This document outlines the operation and maintenance of the EW Series Insulation Ferrule Crimping Machine, specifically the EW-5010A model, manufactured by Wenzhou East World Import&Export Co., Ltd. This machine is designed for pre-insulation terminal crimping and features a human-machine interface, electronic control, and pneumatic control. It supports both automatic trigger operation and manual operation.
Function Description
The EW-5010A is a specialized machine for crimping pre-insulated terminals onto wires. Its primary function is to automate the process of stripping wire insulation and then crimping a terminal onto the exposed conductor. The machine includes a vibrating plate for feeding terminals, a stripping mechanism for preparing the wire, and a crimping mechanism for securing the terminal. It also features various sensors for detecting terminal presence, safety door status, and material jams, ensuring safe and efficient operation.
The machine's interface allows users to set various parameters, including wire size, stripping length, and production targets. It provides real-time monitoring of production count and efficiency. Manual control options are available for individual operations like wire clamping, peeling, crimping, and terminal feeding, which are useful for setup, troubleshooting, and maintenance.
Important Technical Specifications
- Model: EW-5010A
- Control Mode: Human-machine interface, electronic control, pneumatic control.
- Operation Mode: Automatic trigger operation and manual operation.
- Wire Size: BVR wire 0.5, 0.75, 1.0, 1.5, 2.5, 4.0mm².
- Terminal Size: Insulator length ≤7.5mm, conductor length≤10mm.
- Stripping Length: Max. 17mm.
- Crimp Shape: Quadrilateral Crimp.
- Product Replacement: Manual replacement of related parts, adjustment of vibration plate, and electric memory adjustment.
- Production Capacity: 2.5s/wire (considered as a single cycle of the machine).
- Detection Items: Terminal presence or absence, right side safety door open detection.
- Power Source: External input power AC220V / 50Hz (single-phase) 10A; internal power DC24V, DC12V.
- Air Source: 0.6-0.8Mpa (requires a stable, clean, and dry air source, and keep the air source at least 0.6 Mpa).
- Working Temperature: 10~25℃.
- Operating Humidity: 30~80%HR (non-condensing).
- Dimensions: W350mm×L450mm×H400mm (excluding protrusions).
- Weight: 40KG.
Usage Features
The machine's operation is managed through a user-friendly interface.
- Home Screen: Displays total production, set production target, and production efficiency. It also provides access to stripping settings, parameter settings, and manual control.
- Total Production: Counts the quantity produced in automatic mode.
- Total Setting: Allows setting a production target (max 32000), with an alert when reached.
- Production Capacity: Shows the machine's efficiency in automatic mode (excluding manual take-up/release time).
- Peeling Settings: Configurable for 6 wire number specifications (0.5mm² to 4.0mm²), each with settable depth and three stripping lengths (A, B, C). Stripping length values directly correspond to the physical length in mm. "Modify Confirmation" adjusts the actual position after changes.
- Parameter Settings: Divided into multiple screens, these settings control various timing sequences (e.g., stripping cut-in to withdrawal, terminal feed to crimping). Most of these are factory-set and generally do not require modification, except for specific situations like adjusting "blowing terminal delay time" if feeding is not smooth. Other parameters include wire-releasing trigger delay, reset delay for pay-off trigger, and vibration disk timing.
- Manual Control: Provides jog self-locking switches for individual operations like wire clamp, peel cut-in, crimp terminal, feed terminal, etc. This mode is crucial for setup, testing, and clearing jams. A "Manual Trigger" button allows for a short automatic operation sequence for testing. Safety interlocks prevent conflicting operations (e.g., peeling and backing while a terminal is being penetrated).
- IO Monitoring: Allows observation of input and output signals, useful for diagnosing sensor or actuator issues. Input monitors show states like wire trigger induction, emergency stop, and safety door status. Output monitors show states like motor pulses, cylinder operations, and vibrating disk control.
