CONTENTS

Chapter I Operation Guide to the Designed Software ------------------------ 2

§1-1 Winding Rule Design ------------------------------------------------------2

§1-2 Winding Process Design -------------------------------------------------- 4

§1-3 Mandrel Save -------------------------------------------------------------- 5

§1-4 Mandrel Choice ------------------------------------------------------------ 6

§1-5 Mandrel Delete ------------------------------------------------------------ 7

Chapter 2 Winding -------------------------------------------------------------- 8

§2-1 Manual --------------------------------------------------------------------- 8

§2-2 Semi-auto ------------------------------------------------------------------ 9

§2-3 Automatic Winding ------------------------------------------------------- 10
Chapter 3 The Installation and Adjustment of the System ------------------ 11
Chapter 4 System Testing, Failure Analysis and Dealing --------------------- 13
§4-1 Spindle Encoder -----------------------------------------------------------14
§4-2 Signal Testing of Input Switch ------------------------------------------- 17
§4-2 Signal Testing of Input Switch ------------------------------------------- 18
§4-4 Testing of the Simulated Signal of the Carriage ------------------------- 19

§4-5 Signal Testing of Carriage System --------------------------------------- 19

§4-6 Testing of the Simulated Signals of Add-Sand -------------------------- 20

§4-7 Testing of Controlling Module Clock ------------------------------------- 21

§4-8 Comprehensive Failure Analysis of the Carriage System--------------- 22

§4-9 Failure Analysis of the Computer System ------------------------------ 24

Chapter 5 Electric Scheme ---------------------------------------------------- 25

1
 Chapter I Operation Guide to the Designed Software
§1-1 Winding Rule Design

Start the computer. In Figure 1 on the screen, the black squares show various

functions from Winding-Rule “design” to “exit” by function keys F1 to F8.

Figure 1

Figure 2 appears on the screen by pressing the function key F1. The

corresponding key will then appear in high brightness with the black square

indicating how to input index.

Figure 2

The existing index shown in the system, being dynamic, can indicate the current
inputted next time without repeated input of the same index. Thus, only new index
needs to be put in every time. For example, the length can be modified by pressing
F2 as illustrated in Figure 3.

2
 Figure 3

The inputted length is shown as Figure 4.

Figure 4

When Figure 4 shows press “Enter” and the system will return to Figure 2. After

every index is inputted, the system will perform the design automatically and output

the corresponding results. After the design meets the processing requirement, press

the function key “Esc” at the upper left side of the keyboard under Figure 2 and

Figure 5 will appear on the screen. The system will return to Figure 1 by pressing

“Enter”, thus finishing one round of design. The repetition of the above process can

perform various winding rule for a product. Please remember the design number

every time, which must correspond with sequence number in the process design.

Note:

1 .The left and right stay angel is the angle that the mandrel turns when the
carriage stays at the either end 。 Because the stay angle refers to that of a single
layer whereas each terminal includes the end of one layer and the starting point of

3
another layer, the actual stay angle of the mandrel should be twice of the input.

2. The left and right down-speed length refers to the length that the carriage
when its down-speed from the normal one to zero and again up-speed from zero to
the normal one in the course of its direction changing at the two terminals. The
length, defined by the system according to the principle of the band will not “slide”
in direction changing when the stay angel is zero”, generally needs no modification
without special requirement.

3. The index inputted by the user does not always meet the geometrical condition
of the winding. Thus, the software will adjust the input automatically. Meanwhile,
because different indexes have different effect on the mechanical property of the
product, the user can make a choice according to concrete conditions. For example,
the relatively strict requirement for the product’s mechanical property will lead to
the choice of fixed winding angle ; the multi-product winding in one winding
machine means the choice of fixed band width; and the need for a comprehensive
index will be optimized by the system. The concrete choice can be referred to in the
on-line help of the software.

