Five Methods for Troubleshooting Winding Machine Failures

Any machine subjected to high usage frequency is bound to encounter malfunctions, and winding machines are no exception. When a winding machine malfunctions, there is no need to panic. By conducting proper inspection and maintenance, the issue can be effectively resolved.

I. Replacement Method

During winding machine maintenance, replacing suspected faulty components with functional spare parts allows technicians to quickly narrow down the fault range after preliminary diagnosis. This enables rapid restoration of normal operation, with the defective part sent for repair afterward. This is a widely used troubleshooting approach.

II. Test Run Program Method

Successfully executing a properly designed program serves as verification of the entire system's functionality. Incorrect winding parameter settings may cause system failures or render certain functions inoperative. Occasionally, user program errors lead to malfunctions and shutdowns. In such cases, creating a test run program allows for inspection and correction of user program errors, ensuring normal operation.

III. System Reset Method

For general winding machine errors caused by transient faults—such as collisions from improper operation, or momentary power loss, can be cleared by performing a hardware reset or sequentially switching the system power. If the system's working memory becomes corrupted due to unstable voltage, removing circuit boards, or under-voltage in the rectifier switch power supply, the system must be initialized to clear the corruption. Before clearing, ensure current data is backed up and recorded. If the fault persists after reset and initialization, proceed with hardware replacement diagnostics.

IV. Utilize Adjustable Components Effectively

Adjusting parameters such as winding tension, input voltage, and cable rack starting positions represents a simple yet effective troubleshooting approach. Modifying these adjustable components can correct certain hardware malfunctions. For internal winding machine fault alarms, independently inspect potential causes: improper workpiece alignment, collisions or interference, loose/displaced detection points, damaged wiring, or obstructions like dust or grease on sensing points.

V. Environmental Quality Improvement Method

For highly unusual faults that remain undiagnosed even after systematic troubleshooting and component replacement, addressing the surrounding environment is often necessary. Environmental factors generally fall into two categories: power supply and physical space. Power supply improvements can utilize voltage-stabilized isolation power supplies to mitigate fluctuations. For high-frequency interference originating from the power source, capacitive filtering methods can be employed. Implementing these preventive measures reduces power-related faults. Additionally, verifying and enhancing grounding integrity is essential. Environmental interference stems from diverse sources: dust, gases, unstable foundations, vibrations, spatial radiation interference, and more. Addressing these requires experienced technicians and specialized equipment for detection and maintenance.