostly use CNC systems, and control system failures will directly affect equipment operation. Common problems include:

Program error: improper parameter settings or program bugs cause abnormal winding action.

Sensor failure: position sensor or speed sensor failure affects winding accuracy.

Display screen failure: touch screen or display screen is slow to respond, affecting operation. Regularly updating system software, checking sensor status, and protecting the control system from dust and moisture are effective preventive measures.

4. Wear of mechanical parts

The mechanical parts of the internal winding machine, such as molds, clamping devices, and transmission shafts, are subject to large loads and are prone to wear after long-term use. Common manifestations are:

Mold deformation: The mold is deformed due to long-term force, affecting the coil forming accuracy.

Loose drive shaft: loose screws or worn bearings lead to unstable operation.

Insufficient clamping force: The clamping device is aging and the coil is not firmly fixed. Regular inspection of mechanical parts, timely tightening of screws and replacement of worn parts can extend the life of the equipment.

5. Electrical system failure

The electrical system is the core of the inner winding machine. Failures are manifested as power failure, short circuit or component burnout of the equipment. Reasons include:

Aging of the line: Damage to the insulation layer of the wire leads to leakage or short circuit.

Relay failure: Relay contacts are burned, affecting the on and off of the circuit.

Unstable power supply: Voltage fluctuations cause abnormal operation of the equipment. Using a stable power supply, regularly checking the line and replacing aging components are the key.

Conclusion

Common failures of the inner winding machine are mainly concentrated in winding tension, motor, control system, mechanical parts and electrical system. Through regular maintenance, selection of high-quality materials and strengthening of operation training, the failure rate can be effectively reduced, and the equipment operation efficiency and coil quality can be improved. I hope this article can provide users with a reference and help the efficient operation of the inner winding machine.