4. The software cannot check the rationality of the geometrical indexes,

therefore, the indexes which cannot meet the basic geometrical condition may lead
to the “death” of the system. For example, the repeated input of the index “mandrel
diameter =1.0” in Figure 2, as an illegal index, will make the system stop, under the
condition of which the system should have a warm start again.

5 、 F7 should be implemented every time before the design to eliminate the

previous design data in common areas.

Figure 5

1-2 Winding Process Design

In Figure 1 press the function key F2, the corresponding function will appear in

high brightness as shown in Figure 6 to enter winding process design. F1 and F2 can

be used to choose spiral indexes and F3 to F8 can be used to choose circumferential

4
winding index. The concrete process is as follows.

 Press F1 to choose spiral winding layers. (the supposed index is 2)；

 Press F2 to choose the sequence number (the supposed number is 1). Note

that the sequence number should correspond with the design number in the

design. When the sequence number is inputted, the column of mandrel index

fill shows the corresponding index.

 If there is no mistake after checking, press “Enter”. The sequence number

will be shown as 2 to enter next round of input.

 The concrete indexes in winding process design are inputted in the same

way as the design index. Figure 6 and 7 show the corresponding pictures for

winding process input.

 The keys PgUp and PgDn are used to look up the index of every winding

process.

 Press Enter after finishing each process to enter next process.

 Press Esc to finish winding process design after the whole process is

completed.

 The wreath band width (F7) must be inputted before the layer (F8) is.

 In the standard wreath winding, the starting winding angel is equal to the

terminating winding angle. Therefore, it is unnecessary to input the two

indexes in wreath winding.

 If the starting winding angel is not equal to the terminating one, over-

winding with variable angels will be conducted. The function can only be

applied to winding rule transfer.

5
 Figure 6

Figure 7

§1-3 Mandrel Save

Press F3 in Figure 1, Figure 8 will appear on the screen. Input a mandrel number.

The number cannot be the same as the existing numbers, otherwise the system will

prompt for another input. For example, Press F3 in Figure 8 and then press Enter,

the system will return to Figure 1, thus completing the storage. The mandrel number

can be a three-digit number ranging from 1 to 999. For the sake of quick memory, a

mandrel wills a diameter of one meter can be numbered 100.

6
 Figure 8

§1-4 Mandrel Choice

Choose F4 in Figure 1, Figure 9 will appear on the screen. Input a mandrel

number that has already existed in the storage column. If the chosen mandrel

number is not in the column, the system will prompt for another input. For example,

press F3 and then press Enter in Figure 8, the system will return to Figure 1 and

finish the choosing process.

§1-5 Mandrel Delete

Press F5 in Figure 1 as Figure 9 shows, the system will enter deletion stage. Input

the mandrel number to be deleted (the mandrel number must be an existed one in

the storage column) and then press Enter, Figure 10 will show. Answer Y and then

press Enter, the system will return to Figure 1 to finish the deletion process.

7
 Figure 9

Figure 10

The above figures 1，2，3，4，6，7 all have a window spring out to indicate the

user how to input the index. Press the Space bar in Figure 1 to close the window as

shown in Figure 11. Note, the space bar at present is a 0 , 1 switch with the single

press as off, the double press as on and the third press as off, etc.

Figure 11

8
 Chapter 2 Winding

Press F6 in Figure 1 to enter winding stage. Figure 12 will appear on the

screen with three sign lights in the upper right of the picture to represent

spindle, carriage, and motor controlling sand. The green lights indicate “not

ready” or “failure” of the system whereas the yellow lights indicate operation

state.

Figure 12

Attention: Before entering winding stage, the controlling switch “auto, manual,

semi-auto” and “left, carriage, right” should be placed in the middle.

§2-1 Manual

1、 Manual Control of Carriage

Place the switch “L carriage R” ( “left carriage right” )in the “L” or “R”, the

carriage can move towards the head or the end. The moving direction will show in

the window of “WINDING DIRECTION”.

