Analyze and investigate the cause
1. Uneven tension during wire laying
Reason: The tension in the skeleton groove during cable laying is too low or unstable, resulting in the skeleton belt being unable to tightly adhere to the cable core during the cable formation process.
Solution: Check the tension control system of the pay off device to ensure that the tension is moderate and constant. Optimization can be achieved by adding tension sensors or adjusting air pressure/weight.
2. Material or structural issues with the skeleton belt
Reason: The material of the skeleton belt is too soft (such as PVC or PE being too thin) or the structural strength is insufficient, which causes tensile deformation during cable formation, resulting in elongation of the pitch.
solve:
Choose materials with higher strength or thicker skeleton bands.
Check the storage conditions of the skeleton belt to avoid moisture or aging of the materials.
3. Abnormal pitch control device
Reason: The pitch control mechanism of the cable laying machine (such as gearbox, servo motor) has mechanical wear or parameter setting errors.
solve:
Calibrate pitch control parameters (such as matching spindle speed with traction speed).
Check if the transmission components (gears, belts) are worn and replace them if necessary.
4. Poor matching between skeleton groove and cable core
Reason: The geometric dimensions (width, depth) of the skeleton groove do not match the outer diameter of the cable core, resulting in sliding or displacement during wrapping.
Solution: Re measure the dimensions of the cable core and skeleton groove, adjust the skeleton groove mold or choose a more suitable specification.
5. Temperature effect (applicable to thermoplastic materials)
Reason: The processing environment temperature is too high or the equipment heating temperature is unstable, causing the skeleton belt to elongate due to heat.
Solution: Control the temperature of the production environment and check the temperature control accuracy of the heating device.
6. Mechanical failure of equipment
Reason: The guide wheels and bearings of the cable laying machine are worn or the axis is offset, resulting in unstable skeleton belt paths.
Solution: Stop the machine and check if the guide wheel rotates flexibly and if there is any abnormal noise from the bearings. If necessary, replace the components and calibrate the axis.
7. Insufficient tension in the winding process
Reason: The tension at the winding end is too low to counteract the reverse force during the cable formation process, resulting in loose pitch.
Solution: Increase the tension of the winding to ensure it matches the tension of the unwinding.
Suggested troubleshooting steps
1. Prioritize checking the tension system: Use a tension meter to measure the real-time tension at the unwinding and rewinding ends.
2. Observe deformation points: Mark the skeleton belt during equipment operation and observe the specific location where the pitch increases (such as whether there is an abnormality starting behind a certain guide wheel).
3. Parameter review: Verify whether the pitch calculation formula of the cable laying machine (such as pitch=traction speed/spindle speed) is consistent with the process requirements.
4. Material testing: Take a section of the skeleton belt for manual tensile testing to check if its elastic deformation exceeds the standard.
Through the above targeted investigation, the root cause of the problem can usually be located. If the problem persists, it is recommended to contact the equipment manufacturer for specialized debugging of the pitch control system.