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As the key equipment in the production of power transformers, reactors and other electrical equipment, the foil winding machine may seriously affect the production schedule in case of failure. In an emergency, maintenance personnel need to quickly determine the cause of the failure and take effective measures.

This paper will introduce the common fault diagnosis and emergency maintenance methods of foil winding machine in detail.，I hope it can help you solve the emergency equipment failure.

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Fault 1:Mechanical transmission system fault

-Symptoms: abnormal noise, significant increase in vibration and heating of transmission parts when the machine is running

-Cause analysis：

Worn or poorly lubricated bearings

Poor gear engagement or wear

Belt/Loose or damaged chain

Misalignment of coupling

Fault 2:Fault of electrical control system

-Symptoms: the motor does not start, the speed is unstable, and the control panel displays abnormally.

-Possible causes:

Power supply problem (voltage instability, phase loss)

Frequency converter/Servo drive failure

PLCProgram error or communication interruption

Sensor (encoder, limit switch) failure

Fault 3:Foil handling system failure

-Symptoms: Foil deviation, wrinkling, unstable tension, broken foil

-Possible causes:

Tension control system fault

Deviation or wear of guide roller position

Deviation correction device fails

Quality problem of foil material

II. Emergency maintenance steps and measures

1.Safety principles

-Press the emergency stop button immediately to cut off the power supply.

-Set up warning signs to prevent misoperation by others

-Make sure that the equipment is completely stopped before checking

-Handle electrical components with insulated tool

2.Fast fault diagnosis method

1.Sensory inspection: preliminarily judge the fault location by listening, seeing, touching and smelling.

2.Segmented exclusion method: divide the system into mechanical, electrical, control and other parts to check one by one

3.Parameter comparison method: compare the current, voltage, temperature and other parameters during normal operation

4.Replacement method: conduct temporary replacement test for suspected parts.

3.Emergency maintenance of mechanical system

Bearing fault treatment:

-Temporarily add special grease (such as high temperature lithium grease)

-If the bearing is damaged, the pre-tightening force can be temporarily adjusted to continue operation in case of emergency.

-Take care to monitor the bearing temperature and increase external cooling if necessary

Maintenance of transmission components:

-Loose belt: temporarily adjust the tensioning device or apply rosin to increase the friction

-Gear wear: clean tooth surface and apply molybdenum disulfide grease

-Chain failure: remove the damaged chain link and temporarily shorten it for use

4.Emergency treatment of electrical system

Power supply problem:

-Check three-phase voltage balance (deviation not more than ±10%）

-Temporary use of regulated power supply or quarantine transformer

-Check the contact of fuse and contactor in case of phase loss

Frequency converter fault:

-Reset Operation (Power Off30Restart after seconds)

-Check if the cooling fan is running

-Temporarily reduce carrier frequency to reduce heating

PLCBreakdown

-Attempt to restore factory settings after backing up current parameter

-CheckI/OModule led Status

-Temporary use of manual mode to maintain production

5.Emergency plan for foil handling system

Abnormal tension control:

-Switch to Manual Tension Mode

-Temporarily increase the counterweight or adjust the air pressure value

-Check whether the signal of tension sensor is normal.

Foil deviation treatment:

-Manually adjust the position of the guide roller

-Clean detection surface of the correction sensor

-Temporarily reduce the operating speed within the allowable range

III. Test and verification after maintenance

1.No-load test:

-Check the action of each component during low-speed operation

-Increase the speed gradually to observe the vibration and noise.

-Verify the function of each limit switch

2.On-load test:

-Use scrap for trial winding

-Check foil tension stability

-Measure the tightness and uniformity after winding

3.Parameter record:

-Record key operating parameters after repair

-Comparative analysis with historical data

-Establish the maintenance file of this fault

IV. Preventive Maintenance Recommendations

1.Key points of daily maintenance:

-Regularly lubricate all moving parts

-Clean dust and foil debris inside the equipment

-Check for loose fasteners

2.Periodic inspection:

-Check the wear of the transmission system every month.

-Quarterly calibration of measurement sensors

-Insulation test of electrical system shall be carried out annually.

3.Operator training:

-Equipment Abnormal Symptom Identification

-Basic fault emergency treatment method

-Review of safety operation procedures

V. Precautions

1.Emergency maintenance is only a temporary measure, and a thorough overhaul must be arranged as soon as possible.

2.It is not allowed to modify the parameters of the equipment safety protection device without authorization.

3.Contact professional technicians for complex electrical faults.

4.Pay attention to protecting the surface quality of foil during maintenance

5.Safety function test must be carried out after every repair

Sum up

Through the above method, in case of emergency,PreliminaryRestore the basic functions of the foil winding machine and ensure the continuity of production. However, it should be emphasized that all emergency treatment should be followed."Safe"When the fault exceeds its own maintenance capacity, the operation must be stopped and professional support must be sought.

As one of the most professional transformer equipment manufacturers in China, we focus on the production and service of foil winding machines, and can provide customers with free technical support for life.

If you want to purchase foil winding machine, I believe we will be your most suitable choice.