The computer has set an initial velocity when the carriage starts. Press the button

“SPEED-UP” and “SPEED-DOWN” to modify the carriage speed.

Attention: When the switch “L carriage R” is put in the middle, the carriage will

stop immediately. Please switch when the carriage is at a low speed to reduce strike.

2、 Manual Control of the Spindle

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 The switch “CW spindle CCW” is used to control the direction of the spindle. When

the switch is put in the middle the spindle will stop. The speed knob is used to adjust

the speed of the spindle. Reduce the speed of the spindle before stop it to avoid the

strike and then put the switch in the middle.

§2-2 Semi-auto
The semi-auto method is operated as follows:
1. Enter the state of semi-auto control by putting the switch “A manual S”(auto

manual semi-auto) in the position of “S”.

2. Put the switch “CW spindle CCW” in the position of “CW” or “CCW”. Rotate the

speed knob slowly. The spindle begins to rotate.

3. Put the switch “L carriage R” in the position of “L” or “R” as needed. The

window “WINDING MANNER” will indicate the moving direction of the carriage such

as “HEADSTOCK ” or “TAILSTOCK”. The carriage will then start moving with

automatic speed-up when the spindle does.

4、In semi-auto control, the initial band width is the value in linear design. In case

of its difference with the actual pitch in the semi-auto control, the band width can be

increased or reduced through “SPEED-UP” or “SPEED-DOWN” in semi-auto winding.

5. The length of semi-auto winding can be arbitrary, which depends on the

position of the switch

“L carriage R”. The carriage stops when the switch is placed in the middle.

6. The semi-auto control can be stopped as follows: first, put the switch “L

carriage R” in the middle to stop the carriage. Then, put the switch “A manual S” in

the middle to exit the semi-auto control

Attention: The spindle cannot be stopped before exiting the semi-auto control.

§2-3 Automatic Winding

The automatic winding starting from the headstock can be operated as follows:

1 、 Use the Manual manner to move the carriage to the starting point of the

headstock.

2 、 Put the switch “CW spindle CCW” in the position “CW” or “CCW”. Turn the

10
speed knob slowly and the spindle will begin to rotate.

3、Put the switch “A manual S” in the position of “A” to enter the automatic stage.

4 、 The computer will automatically set the winding start point as zero. The

window “IMPORTANT PROMPT” will indicate “SET INITIAL POINT”. The process will

finish very quickly before the user is aware.

5 、 After finishing the above processes, the window “IMPORTANT PROMPT” will

indicate “WAIT FOR START”. If it can be ensured that everything is ready, press the

button “START”. The window will indicate “WINDING HEADSTOCK” and the system

will enter automatic winding.

6 、 Change the speed of the spindle by speed knob and the carriage will

automatically adjust accordingly.

7、Except the speed knob, the switch “CW spindle CCW” cannot be operated in

automatic winding.

8、If it needs to stop in case of broken band or other abnormal conditions, use

the speed knob to reduce the speed of the spindle. The carriage will stop

automatically if the speed of the spindle is reduced to zero.

9、To restart the winding after the problem is solved, turn the speed knob slowly

till the normal winding speed.

10、The wreath winding and spiral winding will adjust automatically in automatic

winding. After the winding stops, the carriage will stop at the end and the spindle

will continue rotating.

11 、 Please note the indexes on the screen in automatic winding. In normal

condition, the value of the mandrel’s rotational speed will have a timely update,

which shows the stability of the mandrel. The radical change indicates the instable

running of the mandrel. If the speed value remains stable despite of the high

rotational speed, it shows that the rotation speed has exceeds the extreme and the

speed should be reduced immediately. Otherwise, the disorder of winding will occur.

The automatic winding starting from the tailstock can be operated as follows:

11
 The automatic winding starting from the tailstock is different from that from the

headstock in that：

1、First, use the Manual Mode to move the carriage to the tailstock to start the

winding.