- Vibration Plate Feed Adjustment: The vibrating disk controller (Figure 212) allows adjustment of voltage (H100) to control feeding speed. Frequency (E50/E100) is typically factory-set. An amplifier (Figure 214) monitors terminal presence, with green numbers indicating set values and red numbers indicating current values.
- Terminal Guide Adjustment:
- Discharge Guide 1: Adjustable width by loosening M4 bolts (Figure 215).
- Discharge Guide 2: Features three clamping positions for different wire sizes (0.5-1.0mm², 1.5-2.5mm², 4.0mm²) by loosening M4 bolts (Figure 216).
- Terminal Guide Ring: The machine comes with three types of guide rings for different terminal sizes (0.5-1.0mm², 1.5-2.5mm², 4.0mm²). The guide ring can be rotated and pressed into position after selecting the appropriate U-port for the terminal size (Figure 218).
- Jig and Copper Core Guide Adjustment:
- Terminal Guide Rings: Six specifications (0.5 to 4.0 square) are available. Loosen M2.5-21.5 bolts to replace (Figure 221).
- Copper Core Guides (A and B): Five specifications (0.5 to 4.0 square) are available. Loosen M2.5-6 bolts for replacement. Proper alignment with the terminal guide ring, leaving a 0.1-0.2mm gap, is crucial (Figure 222).
- Clip Adjustment: The clamp width can be adjusted based on wire size. Users can record scale settings for different wire numbers. Adjustment is necessary if the wire is damaged during clamping.
Maintenance Features
Regular maintenance is essential for the machine's longevity and performance.
- Cleaning:
- Forbidden to use an air gun on certain parts to avoid short circuits or mechanical damage; use a vacuum cleaner or rag instead.
- Keep the machine box dry and tidy.
- Lubrication:
- Clean and add butter to the two motor screws regularly (at least every 15 days).
- Clean and grease the crimping part of the terminal crimping cylinder regularly (at least once every 15 days).
- Wipe the four-side crimping mechanism with a fine cloth or cotton and alcohol at regular intervals (at least every 15 days).
- Clean and lubricate other active parts regularly (at least once every 30 days).
- Control the amount of butter/lubricating oil; it should be comprehensive but not excessive.
- Troubleshooting and Alarms: The manual provides a comprehensive list of alarm contents and their corresponding processing methods.
- Safety Door Open: Machine will not power on if the right door is open. Detection can be turned off in administrator settings for tuning.
- Material Jam: Check for jammed terminals or deformation. Use manual control to clear.
- Vibrating Plate Empty/Abnormal: Check if the vibrating plate is feeding terminals and if the fiber amplifier is detecting them correctly.
- Production Target Reached: Clear the total production count on the main screen.
- Emergency Stop: Release the emergency stop button. Check for wire breaks or loose rubber seat plugs if the input X13 is not red.
- Peeling Abnormal: Check air pressure and input X07.
- Terminal Abnormal (Copper Core Issues): Check for bent, loose, or too-long copper cores. If the wire is bent and doesn't penetrate the terminal, switch to manual mode, open the copper core guide, remove the faulty terminal, insert a good one, reset, and return to automatic mode.
- Gel Box Full: Reset after clearing. The number of colloid particles can be modified.
- Gel Particle/Trigger Induction Abnormal: Check for rubber particles or if the trigger sensor light is off.
- Trigger Sensor Abnormal: Check if the trigger sensor light is off.
- No Terminal Detected: Check if the terminal feed rail is stuck.
- Cylinder Origin Abnormal: Check for wire disconnection or loose terminal rubber seat plug.
- Peeling Length Motor Alarm: Check if the touch is normal, if the wire is broken, or if the terminal rubber seat plug is loosened.
- Safety Precaution: When handling alarms or performing maintenance inside the machine, always turn off automatic mode or engage the emergency stop. If necessary, cut off the air source to prevent injury.
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