#Precautions for Annual Overhaul of Data Cable Weaving Machine

Annual major maintenance is a comprehensive overhaul of the entire machine, aimed at eliminating wear and tear gaps, restoring equipment accuracy, and eliminating potential faults. After the major maintenance is completed, the equipment should achieve similar process capabilities to the new machine and be suitable for copper/nylon data cable weaving machines. The entire overhaul process must be powered off, tagged, and locked.

##1、 Preparation before major overhaul

1. * * Preparation of materials and records**

-Retrieve equipment historical records: total operating hours, past fault records, replacement records of vulnerable parts, and commonly used process parameters (speed, pitch, coverage).
-Record the current status of the entire machine before major repairs, including spindle noise, spindle runout, actual weaving pitch, and wire breakage failure rate, as a basis for comparison before and after major repairs.

2. * * Advance confirmation of spare parts**
Pre check the spare parts list: various types of bearings, runner spindle assemblies, ceramic eye molds, synchronous belts, tension springs, oil seals, gear oils, seals, sensors, etc; Prevent downtime due to missing parts after disassembly.
3. * * Tools and venue preparation**
Special wrench, puller, level, torque wrench, cleaning oil, brush, compressed air; Divide the parts placement area, label the parts by category, and prevent assembly errors or omissions.
4. * * Safety Confirmation**
Power off the entire machine and hang a warning sign that reads' Do not close during maintenance '; Cut off the gas source and release the residual pressure in the system.

##2、 Key points to note during disassembly process

1. Disassemble in order and mark the cam, gear, synchronous wheel, bearing seat, and locating pin. Store screws and washers at different positions separately and avoid mixing to avoid assembly misalignment.
2. Disassemble the track and spindle components of the carriage: do not forcefully knock or pry, and the working surface of the track must not be bumped or scratched; Once the track collides, it will continue to bounce and break wires in the later stage.
3. Disassembly of electrical components: Each wire should be numbered and marked, and the plugs of sensors and wire breakage alarms should be labeled. It is strictly prohibited to forcefully pull or tug on the cables.
4. Remove and inspect all rubber parts (pressure wheels, seals), and discard them if they have aged or hardened. It is not recommended to continue reusing them.
5. Clean all components thoroughly: thoroughly clean copper powder, oil sludge, and old lubricating oil; Handle ceramic parts with care to avoid collision and edge breakage.

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>  ⚠️ Prohibition: Scratching the track and cam working surface with hard objects will leave scratches and accelerate later wear.

##3、 Component inspection and judgment (core process)

###Mechanical transmission part

1. * * Main shaft and transmission shaft bearings * *: Check for clearance, abnormal noise, and jamming during rotation. If there is any looseness, replace the entire set directly. It is not recommended to make up for it and continue using it.
2. * * Gear and cam * *: Check for pitting, wear, and burrs on the tooth surface and cam working surface; Slight burrs must be polished, and severe wear and pitting must be replaced without compromise, otherwise periodic quality defects may occur during weaving.
3. * * Running on the horse track (racecourse) * *: Focus! If the wear groove on the working surface is greater than 0.1mm, it must be replaced or ground; Track wear can directly cause frequent wire jumping, tangled nets, and broken wires.
4. * * Running Horse Ingot Assembly * *: If there is a large gap between the spindles, rotation jamming, or roller wear, replace the entire set instead of only replacing local parts.
5. * * Traction and winding mechanism**
-Traction rubber pressure wheel: replace directly for surface hardening, grooves, and slipping;
-Wire connector: If the screw is worn or the gap is too large, replace the screw or the entire wire connector;
-Chain wheel chain: worn, elongated, stuck, replace the chain as needed.
6. * * Rack and Base * *: Check for cracks in the foundation and rack welds; Use a spirit level to calibrate the overall level of the machine, with a horizontal error control of ≤ 0.2mm/m.