2、Before pressing the button of “START”, put the switch “ L carriage R” in the

position of the Right. The window of “IMPORTANT PROMPT” will indicate “WAIT FOR

START TAILSTOCK”. After entering the automatic winding, the window of

“IMPORTANT PROMPT” will indicate “ WINDING TAILSTOCK.”

Chapter 3 The Installation and Adjustment of the System

Step 1 Connect the power circuit, signal and earth circuit as the connecting

diagram shows without any mistake.

Step 2 Break all the air switches in the controlling tank. To supply power to the

system, connect the air switch at the side of the tank. Measure the input voltage

at the connecting terminals, including the phase voltage （ ~220V ） and line

voltage （ ~380V ） . The working voltage for the system is ~360V — ~440V.

Measures must be taken to deal with the failure to meet the requirement;

otherwise, the poor contact in the circuit may cause trouble.

Step 3: Connect the power supply of the controlling part. The voltage meter in

the front board of the controlling tank is working. Press the “ENABLE” and a small

relay will work. Press the “EMERGENCY” button and the other relay will be on or off.

When the two relays are both on, the check of the converters 9 and 63 will find

them a connected circuit.

Step 4: Turn on the computer power and enter the main Figure in a few

seconds. Press Enter to enter the winding stage. Check signals such as Left, Right,

Auto, Semi-auto, Start winding, Carriage speed-up, Carriage speed-down, etc. When

12
the Main Figure enters the winding stage, the check of the converters 9 and 65 by

the universal meter will find them a connected circuit. In the status of carriage being

in the left or in the right, the check of the converters 56 and 14 by the universal

meter will find the voltage direct current +0﹒3V and —0﹒3V.

Step 5: Enter automatic state. Turn on the carriage motor manually and the

prompt window will indicate “wait for start”. Return to the manual state. The Actual

Position of Carriage indicates 0. Make a mark and turn the carriage motor clockwise

for a round. The actual position of the carriage will show the corresponding value as

P×Z ／ I, in which P refers to the pitch of the chain, Z the number of teeth of the

sprocket, I the drive ratio. In the driving system of gears and gear racks, Z refers to

the number of gear tooth, P the gear module. A counterclockwise turn will indicate a

0 again.

Step 6: Press the “EMERGENCY” button and turn on the air switch of the

converter, the green signal on the converter will turn on to enter the manual state.

Press the “ENABLE” button and turn the “EMERGENCY” button clockwise to make it

spring-up. The green signal will turn off and the yellow one turns on. Meanwhile, the

Siemens motor will beep slight with four possibilities:

A. The carriage remains stable with the actual position change in the range of

0.01. Put the carriage in the position of Left or Right and the Headstock or the

Tailstock position shown on the screen is identical with the actual moving direction

of the carriage. Thus, no adjustment is needed before entering Step 7.

B. The carriage remains stable with the actual position change in the range of

0.01. Put the carriage in the position of Left or Right and the Headstock or the

Tailstock position shown on the screen is opposite to the actual moving direction of

the carriage. Thus, exchange 56 with 14 and change the “short circuit connection”

on the controlling board before entering Step 7.

C. The carriage moves at comparatively low speed with the actual position

changing. Put the carriage in the position of Left or Right and the Headstock or the

13
Tailstock position shown on the screen is opposite to the actual moving direction of

the carriage. Thus, exchange 56 with 14 before entering Step 7.

D. The carriage moves at comparatively low speed with the actual position

changing. Put the carriage in the position of Left or Right and the Headstock or the

Tailstock position shown on the screen is identical with the actual moving direction

of the carriage. Thus, change the short circuit connection on the controlling board

before entering Step 7.

