Insulated Terminal Crimping: Fix Vibratory Feed Crimper Woes!

Insulated Terminal Crimping: Fix Vibratory Feed Crimper Woes!

This guide offers a comprehensive approach to identifying and resolving common issues that arise with vibratory feeding systems in insulated terminal crimping machines.By following these steps, you can quickly identify issues and implement solutions to ensure smooth and efficient operation of the feeder.

Common Problems and Causes:

Feeder Not Functioning
Insufficient power supply voltage.
Broken wires between the feeder and controller.
Blown fuse in the controller.
Burnt coil.
Improper gap between the coil and the frame.
Objects jammed between the coil and the frame.
Feeder colliding with hard objects, causing the top plate or base plate to hit other equipment.
Weak or Slow Vibration, Intermittent or Irregular Feeding
Broken springs.
Thin base plate (less than 1.5 inches thick). A thicker base prevents vibration absorption and ensures proper operation.
Improperly installed mounting table lacking rigidity. The table should be secure and equipped with triangular support pieces for cylindrical support feet.
Uneven mounting surface.
Debris inside the feeder.
Excessive coil air gap (minimize the gap for optimal performance).
Machine cycle speed too fast, causing parts to bounce off the feeder.
Fluctuating power supply requiring controller readjustment.
Part issues: oversized, bent, oily, etc.
Loose or misaligned screws securing the feeder to the base.
Too many parts being fed at once.
Improper base adjustment.
Material change requiring adjustments to the feeder surface and base.
Issues with Compressed Air (if applicable)
Unstable air pressure.
Contaminated air source (water or oil). This can slow or stop feeding entirely. Ensure the air source is clean, dry, and uses independent regulators and filters.
Rigid air pipes (use flexible hoses instead for better performance).
Additional Factors Affecting Tuning
The controller frequency (such as half-wave/full-wave selector switch) can impact feeding performance.

Here’s how to adjust the feeder:

Turn on the controller and adjust the amplitude to about 35-40% of full scale. Parts should begin to move. If the speed is slow, gradually increase the amplitude until satisfactory.
If satisfactory feeding is not achieved at 80% amplitude, follow these steps:
Loosen a spring plate fixing screw slowly until the feeder’s speed changes. If it speeds up, there’s excessive elasticity. Remove the thinnest spring plate from that set (refer to the attached table for replacements).
If there’s insufficient elasticity, add more spring plates. However, ensure all spring plates in a set are the same quantity for smooth feeding.
Over time, spring plates can harden, causing over-tuning. Check vibration as described in section 1.
If adding spring plates doesn’t resolve the issue, there might be spring plate fractures (usually at the bottom or support top). These can be difficult to detect. Remove a suspect spring plate and strike it against a hard object to see if it fractures. Check the thinnest plate first.
Ensure screws have sufficient length to properly tighten the spring plates to the base.
Use grade 5 bolts for the screws to ensure lasting hardness.

Additional Notes:

Weld cracks in specific vibrator parts (installation flange, spiral track, return plate bottom, suspension straps, side walls, return material area) can affect vibration frequency. These cracks often cause noticeable noise.
Re-tighten the rubber feet if they are not secure or properly positioned, as this can cause resonance drift.
Ensure a firm connection between the top plate and the vibrator. Use a lever or torque wrench when reinstalling or moving the top plate. Avoid pulling it outward towards the feeding rail. If necessary, use a jack. A level top plate is crucial for smooth feeding, as any unevenness can cause parts to fall or deviate from the feeding track.

Shims between spring plates play a vital role and should not be overlooked when replacing spring plates. Missing shims can hinder proper feeder adjustment.
Insecurely fastened rubber feet can also affect feeding performance.

If the feeder uses chutes or linear tracks relying on its driving force, consider using an independent linear drive unit to avoid potential side effects.
Multiple “dead spots” in the feeder might require checking diagonally opposite corners for issues like unbalanced weight, improper coil air gap, weld cracks, spring plate fractures, or loose fixing bolts.

By following these guidelines and addressing the potential causes, you can effectively troubleshoot and maintain your vibratory feeding system for optimal performance in your insulated terminal crimping machine.

Find expert terminal crimping machine technical resources on our specialized page.