1、Over-twisting
Over-twisting refers to the twisting process, twisting excessive twisting twist-shaped phenomenon.
Causes of generation.
1, stranded wire in the traction wheel around the number of turns is not enough, generally less than 4 turns, the friction is too small and slippery, resulting in excessive twisting and twisting.
2, the closing tension loose or the closing disk does not turn, while the rotating body is still rotating, and cause excessive twisting.
Exclusion method.
If the outer single line has been violently deformed, the damage is serious, there is no possibility of repair, only cut off. If the single line is not severely damaged, the equipment can be separated from the part of the rotating body and traction part, it will turn in the opposite direction towards the twist, so that the local twist part back, and then hand to repair the core, and the excess single line and then winding to the take-up tray, the equipment and the rotating body traction unity, the looser over the pressure line mold, hard pressure line, another manual repair with the mold, so that you can restart the production.
2、Single wire breakage during stranding and the reasons for it
Causes of generation.
1, due to excessive tension in the release line pulled off the core.
2, single line in the pulling system loose mess, bad line, pressure line across the line, causing the core to break.
3, the single line itself has cracks in the material, mechanical properties are not good brittle break.
4、Improper installation position of the payoff tray, axial shaking, resulting in broken wire.
5, the single line jumped out of the pulley groove, mechanical snap off.
Exclusion methods.
1、Adjust the payoff tension to make it appropriate.
2, pay attention to the selection of the incoming line, found to pull the line with loose chaos, must be rewound before the machine.
3, pay attention to the method of operation, carefully check the position of the payoff tray, so that the line is not put out without swinging or jumping, check the single line through the place, there is no jump out of the guide wheel slot phenomenon.
4, to check the surface quality of the wire core, to see if there are cracks, slag, spot scars and other defects. If the broken line occurs in the inner layer, and the broken head has gone too long, it can not be repaired, only to cut this section of the missing strand core, if the broken line occurs in the outer layer, the line should be repaired and then turn on the machine.
3、Surface abrasion of stranded wire, scratching the core
Causes of generation.
Usually one is the line on the sub-tray mouth wear, the second is a single line jumped out of the pulley, three is threading with wood or plastic pipe grinding through, four is traction equipment to push the positioning pin on the board is damaged, five is the pressure mold in the foreign body and other reasons.
Exclusion methods.
Replace the wire spout on the distribution plate and threading with wooden and plastic tubes, check whether the direction of the core is normal, protect the core from direct wear and tear with the equipment, and always check whether the pressure die is intact, and pay attention to the method of operation.
4、Single wire back strand and loose strand in bundle and stranded wire
Causes of generation.
1, uneven release tension, loose and tight, tension loose cores go more, resulting in back stock.
2、The pressure mold hole type is too large to play the role of proper tension adjustment.
3, improperly positioned compression mold, unreasonable strand angle, four, the pitch is relatively large, etc.
Bunching machine bunching 19 shares and more than a single core, due to the distinction between the direction of the bundle, only the same bundle, so the combination of the core is irregular, most manufacturers currently use double-pitch bundle, so the bundle of more than 19 shares of the core, the back of the strand, the loose strand phenomenon than stranded wire.
Exclusion methods.
For bundled wire (bundled products with more than l strands)
1、Improve the payoff device of the bundle, using the more advanced single wire tension payoff device, so that the tension of each single wire can be adjusted and controlled.
2、Adopt guiding die, the aperture of the guiding die is 97% of the calculated outer diameter of the bundle. This guide die can properly adjust the tension. 3, switch to a single-pitch bunching machine, this bunching machine bunching products, can reach the level of stranded wire. Fourth, the back of the strand, loose strands of serious cores, with over-mode rewinding repair method, can also meet the requirements of use. Fifth, the appropriate adjustment of the pitch ratio.
For stranded wire products
1、Adjust the release tension to make it even.