Adjustment of short circuit on the controlling board: Turn off the

computer power, open the upper cover of the computer, eliminate the static

electricity on the body. On the upper right of the controlling board are the

signs:

1—2 4—5 or 2—3 5—6

The mean that there are two ways of short circuits: the first is to

connect 1—2 short circuit and 4—5 short circuit (initial state) in 1—6. The

other is to 2—3 and 5—6. With only these two allowed, all the other

connections will lead to system failure.

Step 7 Turn on the converter power of the spindle. Put the direction switch

of the spindle in the position of Forward or Backward. Turn the speed knob and

the spindle rotates.

Preproduction can be conducted after finishing the above steps.

Chapter 4 System Testing, Failure Analysis and Dealing

Press F8 in Figure 1 and the system will show:

C:\USER>

Key into TEST and press Enter and the system will show Figure 13

14
 Figure 13

§4-1 Spindle Encoder

1. Signal Testing

The spindle encoder, which reflects the angel of the winding mandrel, is the

important signal source for the whole winding system. Even a one ten-thousandth

error will seriously affect the complete closure of the winding model.

Press F1 in Figure 13 and the system will show Figure 14. The high brightness

indicates that the system is activated. The default pulse number for every turn of

the spindle is 2500. In case of inconsistence, press F1 to input again. If there is no

inconsistence, press Enter. When the column “number of the spindle encoder”

indicates 0, turn the encoder. Each turn of the encoder will add the turn number by

1.

Attention: The encoder can just be turned in one direction under the test. No

reverse turn is allowed, otherwise, the testing precision would be affected.

2. System Composition

The signal system of the spindle encoder is composed of Siemens Encoder,

Siemens transmission cable, reception circuit and software etc.

15
 Figure 14

3. Possible Failures, Their Reasons and Solutions

Phenomenon:

1. The actual winding band width is larger or smaller than the theoretical width.

2. In automatic or semi-auto winding, the mandrel rotates while the “actual

rotational speed of the mandrel” remains unchanged instead of changing

accordingly. The carriage and the simulating cartoons remain stable.

Reason and Solution:

1. The mechanical connection of the encoder fails, for example, the slipping or

damaging coupling or loosing of the built-in fitting.

In case of the above failure, especially when the actual winding band width is

larger or smaller than the theoretical width, the first examination involves checking

whether the elastic coupling of the input axis slips. In fact, a majority of similar

failure concerns the installation of the encoder, which should thus be regarded as

one of the most important work to ensure the normal working of the winder. The

installation of the encoder are instructed as follows:

The encoder and the motor is connected by a coupling. The diameter of the axis

installed at the end of the encoder should be Φ6-0.02 mm and its size at the end of

the motor should be the same. The circular run out of the installed axis at the side

of the motor should be no more than 0.05; and the axiality error should be no more

than 0.1mm. If the Siemens couplings are used, a gap of 2~3 mm should be allowed

at the end of the two axes. Failure to meet the above condition will lead to the

16
precision of winding and the life span of the encoder.

Another phenomenon that frequently occurs is that the diameter of the 6-mm

small axis is less than the standard, say, only 5.8 mm. In this condition, the encoder

will slip even because even the screw cannot grip the axis enough due to the limited

shrinkage mass is limited. Therefore, please wring the coupling forcibly by hand

after installation to check if the coupling slips or not.

It also works well to replace the coupling with a plastic high-pressure air tube

with 5 mm inner diameter and over 8 mm outer diameter. In this condition, the gap

between two small axes can be enlarged to 5 mm.

2. Unreliable earth connection of the controlling tank.

If the slip between the encoder and the coupling will “reduce” the actual pulse,

then the unreliable earth connection will interfere the signal and “increase” the

pulse, thus making the actual winding band width appear larger or smaller than the

theoretical width.

3. The loose attachment plug

The loose plug will cause the signal stop completely. If in a state of “virtual

connection”, the signal can appear “increased” or “reduced”.

If the signal stops, turn the encoder and the “Number of encoder turn” will not

increase with the turn. Instead, it will appear zero or a fixed value when it is

checked with the above-mentioned method.

