Common Faults and Troubleshooting Methods for Cable Tray Forming Machines

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Common Faults and Troubleshooting Methods for Cable Tray Forming Machines

機械類 Co.,Ltd を形作る滄州 Zhongtuo ロールは河北中国から来ます。それは設計および製造に専用されている製造業者です。
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説明

Cable Tray Forming Machine

Upon equipment shutdown, the entire system becomes paralyzed. For cable tray manufacturers, a one-hour downtime may result in a loss of production value amounting to several thousand yuan. Rather than scrambling to make after-sales calls when issues arise, it is advisable to first conduct a self-inspection by referring to this “Emergency Response Manual”.

Below are the six most Common Faults and Troubleshooting Methods for Cable Tray Forming Machines, compiled by us.

一、Forming dimensional deviations (deviation, distortion, length inaccuracies)

This is the most common issue, typically manifesting as inconsistent heights on both sides of the cable tray, uneven diagonals, or varying lengths in cut sections.

Fault phenomenon	Possible Reasons	Solution
Plate misalignment (asymmetric left-right)	1.Incorrect feed material. 2.Uneven pressure on both rollers. 3.Damaged or stuck bearings in a specific roller set.	1. Adjust the guide frame to align the plate centerline with the machine centerline. 2. Fine-tune the roller clearance on the deviated side (loosen slightly) or on the opposite side (tighten slightly). 3. Stop the machine to check bearing temperature and replace damaged bearings.
Forming deformation	1.Roll misalignment (not on the same straight line). 2.Upper and lower rollers are not parallel. 3.Uneven internal stress in the plate itself.	1. Re-calibrate the straightness of all machine rollers. 2. Use a level to adjust the base, ensuring the upper and lower shafts are parallel. 3. Adjust the pressure of the leveling machine to eliminate internal stresses in the plate.
Length inaccurate (significant fixed-scale error)	1.The encoder (speed sensor wheel) is slipping or accumulating dust. 2.Signal interruption interference. 3.Feed servo parameter drift.	1. Key inspection points: Clean the encoder rollers and compression springs, ensuring they adhere tightly to the plate without slipping. 2. Check whether the shielded wires are properly grounded. 3. Re-calibrate the pulse count.

二、Punching anomaly(large burrs, material blockage, inaccurate hole spacing)

The quality of punching directly affects the installation of cable trays and represents the most prone stage to defect production.

Fault phenomenon	Possible Reasons	Solution
The burr on the punching hole is too large.	1. Punch needle wear (most common). 2.Excessive clearance between the punch needle and the lower die. 3. The sheet material is too hard.	1.Replace with a new punch (it is recommended to maintain readily available consumables). 2.Adjust the die clearance (typically 5%-8% of the plate thickness). 3.Reduce the stamping speed or replace the material.
Punch fracture/stuck	1.There is a weld at the punching position (accidentally left untreated). 2.Waste material has clogged the lower die. 3. Insufficient lubrication.	1.Do not impact the weld seam! Exercise caution during material feeding to avoid interference. 2.Clear waste materials from the lower die and check whether the blowing device is unobstructed. 3.Add additional stamping lubricating oil.
The spacing is inaccurate.	1.The feed servo triggers an alarm or loses steps. 2.The press clutch operates with delay.	1. Check the servo driver for any alarm codes and restart to reset. 2. Adjust the clutch intake pressure or clearance.

三、Cutting issue (inability to cut, oblique incision, tool breakage)

Fault phenomenon	Possible Reasons	Solution
Can’t cut it off/be out of shape	1. The blade has become dull. 2. Insufficient pressure in the hydraulic system. 3. The plate is excessively thick.	1. Sharpen or replace the cutting blade. 2. Check the oil pump pressure and adjust the relief valve. 3. Do not operate under overload conditions.
The incision is oblique.	1. Insufficient pressure in the pressing cylinder (resulting in plate warping). 2. Wear on the guide rails and slider movement.	1. Increase the material feeding gas pressure and check whether the feeding feet are level. 2. Tighten the guide rail wedges and replace worn sliders.
Flying Saw Not Tracking	1. Track encoder failure. 2. Servo enable connection lost。	1. Check the encoder cable. 2. Reset the servo alarm and inspect the limit switch.

四、Abnormal noises and vibrations from the equipment

Fault phenomenon	Possible Reasons	Solution
Abnormal noise from the gearbox	1. Gear wear or tooth breakage. 2. Lack of lubricating oil or degraded oil quality. 3. Bearing failure.	1. Stop the machine, open the box for inspection, and replace the gears. 2. Add oil immediately. 3. Replace the bearings.
The chain is producing significant vibration noise.	1. The chain is too loose. 2.The sprocket is not in the same plane. 3.There is insufficient lubrication causing dry friction.	1. Adjust the tension wheel. 2.ibrate the sprocket parallelism. 3. Apply lubricating grease.

五、Electrical system failure (Machine stoppedt, give an alarm)

Fault phenomenon	Possible Reasons	Solution
No response when starting up	1. The emergency stop button is not reset. 2. Phase loss or main power trip occurred. 3.The 24V switching power supply has burned out.	1. Turn the emergency stop button clockwise. 2. Check the air switch in the distribution box. 3. Measure the output voltage of the power supply.
PLC/Touchscreen Alarm	1.Limit switch triggered (e.g., material rack reaches bottom). 2. Servo driver overload. 3. Program error (rare).	1. Check the sensor indicator lights at the corresponding locations. 2. Reduce the load and inspect any mechanical lockup points. 3. Backup the program; restore to factory settings if necessary.

六、Hydraulic system failure

Fault phenomenon	Possible Reasons	Solution
The oil temperature is too high.	1. The cooler is blocked or not activated. 2. The relief valve has an excessively high set pressure, causing prolonged overflow. 3. The oil viscosity is incorrect.	1. Clean the cooler fins and open the cooling water valve. 2. Re-adjust the pressure. 3. Replace with hydraulic oil of the appropriate grade.
The hydraulic cylinder moves slowly.	1. Oil suction filter element clogged. 2. Hydraulic pump worn with severe internal leakage. 3. Electromagnetic valve spool stuck.	1. Clean or replace the filter element. 2. Repair the oil pump. 3. Clean the solenoid valve.

Safety Warning (Must Be Retained)

Power-off warning sign: For any operations requiring access to roller or mold areas, immediately activate the emergency stop and display a warning sign stating “Work in progress; do not close circuit.”

Single-user operation: Do not operate the console with another person simultaneously to prevent accidental button presses that could cause injury.

Check the surroundings: Before starting the device, ensure there are no people nearby.

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弊社は国家レベルのハイテク企業である。ISO9001品質システム認証、欧州CE安全認証、北米CAS認証などを取得しました。私達に輸出貿易で豊富な経験があり、異なった国の顧客の必要性を理解します。一方、我々は満足のいく設計ソリューションを顧客に提供することができます。私達の機械は 150 ヶ国以上に輸出され、私達は顧客との長期および安定した協同関係を確立し、顧客の賞賛に勝ちました。