I. Rewinder Fault Troubleshooting Methods
When equipment malfunctions occur, systematic diagnosis is essential. Here is a practical case study and step-by-step troubleshooting approach.
Case Study: Photoelectric Protection Failure
When a full-size tissue paper rewinder experienced photoelectric protection function failure, initial emergency handling allowed the machine to continue operating. However, without protection testing, operational safety became a serious concern, causing efficiency decline.
Diagnostic Steps:
- Remove the circuit board and visually inspect. If the substrate around the power supply bridge stud shows discoloration, this indicates the bridge stud is burned out. Test by powering on — if there is no response, the diagnosis is confirmed.
- Use a multimeter to measure. If the newly replaced bridge stud is also burned out, this indicates a short circuit somewhere in the circuit.
- Trace component by component from the bridge stud downstream. If a voltage regulator is found defective, purchase and replace it with a new component.
- After replacement, the power indicator light on the circuit board should illuminate when powered on.
- Reinstall the circuit board onto the rewinder. Operate according to standard procedures and verify the photoelectric protection function. Block the light eye with your hand — the blade should stop immediately. Repeat testing several times to confirm normal operation.
II. Rewinder Daily Care and Maintenance
1. Voltage Stability Management
Maintain stable voltage supply to the winding shaft. The rewinder transmission system components such as gear drive chains require periodic application of grease. Failure to lubricate properly may cause motor burnout.
2. Wear Parts Management
Generally, rewinders experience few major problems. Consumable wear parts are typically limited to small gears. If an additional gear is installed, the rewinder blade may break more easily. The rewinder wool roller will thin after approximately 18 months of use and should be returned to the factory for refurbishment. The cost for this service is reasonable.
3. Embossing Roller Care
For steel roller embossing equipment, if the embossing pattern needs to be changed, the rewinder steel roller must be shipped back to the factory for modification. Pay careful attention to cleanliness — prevent debris from falling between the steel roller and wool roller.
4. General Maintenance Checklist
- Regularly check and maintain stable voltage for the winding shaft motor
- Apply grease to gear drive chains and transmission system components periodically
- Monitor blade condition and replace when wear becomes apparent
- Track wool roller service life — plan for factory refurbishment at approximately 18-month intervals
- Keep the area between steel rollers and wool rollers free of debris
- Maintain proper alignment of all roller systems
III. Preventive Measures
To maximize rewinder service life and minimize unexpected downtime, the following preventive measures should be implemented:
- Establish a routine inspection schedule covering electrical systems, transmission components, and safety devices
- Document all maintenance activities including dates, parts replaced, and observations for trend analysis
- Keep critical spare parts (blades, small gears, circuit components) in inventory
- Train operators to recognize early warning signs of equipment malfunction such as unusual sounds or vibrations