In actual winding, it appears as:

The value of the “MANDREL SPEED R.P.M” does not change with the change of

the rotating speed of the spindle in automatic and semi-auto winding.

The simulated cartoon of the carriage does not move.

The carriage does not move.

4. The broken transmission cable.

In this case, the phenomenon is similar to that when the plug loosens.

17
 5. Damaging Encoder

6. Damaging reception circuit of the spindle encoder.

The above 5 and 6 will have the same phenomenon as the signal stops. If the

components are not completely damaged but work in a disorderly way, the

signal can also appear as “increased” or “reduced”.

§4-2 Signal Testing of Input Switch

1. Signal Testing

Press F2 in Figure 13 and Figure 15 will show on the screen. The high brightness

shows that the function is activated. If the self-hold three-positioned switch is put

in “Automation”, the light indicating “Auto” and “Carriage Deceleration” in the

upper right will be in high brightness to indicate the normal signal input.

Attention: The switch automation and carriage deceleration is connected in

parallel. Because of the different working process, the computer can distinguish the

signals automatically. The testing of the rest signals is as above.

2. System Composition

The signal input system of switching value is composed of the switch, signal

cable, reception circuit, software etc. installed in the small operation board.

Figure 15

3. Possible Failures, Their Reasons and Solutions

Phenomenon:

18
 1. All the switching signals cannot be inputted.

2. Some switching signals cannot be inputted.

Reasons and Solutions:

1. The damage of direct current power supply (phenomenon 1)

Check the input end （ AC 220V ） and output end （ DC 5V ） of the direct

current. The normal input without output indicates the damage of the direct

current power supply. If there is no input, please check the circuits

concerned.

2. If the 5V power cord in the signal cable breaks, all the signals cannot be

inputted. If a certain cable breaks, the corresponding signals cannot be

inputted.

3. The connector or the mid joint may loosen.

4. The reception circuit of the switching signal may be damaged; the

software may be damaged.

§4-3 Signal Testing of Output Switch

Figure 16

Press F3 in Figure 13 and Figure 16 will appear. The high brightness indicates the

activation of the function. The signal system of output switch is comparatively

simple with the computer connecting to Siemens converters 9 and 65 through a

double-cored cable. It is not necessary to distinguish the positive and negative of

19
the connection. Please refer to the later part of Comprehensive Failure Analysis for

details.

Attention: please press “EMERGENCY” button when testing with electricity to

avoid unexpected movement of the carriage. It is strongly to suggested to test with

the power off.

§4-4 Testing of the Simulated Signal of the Carriage

Press F4 in Figure 13 and Figure 17 will appear on the screen. The high

brightness shows the activation of the function. The system of the simulated signal

of the carriage is simply composed of a connection between the computer and

Siemens converter 56 and 14 by a double-cored cable. Please refer to Step 6 in

Chapter 3 for the concrete connecting measure

In testing, if the voltage remains unchanged and the direct current is always 0

after pressing Enter, the built-in fittings may get loose or the connecting cable may

break.

If the voltage always remains at a high level or above 10V, it is probably caused

by damaged circuits.

The abnormal voltage will directly cause the abnormal movement of the

carriage.

§4-5 Signal Testing of Carriage System

1. Signal Testing

Press F5 in Figure 13 and Figure 18 will appear on the screen. The high

brightness indicates the activation of the function. The initial set value of the system

is 2000 round/ min; 2500 pulses / round for the carriage motor. If the number is not

correct, press F1 and F2 to modify; if it is, press Enter to enter testing.

Attention: 1. In testing, the carriage system should have finished all the process

in system installation and the power should be turned on. Press “Jerk” switch to

avoid the movement of the parts other than the carriage.

