Establishing a strict periodic maintenance schedule effectively extends equipment lifespan, reduces failure rates, and ensures processing accuracy.
Maintenance Cycle | Area / Component | Specific Operational Requirements |
Daily | Machine Frame & Scrap Chute | Thoroughly clean off wire chips, insulation scraps, and debris using an air gun to keep the machine clean. |
Critical Moving Parts | Apply an appropriate amount of lubricating oil or grease to the guide rails, stamping bearings, and other moving components. | |
Monthly | Transmission System | Check the tension of the belts and adjust it if necessary. |
Electrical & Power | Inspect the wear of the motor carbon brushes and replace them in time if they reach their limit. | |
Signal Detection | Test the sensitivity of each error-proofing and positioning sensor one by one, and clean any dust off their surfaces. | |
Yearly | Deep Overhaul | Disassemble and inspect the equipment completely, and perform a major overhaul on heavily worn mechanical structures. |
Accuracy Calibration | Use professional measuring tools to calibrate the processing and crimping accuracy of the machine in all dimensions. |
When anomalies occur during production, refer to the following guide for rapid troubleshooting and resolution:
2.1 Incomplete Stripping or Core Wire Damage
Root Cause: Usually caused by improper blade depth adjustment or severe blade wear.
Symptom A: Insulation Layer Residue (Incomplete Stripping)
Countermeasure: Fine-tune the parameters to slightly increase the cutting depth (lower the blade further).
Symptom B: Damaged Copper Wire (Core Wire Damage / Broken Strands)
Countermeasure: Properly reduce the cutting pressure (decrease the cutting depth). If this does not work, inspect the blade edge for chipping and replace it with a new blade.
2.2 Abnormal Feeding / Material Jamming
Root Cause: Abnormal resistance in the wire intake system or mismatched specifications.
Inspection & Countermeasures:
Check the Guide Wheels: Verify that the guide wheels rotate smoothly and are free of any jammed debris.
Verify the V-Groove: Ensure that the V-groove specification of the feeding wheel matches the current wire diameter being processed.
Adjust the Tension: Check and fine-tune the tension of the magnetic powder brake or the wire feeding wheel to ensure it is within a suitable range (neither slipping nor over tight).
Root Cause: Changes in crimp height or an unstable feeding system.
Inspection & Countermeasures:
Re-learn Waveform: If environmental or batch variations trigger a false alarm, verify that the product is qualified first, then have the Crimp Force Monitor (CFM) re-learn the pressure waveform.
Adjust the Mechanism: Adjust the crimp height adjustment screw to ensure the terminal is crimped fully into position.
Feeding Check: Check the terminal reel and feeding strip/pawl to ensure that terminals feed smoothly without twisting or deformation.
