2025-10-25 14:11:17
The core of automatic Coil Winding Machine maintenance is "daily cleaning to prevent hidden risks, regular lubrication to maintain accuracy, and long-term inspection to extend service life". Through systematic maintenance by cycle and component, downtime caused by faults can be effectively reduced, and the stability of winding quality can be ensured.
Maintenance should follow the principle of "prevention first and adjustment as needed". The cycle can be flexibly adjusted according to the equipment usage frequency (e.g., 8-hour/24-hour daily operation) and is mainly divided into 4 levels:
Daily Maintenance: Conducted before starting up and after shutting down the machine every day, focusing on surface cleaning and status confirmation, taking 5-10 minutes.
Regular Maintenance: Performed weekly/monthly, involving in-depth inspection of the equipment interior to address lubrication and calibration issues, taking 30-60 minutes.
Long-term Maintenance: Carried out quarterly, targeting the inspection of core components to prevent potential faults, taking 1-2 hours.
Annual Maintenance: Professional-level maintenance involving the replacement of aging components and overall machine debugging. It is recommended to be operated by technicians, taking half a day.
Daily maintenance is the foundation for the stable operation of the equipment, focusing on preventing dust and wire chips from affecting key components.
1. Clean Key Areas: Wipe the surface of the machine body with a dry soft cloth, and clean wire chips on the winding spindle, wire guide wheels, and tensioners with a brush. This avoids wire breakage or uneven tension caused by wire chip entanglement.
2. Quick Inspection of Wear Parts: Visually check that there are no scratches on the wire guide wheels, no looseness in the tensioner springs, and no deformation of the winding guide nozzles. Replace faulty parts immediately to prevent damage to the enameled wire.
3. Test Run Before Startup: Run the machine idly for 1-2 minutes, listen for abnormal noises or vibrations of the equipment, check if the display reports errors, and ensure the spindle rotates smoothly with normal parameters.
In-depth inspection of the equipment interior is required to resolve lubrication issues of moving parts and accuracy deviations, which is crucial for ensuring winding accuracy.
1. Lubrication of Moving Parts: Add special lubricating oil to the spindle bearings, transmission gears, and guide rails as required by the instruction manual, with 1-2 drops each time. Do not use ordinary engine oil, and avoid excessive oil to prevent dust adsorption.
2. Electrical Cabinet Cleaning: Blow off dust in the electrical cabinet with low-pressure compressed air (≤0.5MPa), avoiding direct blowing towards terminal blocks. This prevents short circuits caused by dust accumulation; check if terminals are loose after cleaning.
1. Tension Calibration: Measure the actual tension with a tension meter. If the deviation exceeds ±5%, correct it using the tensioner adjustment knob. Ensure the tension value matches the current winding process to avoid stretching or slackening of the enameled wire.
2. Wire Arrangement Accuracy Calibration: Wind a standard coil, then measure the wire arrangement spacing and inter-layer flatness. Adjust parameters if the deviation exceeds 0.1mm to ensure uniform wire arrangement without overlapping or gaps, which meets process standards.
Professional operation is required for core components and aging issues to avoid sudden faults.
1. Core Component Inspection: After the equipment runs at full load for 1 hour, measure the surface temperature of the servo motor with a temperature detector. The temperature should not exceed the value specified in the equipment manual (usually ≤60℃).
2. Bearing Status Check: Manually rotate the spindle and wire arrangement shaft to check for jamming or abnormal noises, and determine if the bearings need to be replaced based on the feel and sound.
1. Motor Insulation Resistance Test: After powering off the machine, measure the insulation resistance between the motor windings and the housing with a multimeter (megohm range). The insulation resistance should be ≥5MΩ; if it is lower than the standard, the motor needs to be repaired or replaced.
2. Replacement of Aging Wear Parts: Replace wear parts such as belts, seals, and wire guide wheels that have been used for one year, regardless of their appearance. Ensure the model of the replaced parts is consistent with the original ones and that they are installed firmly.
3. Overall Machine Load Test: Wind 5 batches of standard coils continuously, calculate the qualification rate, and check the operation stability of the equipment. The product qualification rate should be ≥99%, and the equipment should have no mid-operation shutdown or error reporting.
Daily: Clean key areas → Inspect wear parts → Conduct idle test run.
Weekly: Lubricate moving parts → Clean electrical cabinet.
Monthly: Calibrate tension → Calibrate wire arrangement accuracy.
Quarterly: Test servo motor temperature → Check bearing wear.
Annual: Test motor insulation resistance → Replace aging wear parts → Conduct load test.
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