2. In testing, the carriage will move towards the end. Therefore, the carriage

20
should be put at the head before testing. After entering the testing picture, set the

index and loose the Jerk switch. Observe the gap between the “theoretical rotational

speed” and the “actual rotational speed” of the carriage, which should be less than 3

rounds.

2. System Composition

The system includes output switch signal, carriage mode signor, conveyer

encoder signal, controller enablement signal, reception circuits and software, etc.

Please refer to the later Comprehensive Failure Analysis for the possible failure.

Figure 17

Figure 18

§4-6 Testing of the Simulated Signals of Add-Sand

Press F6 in Figure 13 and Figure 19 will appear on the screen. The high

brightness shows the activation of the function. The system of the simulated signal

21
of add-sand is simply composed of a connection between the computer and Siemens

converter 3 (the red) and 4 (the yellow) by a double-cored cable.

In testing, if the voltage remains unchanged and the direct current is always 0

after pressing Enter, the built-in fittings may get loose or the connecting cable may

break.

If the voltage always remains at a high level or above 10V, it is probably caused

by damaged circuits.

The abnormal voltage will directly cause the abnormality of motors for add-sand

and automatic supply-resin.

Figure 19

§4-7 Testing of Controlling Module Clock

Press F7 in Figure 13 and Figure 20 will appear on the screen. The clock has no

exterior connect. In successful testing, the second hand of a clock will appear on the

screen. The failure in this system will lead to the disorder of the whole controlling

system.

If the second hand moves too fast, too slow or remain stable, it will affect the

system as encoder failure.

22
 Figure 20

§4-8 Comprehensive Failure Analysis of the Carriage System

1. The carriage does not move in manual control when the switch is put in the

position of Left or Right

 Check whether the column “Current Working Mode” on the screen indicate “

Manual Tailstock” or “Manual Headstock”. If not, please refer to the part “Signal

Testing of Input Switch”.

 If the input switch is in order, check whether the driving system of the carriage

has failure encode or failure warning light (red) or not.

 If the above mentioned are in order, check whether indicating light of the driving

system of the carriage is yellow. The green light indicates that the driving

system is not in working state. Analyze as follows:

The driving system has connecting terminals with different functions, among

which 63、64、65、663、48、112 are signal enablement terminals. The basic condition

for the driving system to work is that the above signals must be connected in short

circuit with converter 9, that is, 24VDC voltage must be supplied. (Converter 9 is the

interior 24V power supply of the driving system). If all the wires are connected

according to the signal scheme, the green light on the driving system will be on

when the system gets the power. When all the exterior limit switches and

emergency button are not working, press emergency button and the green light will

23
be off with the yellow light on, thus the system will be in working state. If the yellow

light does not glow, check the voltage in terminals 9, 63 and 48. If the voltage is 0V

DC (connected circuit), it indicates that relay C1 C2 and circuits concerned are

working normally. Otherwise, check them to see whether the relay itself is wrong, or

whether there is something wrong in the emergency button, the limit switch, the

connecting circuit etc.

 If all the above-mentioned are in order, check the voltage between terminals 56

and 14 in the driving system.

There should be 0.3V between the two when the switch is in the position Left or

Right in manual control. If there is no voltage or the abnormal voltage, please

refer to the “Testing of the Simulated Signal of the Carriage”.

 If the carriage still cannot move when all of the above mentioned are in order, it

is probably caused by the damage of computer hardware or software. If that is

the case, please send it for repair.

2. The carriage does not move in automatic or semiautomatic control

The carriage’s moving condition in automatic or semiautomatic control should

meet the following conditions in addition to the above mentioned conditions in

manual control.

1. In semiautomatic control, the value in the column “actual rotational speed of

the mandrel” must change correspondingly with the mandrel rotation.

2. In automatic control, besides the condition for semiautomatic control, the

simulated cartoon in the right bottom should also work If not, please check the part

“Spindle Encoder” and “Testing of Controlling Module Clock”

§4-9 Failure Analysis of the Spindle System (Applied to Ordinary MM440 Siemens

Converter)

The failure of spindle system is mainly that the spindle does not move when the

switch is put in the position “Forward or Backward” and the speed knob is turned.