2, change the pressure mold, the core in the mold hole do not loose, pay attention to the pressure mold flare, if the flare has been damaged, also can not make.
3, adjust the position of the pressure die seat, so that the stranded wire stranded into a reasonable angle. Fourth, if the stranding pitch is large, should be properly reduced.
5、Single line grooving or surface defects in stranded wire
Causes of generation.
Single line surface pockmark, spot scar, triangular crack, slag and other defects, mainly brought about by the material, of course, the core surface cracking phenomenon, also does not exclude the pulling of the mold hole type unreasonable and generated, at this time need specific analysis. The core surface groove is continuous, generally caused by pulling the wire, pulling the wire lubrication conditions deteriorate, the surface of the sticky aluminum and caused by not being continuous groove, it is possible that the stranding pressure mold sticky foreign matter.
Exclusion methods.
For the pulling of the aluminum line groove, should first check whether the pulling line lubrication effect can meet the requirements of the pulling line, the need for timely replacement of lubricants, replace the pulling line mold, or exclude the sticky line on the mold debris, carefully check the incoming line, the unqualified incoming line should be excluded in a timely manner, while checking whether the pressure line mold damage, debris, to repair and replace in a timely manner.
6、Single line wire diameter suddenly large, suddenly small or mixed with the wrong core
Causes of generation.
Stranding found in the single line diameter over poor or mixed with the wrong core, the main reason is not seriously implement the process regulations, another reason is the management of certain problems.
Exclusion methods.
The wrong core if the length is not long, you can pick off, re-exchange the line, according to the wiring repair method to repair. If the length is too long, it can not be repaired, only off the machine, another treatment. Therefore, before the machine, the operator should be carefully checked and measured. Of course the manager should also provide a guarantee approach, such as whether the line gauge is too much, whether the tolerance is reasonable, whether the production scheduling is properly arranged, according to the PDCA principle to seriously think about the problems in management, to avoid the generation of man-made defective products and scrap.
7、Stranded wire cores with loose strands
Causes of generation.
1, the pitch is too large, resulting in stranded wire core is not solid.
2、The compression mold hole type is too large, not playing the role of compaction and regulation. Wire mold flare is too large or worn, damaged.
3、Uneven tension of the release line, loose and tight.
4、The pitch ratio of each layer is not good with.
5, the state of the wire core does not meet the process regulations, especially the aluminum core.
6、The position of the wire splitter and pressure mold seat is not appropriate, etc.
Exclusion methods.
First of all, strict process discipline, implementation of the process operating procedures, appropriate reduction of excessive pitch, adjust the release tension and pressure die. Divider to the position of the pressure die seat, according to the different structures, generally adjusted to 200 ~ 250mm is appropriate. For stranding some tensile strength is particularly large strand, you can use a combination of mold method, also has a better effect, of course, the operator according to the method specified in the process operating procedures, is quite important.
8、Wrong stranding direction, unqualified stranding pitch
Causes of generation.
Wrong direction is mainly a judgment error. Operators should be more responsible when operating, strictly according to the process card, and should strengthen the flow inspection to prevent the generation of man-made defective products and scrap.
9、Disorganization of the line, pressure line
Causes of generation.
Stranded products are generally supplied in reels. Large cross-section, to be lined up one by one, especially the bottom layer of the line should pay special attention to row neatly, in the row of line transfer, because there is a stay, should pay special attention to the upper and lower layers can not leave too big a gap between the row of distance to be appropriate, too large easily cause pressure line.
Exclusion methods.
1, first of all to adjust the winding tension, when the manual row of wire, can row to move as appropriate
2, according to the size of the wire core diameter to replace the pitch of the line, line up the first layer is the key, must be neat; line up the second layer, when adjusting the layer, to carry out manual line, to ensure the quality of the line.
3、Strengthen the operation responsibility to observe the quality of the line at any time, find problems to adjust in a timely manner, pay attention to fixing the two threads and leave the edge distance.
