Common faults and solutions during commissioning of terminal machine

In the process of terminal machine adjustment, we often have problems such as sinking, pressing glue, terminal deformation, core wire not driven in, core wire breakage, core wire exposure，stuck terminal.

Subsidence: Subsidence refers to that no rubber can be seen vertically between the pressure core and the pressure glue.

Failure cause:

• The wire is unqualified, and the rubber expands greatly

• The wire is stretched, and the wire feeding is not matched properly

• The cutting blade is too long (peeling blade 42mm, cutting blade 42.2mm)

• The lower cutter is too long or short

• The upper crimp tool is too long or short

Solution:

• Contact PQE, IE and IQC for settlement

• Adjust the feeding part to ensure uniform and smooth feeding

• Replace the proper peeling blade

• Change the  lower cutter

• Replace the upper cutter

Glue pressing: wire rubber is pressed inside the core pressing part.

Failure cause:

• The wire is unqualified, and the rubber expansion is large

• The size of the peeling blade is too large, and the peeling is irregular

• The cutting blade is too long

• The wire clamp does not clamp the wire

• It is not peeled, and there is debris between the peeling blades

• The lower cutter is too long or short

Solution:

• Contact PQE, IE and IQC for settlement

• Replace the appropriate blade

• Adjust the appropriate clamping force

• Clean up

• Replace the lower cutter

Terminal deformation: after the terminal is crimped and formed, it is greatly different from its own shape and is not easy to pierce.

Failure cause:

• Feeding is not in place (feeding claw, stop plate and pressing plate are worn)

• The blade is deformed, the blade is missing or worn

• The gap between lower cutters is large, so that the terminal is clamped into the cutter

• The lower cutter is too thin or too thick

• The terminal is stuck by the upper blade, and the linear part is too long or stuck

• The terminal itself is deformed

• Excessive tension during feeding

• Material return deformation

• The upper cutter is too long

Solution:

• Replaced parts

• Replace the blade

• Replace the lower cutter

• Replace the blade or thin the thick blade to fit

• Contact relevant departments for negotiation

• Adjust the feeding tightness

• Adjust the return height

Core wire is not driven in: after the terminal is finished, part of the core wire is attached to the terminal surface or visible outside the terminal.

Failure cause:

• The terminal feeding is not in place

• Wire feeding is not in place

• Terminal deformation

• Rough blade treatment

• The sinking time of feeding clamp or arm is not matched with the sinking time of terminal machine

• The lower cutter is too thick or thin

• The pressing spring is not pressed in place

Solution:

• Adjust the feeding claw to the proper position

• Adjust the feeding angle

• Check the cause of deformation and solve it

• Replace the blade

• Adjust sinking time

• Replace the upper press knife or grind off the long part

• Adjust the position of pressing spring

Core wire breakage: few cores of the same length.

Failure cause:

• Peel off when peeling

• The upper core cutter is too thick

• The pressure core is too low

• Blade rivet mouth is narrow

• The upper press tool is too short

• The upper blade is too long

Solution:

• Replace the peeling blade

• Replace the upper core cutter

• Adjust to proper height

• Replace the blade

• Replace the proper upper cutter

Exposed core wire and sinking core wire: no core wire can be seen above the terminal core.

Failure cause:

• Peeling too long or too short

• The front and rear positions of the terminal machine are not adjusted properly

• Uneven shrinkage of wire

• The peeling knife is too long

• Cutting blade notch

• Large edge of peeling blade

Solution:

• Adjust the thickness of the peeling blade

• Adjust the terminal machine to a proper position

• Contact relevant departments for negotiation

• Replace the peeling blade

• Replace the cutting blade

• Replace with a suitable peeling blade

Stuck terminal: the terminal is easily stuck in the blade or cutter.

Failure cause:

• The blade is deformed, worn or the linear part is too long

• Terminal deformation

• The cutting knife is worn and the clearance is large

• Blade rivet mouth is too narrow

Solution:

• Replace the blade

• Replace the terminal or find out the cause of its deformation and solve it