The reasons may be:

24
 1. The contact point of SB7 switch is damaged or the cables or the terminal

connected to SB7 is broken or loose. When the SB7 is placed in the middle, Terminal

9 (24V direct current power) cannot be connected to Terminal 5 and 6. When the

switch is in “CW” position, terminal 9 and 5 should be connected. When the switch is

in “CCW” position, terminal 9 should be connected with terminals 5 and 6. In normal

state, the spindle system should beep slightly in Forward or Backward position.

2. The controlling terminal MM440 contains an interior 10V power supply

marked as 1. When the interior voltage is used as default speed, terminal 2 and 4

are connected with terminal 3 as the speed default. When the speed knob is turned,

the voltage change between 3 and 4 should be checked with electricity on.

Meanwhile, the frequency changing between 0 and the set value is indicated in the

screen window. When the electricity is cut off, the voltage change between terminal

3 and 4 can be checked.

§4-9 Failure Analysis of the Computer System

The hardware failure of the computer is basically similar to that of home

computers. Without physical hard disc, the system applies a C disc of 16M Bytes

electronic hard disc with usage similar to common physical hard disc. If Figure 1

cannot appear after starting the machine, please contact us for repair in case of

hardware failure. The software failure can be stored by a software copy.

The structure of the software system is as follows:

C:\

COMMAND COM

AUTOEXEC BAT

USER <DIR>

The sub directory USER contains all the executable files and other files of the

winder.

Attention: Please copy all the winding software after the successful testing of the

25
 winder.
Chapter 5 Electric Scheme
I Signal
Component List (Control Parts)

No. in Name of the Numb Memo

Figure Component er
Computer Industrial 1 TAIWAN
Computer
SB1 Switch 1 Three in position, two normal open,
automatic, semi-automatic
SB2 Switch 1 As above Carriage left; Carriage Right
SB3 Button 1 Normal Open Start winding
SB4 Button 1 Normal Open Carriage’s Acceleration
SB5 Button 1 Normal Open Carriage’s Deceleration
SB6 Button 1 Normal Open Controller enabled
SB7 Switch 1 Three in position ，four normal open the
forward/backward choice of the spindle
SB8 Switch 1 Normal Open add-sand
C1 C2 Small Relay 2 12V
xk1 overtravel- 1 Protection
limit switch
JT1 JT2 Emergency 2 Emergency Stop
button
dc power Direct- 1 5V +12V
currency
Power
R potentiomet 1 4.7k Speed Adjustment of Spindle
er

26
27
 Electric Schematic Diagram for Controlling System

II Power

28
 Electric Schematic Diagram of Power Supply

Component List （power supply）

No. in Name of Components Num Memo

Figures ber
Q1 Air Switch 1 Three-step switch 60A
Q2 Air Switch 1 Three-step switch 32A
Q3 Air Switch 1 Three-step switch 32A
Q4 Air Switch 1 Three-step switch 15A
Q5 Air Switch 1 Single-pole switch 5A
Q6 Air Switch 1 Single-pole switch 5A
CM AC contactor 1 25A
TQ Time relay 1
V Volt gauge 1 600V
dc power Direct-current power 1 5V 12V
CRT Cathode-Ray Tube Indicator 1
computer Computer Power 1 In the computer chassis
power
PRH2．8 Air Conditioner of the Controller 1 (Optional)
Mmotor Main Motor 1
Xmotor Servo-actuator 1
Smotor Add-sand motor 1
Hmotor Lubrication Motor 1
611-A Servo-driver 1
MM440/75 Spindle Converter 1
0
MM440/30 Supply resin Convertor 1
0

The further timely modification and supplementation of the instruction will not
be notified.

29
Thank you for use.

30