The high-speed chenille machine (also known as high-speed rope velvet machine, ultra-fine fiber cutting machine) belongs to high-speed precision textile equipment. Its core components include false twists, guide wheels/discs, tension sensors, heating plates, cutting tools, etc. The speed is usually between 8000-15000r/min or even higher. Therefore, the core idea of maintenance is to "clean frequently, control dust, prevent wear, and calibrate accuracy". Below, we will explain the maintenance methods according to the time cycle.
1. Maintenance per shift (must be done before and after starting up every day)
1. Clean the guide wire channel and false twisting device
After completing daily work, use a brush or compressed air to thoroughly clean the guide wire channel, false twisting device, and guide wire wheel surface, removing residual fibers, cotton wool, and oil stains.
. Velvet fibers are extremely fine, and the residue will clump and harden overnight. The next day, when the machine is turned on, it can directly break the fiber bundle or cause a sharp increase in the breakage rate. Based on industry practical experience, the surface of the guide wheel must be kept smooth. Once the guide wheel is worn or has burrs, it should be replaced immediately, otherwise the wire bundle will be scratched during high-speed operation.2. Check the quality of the pre-treatment of the fiber bundle
Before starting the machine, confirm that the surface of the fiber bundle is free of oil stains and no tangled fibers.
. If the oil content of the raw silk is too high or there is dirty silk, the fibers will slip and entangle on the guide wheel during high-speed operation, and in severe cases, the false twisting device may get stuck. So strengthening the pre-treatment of fiber bundles and removing surface oil stains is the first step before starting up every day.3. Test Run and Abnormal Noise Investigation
Before production, run the machine idle for 3-5 minutes in advance, listen for any abnormal noise (such as "squeaking" sound indicating a lack of oil in the guide wheel bearing, and "clicking" sound indicating a problem with the cutting blade), confirm that it is running normally, and then proceed with wire production to avoid batch waste caused by machine jamming.
2. Weekly maintenance
1. Calibrate the tension sensor
Tension is the lifeline of the Shener machine.
. Excessive tension → breakage; Too low tension → uneven elasticity of the velvet strips, poor cutting effect. Calibrate the tension sensor once a week using standard weights to ensure that the tension value is within the process setting range (usually between 0.5 and 3cN, depending on the type of fiber).2. Calibrate the temperature control system
The temperature of the heating plate of the false twisting device directly affects the twisting setting effect.
. Check weekly whether the actual temperature of the heating plate is consistent with the set temperature (recheck with a thermometer or thermocouple). If the temperature difference exceeds ± 5 ℃, adjust or replace the heating element.3. Clean and inspect the cooling system
High speed operation generates a large amount of heat, and the fiber dust accumulated on the cooling ducts and fins can seriously affect the heat dissipation efficiency.
. Blow the heat sink and cooling air duct from the inside out with compressed air every week to ensure smooth heat dissipation.3. Monthly maintenance
1. Check the wear of the guide wheel and false twisting device
These are the most critical vulnerable parts of the high-speed chenille machine.
. Long term high-speed friction between the guide wheel and the filament bundle will gradually wear out grooves on the surface, causing the filament bundle to bounce on the guide wheel. The ceramic parts and bearings of the false twisting device will also wear out. Disassemble and inspect every month, measure the wear of the guide wire wheel diameter with a caliper, and replace it if the wear exceeds the original diameter by 0.3mm or there are obvious grooves on the surface. If there is any abnormal noise or excessive clearance in the false twisting device bearings, they also need to be replaced synchronously.2. Check and replace the drive belt/synchronous belt
The belt of the high-speed machine ages quickly under long-term high temperature and dust environment.
. Check the tension of the belt and whether there are cracks or burrs on the surface every month. Insufficient tension can lead to unstable speed of the false twisting device, directly affecting product quality.3. Clean electrical cabinets and wiring terminals
Fiber dust is an invisible killer of electrical systems.
. Every month, open the electrical cabinet and use dry compressed air to blow away dust. Check for loose or discolored wiring terminals to prevent poor contact from causing parking or false alarms.Fourth, quarterly/semi annual maintenance (major maintenance)
1. Comprehensive inspection of bearings
Including main motor bearings, false twist device bearings, guide wheel bearings, etc. Rotate by hand to check for any jamming or abnormal noise, measure the axial and radial clearances, and replace any clearances that exceed the standard. Bearings are the heart of high-speed machines. Once a bearing breaks, the entire machine becomes useless.
2. Replace lubricating oil/grease
Replace the gear oil of the main transmission gearbox every six months, and add lubricating grease to each bearing according to the equipment manual (usually using high-temperature resistant lithium based grease, drip point ≥ 180 ℃).
. Oil shortage operation is the first reason for bearing burnout.3. Check the cutting tool
The cutting tool of the Schunier machine wears out extremely quickly during high-speed reciprocating motion.
. Remove and check the sharpness of the blade every quarter. If the blade becomes dull or has a broken edge, it must be replaced. Otherwise, if the cutting length is uneven, the product will be directly downgraded.4. Calibrate overall speed accuracy
Use a tachometer to measure the deviation between the actual spindle speed and the set value. High speed engines require the speed deviation to be controlled within ± 1%. If the deviation is too large, it indicates that the frequency converter parameters are drifting or the belt is slipping, and recalibration is needed.
.Fifth, long-term shutdown maintenance (not needed for more than a week)
1. After comprehensive cleaning, oil and seal the machine
Before stopping, thoroughly clean the inside and outside of the machine, apply rust proof oil to all guide wheels, false twists, and bearings, and wrap the whole machine with plastic cloth to prevent dust and moisture from entering.
.2. Regular turning
Even if the machine is stopped, it is necessary to manually turn it every two weeks (rotate the main shaft 180 °) to prevent the bearings and false twists from being pressed due to long-term static pressure (false Brinell pressure marks), which may cause periodic abnormal noise during the next start-up.
.3. Storage environment requirements
The humidity in the warehouse should be controlled below 65%, kept dry and ventilated, and avoided being stored together with acidic and alkaline chemicals.
. A humid environment can cause ceramic parts to absorb moisture and crack, and metal parts to rust.