Common Faults In Winding Machines And Troubleshoot

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Common Faults In Winding Machines

In the textile or coil manufacturing industry, winding serves as a crucial transition phase between spinning and weaving, emphasizing its importance in ensuring optimal yarn, coil or cable quality and machine performance. Addressing faults in winding machines requires a systematic approach to identify both primary and secondary causes and implement effective solutions. Below is a detailed examination of common issues and their resolutions:

1. Tension Device Malfunction

The tension device, consisting of a tension disc and an idle disc, is critical for regulating yarn tension. If residual yarn becomes entangled with the pressure disc, it can obstruct movement, leading to unstable tension and uneven winding density, which often results in frequent yarn breakage. Adhering to proper operational guidelines and thoroughly cleaning the device can restore its functionality and maintain consistent tension control.

2. Failure of Package Rotation

During standard winding operations, the yarn tension sensor detects when the package unwinding is complete and signals the control system. The driving mechanism then moves the package holder towards the empty package conveyor to expel the used package. A stepping motor rotates the ratchet wheel by one tooth to facilitate package rotation. Obstructions, such as lint or residual yarn, can prevent the pawl from engaging, leading to package rotation failure. Disassembling the package components to remove lint or residual yarn and implementing regular compressed air cleaning can prevent such issues.

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3. Inadequate or Failed Splicing

Splicing issues may arise from inadequate process design or improper splicing parameters. Misalignment of the splicing rod or malfunction of internal components like sealing rings and splicing covers can also be contributing factors. Adjusting splicing parameters and performing splicing tests can resolve issues caused by human error. For other causes, realigning the splicing rod and maintaining internal components are necessary.

4. Air Leakage in the Large Suction Nozzle

Inspecting the large suction nozzle for air leaks is essential. A yarn placed near the nozzle should not be drawn into it when the nozzle is in the zero position. Air leakage not only wastes energy but also reduces air pressure available for other components. This leakage is typically caused by lint clogging the energy-saving flap. To address this, disassemble the air valve, clean out the lint, apply sealing grease to the flap's actuating piston, and verify airtightness with yarn.

5. Frequent Yarn Removal from Package Holder

Frequent removal of yarn from the package holder is often due to soiling or malfunctioning of the yarn breakage sensor. Cleaning the sensor's sensing surface can usually resolve this issue. Routine maintenance and cleaning of the sensor are essential preventative measures.

6. Inflexible Rotation of Package Holding Arm's Sizing Heads

Sizing heads on the package holding arm rotate at high speeds, which can lead to bearing wear over time. When bearings become worn, the arm's rotation may become difficult, causing uneven yarn arrangement and triggering alarms. Replacing worn bearings during maintenance can restore proper operation.

7. Dull Scissors

Dull scissors that fail to cut yarn effectively can cause the yarn held by the small suction nozzle to fold at the fixed nozzle, leading to repeated breakages as it passes through the clearer. Replacing dull scissors with sharp ones during maintenance can resolve this issue. Alternatively, blunt scissors can be sharpened in a machine repair workshop for continued use.

Effective tension control and comprehensive maintenance practices are crucial for ensuring the reliable performance of winding machines and the production of high-quality yarn. Regular inspections and prompt interventions will help maintain optimal machine functionality and minimize production disruptions.

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