Motor motor rotor automatic six-station double flying fork winding machine what are the common mechanical faults and solutions?
1、Flying fork failure
Failure phenomenon
l Flying fork movement is not smooth, jamming or shaking phenomenon. This will lead to uneven winding, the line may cross, overlap, affecting the quality of winding.
l The rotational speed of the flyer fork is unstable and cannot wind the wire according to the set speed. This may cause the winding speed to be too slow and affect the productivity, or the speed to be too fast and lead to excessive tension on the wire and breakage of the wire.
Possible causes
l The transmission parts of the flyer fork (e.g. belt, chain, gear, etc.) are worn or loose. Prolonged operation will cause wear and tear of these transmission parts, resulting in a decrease in transmission accuracy.
The bearing of the flyer fork is damaged. Bearings are susceptible to wear and tear, ball breakage and other problems when rotating at high speeds and under certain loads.
l The guide rail of the fly fork is uneven or has debris. Dust, oil or other debris on the guide rail will hinder the smooth movement of the fork, and the wear or deformation of the guide rail itself will also affect the movement accuracy of the fork.
Solution
l For worn or loose transmission parts, they need to be replaced or re-tightened in time. For example, if the belt is seriously worn, replace it with a new one and adjust the tension; for loose gears, check and tighten the fixing screws.
l Check the flying fork bearings. If signs of damage are found, replace them with high quality bearings of the same type. When installing the bearings, make sure they are installed correctly to avoid new damage caused by improper installation.
l Clean the flying fork guides to remove dust, oil and debris. If there is wear or deformation on the guide rail, minor ones can be repaired by grinding and so on, while serious ones need to replace the guide rail. At the same time, add the appropriate amount of grease on the guide rail to ensure smooth movement of the flying fork.
2、Fixture failure
Failure phenomenon
l The fixture can not firmly clamp the rotor, resulting in displacement of the rotor in the winding process. This will make the winding position inaccurate and affect the performance of the motor rotor.
l The opening and closing action of the fixture is not flexible, and it cannot clamp or loosen the rotor accurately in time, which reduces the working efficiency of the winding machine.
Possible causes
l The collet of the fixture is worn out. Prolonged contact with the rotor causes wear on the surface of the collet, resulting in reduced clamping force.
l Problems with the pneumatic or hydraulic system of the clamp (in case of pneumatic or hydraulic clamps). For example, broken air hose, loose fitting, insufficient pressure from air source or leakage of hydraulic oil, malfunctioning of oil pump, etc.
l The mechanical transmission part of the fixture (e.g. linkage, slide, etc.) is damaged or jammed. This may be caused by long-term mechanical friction, entry of foreign objects, etc.
Solution
l Replace the worn out collet and choose the collet material with suitable hardness and precision to ensure good clamping effect.
l For pneumatic clamps, check the air hose, connector and air source pressure. Repair or replace the ruptured air hose, tighten the loose connector, and adjust the air pressure to the normal range. For hydraulic fixture, check the level and quality of hydraulic oil, repair the leakage point, and check whether the oil pump works normally.
l Clean up the foreign matter in the mechanical transmission part of the fixture, and check whether there is any damage to the connecting rod, slider and other parts. For damaged parts, should be replaced in a timely manner; for the case of jamming, to find out why, such as insufficient lubrication to add lubricants, adjust the position of the parts to restore the flexible movement.
3, indexing mechanism failure
Failure phenomenon
l The indexing of the rotor is inaccurate, resulting in the position of the winding deviation. This will make the distribution of the winding does not meet the design requirements, affecting the performance of the motor.
l The indexing mechanism in the process of running an abnormal sound, may be between the parts of the coordination problems or parts are damaged.
Possible causes
l The cams, rollers and other key parts of the indexing mechanism are worn. These parts are prone to wear due to friction during frequent indexing operations, affecting the indexing accuracy.
l The transmission chain or gear of the indexing mechanism is loose and worn. This will lead to inaccurate power transmission, thus affecting the accuracy of indexing.
l The indexing sensor is faulty or improperly installed. The sensor cannot detect the indexing signal accurately, or the installation position is shifted, which will make the indexing control have problems.
Solution
l Replace worn cams, rollers and other parts to ensure that their accuracy meets the requirements. After replacement, make proper debugging to restore the motion of indexing mechanism to normal.
l Check and adjust the tension of the transmission chain or gear, and replace the worn parts. Meanwhile, pay attention to keep the transmission parts clean and lubricated.
l Check the working status of the indexing sensor, clean the surface of the sensor and check whether its output signal is normal. If the sensor is damaged, it should be replaced with the same type of sensor. Adjust the installation position of the sensor so that it can accurately detect the indexing signal.
4、Failure of wire feeding mechanism
Failure phenomenon
l The wire feeding is not smooth, and the wire is stuck, knotted or entangled on the wire feeding wheel in the conveying process. This will lead to the interruption of winding, affecting production efficiency.
l The wire feeding tension is unstable, and the tension of the wire is not consistent. This may cause the wire to be too loose, affecting the tightness of the winding, or the wire to be too tight causing the wire to break.
Possible causes
l The wire feed pulley is worn or has a foreign object. Wear on the surface of the wire feed pulley affects the friction of the wire, while a foreign object prevents the wire from being properly conveyed.
Malfunction of the tension adjusting device. Fatigue of the tension adjusting spring, damage to the tension sensor or jamming of the adjusting mechanism can cause unstable tension.
The quality of the wire or improper installation of the bobbin. For example, the thickness of the wire is not uniform, the rotation of the bobbin is not smooth and so on.
Solution
l Check the wire feeder pulleys, clean the surface of foreign objects, and replace the ones that are badly worn. When installing a new wire feed pulley, make sure that it fits well with other parts.
l Check the tension adjusting device. For fatigued springs, replace the springs with new ones; if the tension sensor is damaged, replace the sensor and recalibrate it; for the jammed adjusting mechanism, clean the foreign matter and add lubricant to make it restore the normal adjusting function.
l Check the quality of the wire and replace the wire with qualified quality. Reinstall the bobbin to make sure that it can rotate smoothly and the wire will not be subjected to additional resistance during the unwinding process.
※ If the above ways and means still can not solve the equipment failure, please contact the technical specialist of Xinhui Mechanical and Electrical Equipment Co.