###Electrical and Sensing Systems

1. Motor: Check the insulation and bearings, and replace the motor bearings if there is any abnormal noise; Clean the dust from the motor cooling fan.
2. Control cabinet: Clean all dust; Tighten all wiring terminals; Replace all cables that are aging, hardening, or have broken skin.
3. * * Key verification of sensors * *: The disconnection alarm sensor, safety threshold, and emergency stop switch must be replaced if damaged or accidentally triggered; **It is strictly prohibited to short-circuit the safety interlock.
4. PLC、 Inverter: Check the heat dissipation, replace the aging fan; Backup device parameters.

###Lubrication seal

1. All oil seals and sealing rings should be replaced directly during major repairs to prevent oil leakage in the future.
2. Drain all old gear oil, clean the inside of the gearbox, remove oil sludge, and add new gear oil according to the instruction manual. The oil level should be strictly controlled in the middle of the oil mark and should not be too much or too little.

##4、 Key considerations during the assembly phase

1. Clean all parts again before assembly to ensure there is no metal dust or impurities; It is forbidden to directly tap the inner ring during bearing assembly. Use a sleeve to evenly press it in.
2. The alignment of gears and synchronous wheels is accurate, and the clearance adjustment is reasonable; The tension adjustment of the synchronous belt is moderate. If it is too tight, it will generate heat, but if it is too loose, it will slip and lose rotation, affecting the weaving pitch.
3. The height difference at the joint of the running horse ingot track must be leveled, and uneven joints are the most common reason for disorderly nets after major repairs.
4. Tighten each fastening bolt according to the torque, and treat the bolts in important parts to prevent loosening; All gaskets and locating pins should be returned to their original positions without missing any parts.
5. Add corresponding lubricating oil to the sliding parts, ensuring * * small amount multiple times * *, to avoid excessive oiling and sticking of copper powder.
6. The electrical wiring should be strictly restored according to the markings, the wiring should be firm, the routing should be regular, and kept away from high-temperature rotating parts.

##5、 Commissioning and inspection after overhaul (can not be omitted)

After assembly, manually turn the entire machine several times: confirm that there is no jamming or collision, and then turn on the power after confirming that there are no errors.
2. First, conduct a no-load low-speed trial run for 30-60 minutes, gradually increase the speed, and observe: spindle temperature rise, abnormal noise, and vibration; Test the safety door, emergency stop, and disconnection shutdown protection, and verify all functions.
3. * * Load testing+process validation (most critical)**
Use production order standard wire for trial production and conduct first piece inspection:
-Weaving pitch and coverage rate;
-Whether there are any jumping wires, broken wires, or disorderly nets;
-Uniformity of tension;
-Traction and rewinding effects.
4. Compare the performance of the equipment before the major overhaul, and if there are any quality abnormalities, re-examine the assembly clearance, track, and spindle issues.
5. Confirm all parameters are qualified, fill out the "Equipment Overhaul Acceptance Form", and record the list of replacement parts.

##6、 Archive of data after major repairs

1. Organize overhaul records: overhaul time, replacement parts list, assembly issues, and test data.
2. Update the equipment maintenance ledger and reset the equipment operation timing.
3. Conduct a brief briefing to the operators, inform them of major repairs and replacement of parts, and remind them to pay more attention to the equipment's operating status in the initial stage.

##7、 Reminder for common pitfalls during major repairs

1. Only replace damaged parts, and do not deal with slight wear and tear on the track and cam. After major repairs, there may be wire jumping and breakage in the short term.
During assembly, uneven track joints are a high incidence of malfunctions after major repairs.
3. Directly short-circuit the electrical safety interlock after maintenance, leaving significant safety hazards.
4. If the gearbox is not cleaned and oil is added directly, the old oil sludge residue will accelerate the wear of the gear bearings.
5. Only perform idling without actual wire load testing, and only discover that the process accuracy is not qualified when put into production.