Wire rolling machine is an essential tool in the jewellery industry, used to shape and form metal sheets into desired shapes. However, like any machinery, jewellery manufacturing machines can also encounter various problems that affect their performance and efficiency. Identifying these issues and fixing them promptly can be vital to ensure smooth operation and maintain productivity. Whether you’re a machine operator, supervisor, or business owner, here we will explore common issues in a wire rolling machine; its fixing tips can help to spend less time fixing and more time on productivity.
Common issues in a wire rolling machine and its solution:
Uneven wire thickness:
Sometimes, the wire may come out with inconsistent thickness, very thin in some areas and bulky in others. Usually, this happens due to a misaligned roller and uneven pressure diffusion.
Solution:
- Always double-check roller alignment before every job.
- Ensure pressure is applied evenly at full width.
- Replace worn-out or faulty rollers- they can disrupt pressure evenly and warp the wire.
Wire breakage:
The wire may break during the rolling process, leading to a wastage of material. It happened due to high tension, rolling speed mismatch, or poor quality of material.
Solution:
- Reduce the speed slightly or relieve the tension.
- Inspect raw wire material before production- or reject it if there are any cracks, rust, or weak spots.
- View annealing the wire if it is too breakable before rolling.
Machine vibration:
A jewellery machine can vibrate whole or shake during production. This vibration can damage internal parts permanently. Usually, it happens due to loose bolts, unbalanced rollers, or worn bearings.
Solution:
- Ensure all bolts are tight and check the frame’s stability before every work.
- Inspect bearings regularly- if they are noisy or rough, replace them.
- Check the roller imbalance- especially if vibration can increase the speed of the jewellery machine.
Continually overheating:
If the wire rolling machine feels unusually hot and the machine’s performance goes down. It is a warning sign of lack of lubrication, excessive workload, or blocked air vents.
Solution:
- Lubricate all friction parts regularly.
- Avoid using jewellery manufacturing machines beyond their capacity of working hours.
- Clean air ducts, fans, and vents for better cooling.
- If possible, use the thermal sensor or touchless thermometer to inspect hot spots.
Marks on the surface of the wire:
Suppose your wire comes with scratches, dents, or marks. The reason behind this uneven productivity is durty, damage, or rough roller. Always check the first few meters of output production for surface quality to reduce the wastage of material and time.
Solution:
- Clean the wire rolling machine thoroughly before and after each production.
- Polish out minor damaged rollers and replace heavily damaged rollers.
- Avoid working with dirty and contaminated wire through a jewellery machine.
Sudden machine stoppage or power failure:
Sometimes, the wire rolling machine can suddenly shut down without any warning and not restart. It happens due to some electrical faults, misstepped breakers, or overload of the motor.
Solution:
- First, check the motor panel for faulty indicators.
- Insect wires, fuses, and circuit breakers.
- Allow the motor to cool down and restart. If the issues continue, then contact the technician.
Wire slippage from roller:
Poorly fed material can cause jams or accidents or it slips through rolling. Usually, this incident happens due to low grip pressure or improper speed settings.
Solution:
- Set roller pressure gradually- don’t overload it.
- Ensure the feed rate is matched with the roller speed.
- Try rollers with a slight texture for better traction.
Additional tips for preventive maintenance of jewellery manufacturing machines:
- Daily clean roller, check wire debris and remove it, and lubricate moving parts.
- At least weekly, inspect roller surfaces, verify alignment, and check emergency stops without fail.
- Check motor condition and bearing monthly. Inspect calibration setting also.
- Keeping a record of issues and routine checking can avoid recurring issues in the wire rolling machine and prevent surprises.
- Summary:
With a little attention and the right strategy, you can manage wire rolling machine issues on the spot. By regularly inspecting, lubricating, replacing parts, calibrating tools, watching material quality, and prioritizing safety, you can minimize downtime, reduce costs, and maintain constant production quality. To know more information or guidance, contact www.ravimalviyaindustries.com
