Maintenance and Troubleshooting Guide for Automatic Winding Machines

Daily Maintenance (Before and After Daily Operation)

Daily maintenance is foundational and should be performed once before startup and once after shutdown.

1. Clean Surface and Workbench: Wipe the machine body, control panel, and workbench with a dry soft cloth to remove wire scraps, dust, and oil stains, preventing debris from entering internal components.

2. Check Power and Air Supply: Ensure power cords are undamaged and plugs are securely connected. For pneumatic Winding Machines, inspect air hoses for leaks and confirm air pressure is within the specified range (typically 0.4–0.6 MPa).

3. No-Load Operation Test: After startup, run the machine without load for 1–2 minutes. Observe if the spindle and traversing mechanism operate smoothly, with no abnormal noise or jamming.

Regular Maintenance (Weekly/Monthly/Quarterly)

Regular maintenance follows fixed intervals, with varying frequencies for different components. Maintain records for tracking.

Special Maintenance (After Malfunctions/Long-Term Shutdown)

1. Post-Malfunction Maintenance: After resolving issues like wire jamming or traversing errors, additionally clean affected parts (e.g., traverser, chuck) and recheck lubrication and fastenings to prevent recurring problems.

2. Long-Term Shutdown (＞1 Month): Disconnect power and air supply. Apply anti-rust oil to metal components (rails, chuck, spindle) and cover the machine with a dustproof to prevent dust and moisture damage.

Maintenance Notes

1. Lubrication Standards: Use lubricants specified in the machine manual; avoid mixing types (e.g., rail oil vs. gear oil). Do not over-lubricate to prevent oil contamination of coils.

2. Safety First: Perform all maintenance with the machine powered off. Ensure no residual voltage in the electrical cabinet to avoid electric shock.

3. Record-Keeping: Maintain a maintenance log detailing dates, components, operations, and anomalies for traceability and troubleshooting.

Common Issues and Solutions

Winding Precision Issues (Uneven Traversing, Wire Diameter Errors)

Uneven Traversing

Cause 1: Insufficient lubrication or debris on traversing rails, causing traverser jamming.

Solution: Clean rails and reapply dedicated lubricant to ensure smooth movement.

Cause 2: Loose or worn timing belt, leading to mismatched traversing and spindle speeds.

Solution: Adjust belt tension (5–10 mm deflection) or replace if cracked.

Wire Diameter Errors (Actual vs. Set Diameter)

Cause 1: Loose spool chuck, causing spool misalignment during winding.

Solution: Tighten chuck screws to ensure coaxial alignment with the spindle.

Cause 2: Abnormal tension controller parameters, leading to unstable wire tension.

Solution: Recalibrate the tension controller per wire specifications (refer to manual for recommended ranges).

Machine Operation Issues (Abnormal Noise, Jamming, Sudden Shutdown)

Abnormal Noise During Operation

Cause 1: Lack of lubrication or worn spindle bearings, causing friction noise.

Solution: Disassemble the spindle end cap, add bearing grease; replace bearings if loose (excessive wobble).

Cause 2: Excessive gear meshing clearance or worn gear teeth.

Solution: Inspect gears in the gearbox; adjust spacing for minor wear or replace severely worn gears.

Jamming or Sudden Shutdown

Cause 1: Poor power cord contact or tripped circuit breaker (electrical fault).

Solution: Check for loose plugs/sockets, reset the breaker; if tripping recurs, inspect for motor short circuits (consult a qualified electrician).

Cause 2: Traverser blocked by wire scraps or debris (mechanical obstruction).

Solution: Power off, clear debris, and manually test traverser movement before restarting.

Electrical Control Issues (Unresponsive Panel, Parameter Saving Failure)

Unresponsive Control Panel

Cause 1: Loose or poor connections in panel wiring.

Solution: Power off, open the machine, reinsert panel-to-mainboard connectors securely.

Cause 2: Damaged display screen or buttons.

Solution: Replace with compatible screen/button modules (match machine brand and model).

Parameter Saving Failure

Cause 1: Depleted internal backup battery, preventing parameter storage.

Solution: Power off, replace the motherboard’s button battery (typically CR2032), then reconfigure parameters.

Cause 2: Parameter values exceed the machine’s allowable range, causing system rejection.

Solution: Refer to the manual to ensure values (e.g., winding turns, traversing speed) are within specified limits, then re-save.