In the copper wire processing industry, the stable operation of the wire drawing machine as one of the core equipment is directly related to the quality and production efficiency of the product. However, in the actual operation process, the wire drawing machine may encounter various debugging and operation failures. This article will analyze these common faults and their corresponding solutions from seven aspects, such as outside diameter difference control, surface oxidation, frequent wire breakage, improper speed setting, noise and vibration, tension instability, and lubrication problems.
1. Outside diameter deviation control
Fault phenomenon: The outside diameter of the copper wire after drawing does not meet the specifications, and the phenomenon is too large or too small.
Solution:
Check the mold: Make sure the mold size is accurate and there is no wear or deformation. Replace worn molds regularly.
Adjust the tension: according to the copper wire material and drawing process, adjust the front and rear tension to ensure that the force of the copper wire is uniform during the stretching process.
Optimize the cooling system: ensure that the cooling water temperature is appropriate and the flow rate is stable, effectively control the temperature of the copper wire, and reduce the influence of thermal expansion and cold contraction on the outer diameter.
2. Surface oxidation
Fault phenomenon: Oxidized layer appears on the surface of copper wire, affecting product quality.
Solution:
Improve the storage environment: Avoid long exposure of copper wire to moisture or corrosive gases.
Strengthen cleaning: effectively clean the copper wire before drawing to remove surface impurities and oil.
Control drawing speed: Avoid drawing too fast to cause copper wire temperature rise, accelerate the oxidation process.
3. Frequent breakage
Fault phenomenon: In the process of wire drawing, the copper wire frequently breaks, affecting the continuity of production.
Solution:
Check the mold fit: ensure that the mold and copper wire fit gap is moderate, to avoid too tight or too loose caused by fracture.
Optimize material quality: Use less impurities and good toughness of copper wire raw materials.
Adjust the tension and speed: set the tension and speed reasonably to avoid the broken wire caused by excessive tension or speed mismatch.
4. The speed is set improperly
Fault phenomenon: The drawing speed is set unreasonable, resulting in low production efficiency or unstable product quality.
solution
Adjust according to material characteristics: Different materials of copper wire have different requirements for speed, and need to be adjusted according to material characteristics. Gradual adjustment: Start from a small speed, gradually increase to the best speed, observe changes in product quality, and avoid instability caused by sudden adjustment.
5. Noise and vibration
Fault phenomenon: When the wire drawing machine is running, excessive noise and vibration affect the equipment life and working environment.
Solution:
Check mechanical parts: tighten loose screws and check transmission parts for wear or imbalance.
Optimize the layout of the equipment: ensure that the equipment is installed on a solid basis to reduce resonance phenomena.
Regular maintenance: Regular lubrication and maintenance of equipment to reduce noise and vibration caused by wear.
6. Tension is unstable
Fault phenomenon: tension fluctuation in the drawing process, affecting the quality of copper wire.
solution
Check the tension control system: make sure the tension sensor is accurate and reliable, and the tension controller is set up properly.
Optimize the tension adjustment mechanism: Regularly clean and adjust the tension adjustment mechanism to ensure its sensitivity and accuracy.
7. Lubrication problems
Fault phenomenon: insufficient or excessive lubrication, resulting in increased equipment wear or affect the drawing effect.
Solution:
Reasonable selection of lubricants: According to the equipment requirements and material characteristics to choose the appropriate lubricant.
Regular inspection and supplement: regularly check the oil level and oil quality of the lubrication system, and timely supplement or replace the lubricant.
Avoid excessive lubrication: Excessive lubrication may lead to oil pollution of copper wire, need to strictly control the amount of lubricant.
In summary, for the common faults that may be encountered during the commissioning and operation of the copper wire drawing machine, careful inspection, reasonable adjustment and optimization of maintenance measures can effectively reduce the occurrence of faults and improve production efficiency and product quality.