How to detect and repair malfunctions during computer embroidery processing?

Common Faults Inspection and Handling Methods for Computerized Embroidery Machines

（1） There are two types of wire breakage: regular and irregular. Regular disconnection includes:

1. The fitting clearance between the needle and the rotary hook is incorrect, and the needle position is too high or too low, requiring readjustment.

2. The machine needle hole and needle plate hole have burrs, the rotary hook has burrs, and the positioning hook has burrs.

3. The thread passing parts are not smooth, including the thread clamping plate, thread clamping screws, thread take-up rod holes, upper and lower thread passing frames, etc. All irregularities or burrs should be smoothed or replaced.

4. The needle is installed reversely and needs to be reinstalled correctly. The needle tip is damaged, and the needle is stained with glue. Replace the needle.

5. The thread take-up cam is damaged, replace the thread take-up cam.

6. The rotary shuttle shaft moves.

7. There are scratches and damages on the thread passing surface of the rotary hook. Irregular disconnection includes:

Irregular disconnection includes:

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1. The ambient humidity is too high, and the line is affected by moisture. Dehumidify and replace the line.

2. Unreasonable printing and needle routing. Revision.

3. The quality of the thread does not meet the requirements, and the installation and threading are also unsatisfactory. The embroidery thread is too thick and does not match the needle specifications. Change the line and reassemble.

4. The moving frame curve and moving frame angle are unreasonable, so adjust the computer parameters.

5. There is a gap between the upper and lower shaft transmissions or the shaft is broken, causing the machine head and the rotary hook to be out of sync. Check the gearbox and adjust the chain tightness or timing belt of the gearbox.

6. The surface of the embroidery thread is rough. Apply silicone oil to the surface of the embroidery thread.

（2） "Blocking the thread" means that the thread forms a ball under the needle plate, blocking the needle hole, and the result is a broken thread.

1. The gap between the positioning hook and the hook frame gap is unreasonable. Readjust.

2. The embroidery is too thin or loose, and the needle plate hole is too large. Two or three layers of nonwoven paper are padded.

3. Threading failure. Check the thread connection.

4. The bottom line is too loose and the lead direction is incorrect. Adjust the bottom line.

5. There are debris or deformation in the shuttle shell, causing poor rotation of the shuttle core and easily breaking the bobbin thread.

（3） Broken needle

1. The needle is bent and the fastening screw is loose. The needle and tightening screw need to be replaced.

2. The fit clearance between the rotary hook and the needle is too small. Adjust the fit clearance.

3. The pressure of the wire clamping plate is too tight, and the surface thread tension is too large. Adjust the tension.

4. The presser foot hole and needle plate hole are not aligned with the machine needle.

5. The frame shifting angle is incorrect. Adjust the frame shifting angle.

6. Adjust the rotary hook by shifting its position.

（4） Skipping stitches

1. The needle does not fit well with the rotary hook, the needle is too high, and the gap is too large. Adjust the needle height position.

2. The rotary hook is damaged. Change the rotary shuttle.

3. The needle bar lower spring is broken. Replace the spring.

4. The embroidered stretch is too loose. Tight embroidered fabric.

5. The presser foot is too high or deformed. Adjust or replace the presser foot. (When the needle stops in the lower position, the gap between the presser foot and the needle plate is 0.5mm-1.5mm.) It depends on the thickness of the fabric.

（5） , throwing line, floating line

1. The tension between the top and bottom threads is too small and loose. Adjust the tension.

2. The line quality is not good. Change the line.

3. Insufficient lubrication of the rotary shuttle. Add white oil (twice per shift)

（6） There are various situations of pattern displacement and deformation pattern displacement, such as X direction displacement, Y direction displacement, overall displacement, individual head displacement, single direction displacement, irregular displacement, and so on.

1. Overall displacement in the X direction, mechanical failures include: loose stepper motor coupling, too loose or tight timing belt, damaged timing wheel bearings, prismatic bearings, tension frame bearings, excessive guide rail clearance, etc.

2. The overall displacement in the Y direction is the same as that in the X direction, but the direction is different.

3. In addition to mechanical reasons, there are also electrical control faults and plate printing reasons for overall displacement. The electrical control part faults include:

① There is a memory failure. You need to clear the computer memory pattern and format it. Then re-enter the pattern. Generally, computers should not store too many patterns or store them for too long. They should be cleaned and formatted regularly.

② Interference caused by power grid interference, leakage of electricity from electromagnets or other electrical components. It is necessary to find interference sources and eliminate interference.

③ If the power failure protection is not set and there is a sudden power failure, it is necessary to reposition and retrieve the original position.

④ The stepper motor fails, mostly due to damage to the stepper motor driver. Repair or replace the driver.

⑤ Encoder fault, self check the encoder in the computer. DTL14-15 ATL1000 BTL1000

⑥ Incorrect platemaking, reprint.

4. Individual head displacement

① The needle bar frame is loose and the bearing is damaged. Adjust the needle bar bracket and replace the bearing.

② Needle rod deformation or needle bending. Replace the needle rod and needle.

③ The color change cam is worn. Replace the cam.

④ The color changing cam moves. Adjust the clearance.

⑤ The needle is not in place when the color change light is on. Adjust the needle position plate gap.

5. Unidirectional shift

① The bottom cloth of the stretcher is loose. Re-tension and reposition the cloth.

② The frame is not straight and the four side interface screws are loose. Adjustments.

③ Unilateral Y-direction guide rail fault. Eliminate the Y-direction guide rail fault.

6. Irregular displacement The embroidery is not fixed properly, and random movement causes irregular displacement.

（7） Head failure

1. Do not place the needle or the needle bounces back half way down (needle dancing phenomenon)

① The electromagnet is not released and is always in working condition. Check the electromagnet.

② The top dead center position is incorrect, adjust the 0 ° position.

③ The swing block is damaged. Replace the swing block.

④ The needle bar guide plate is damaged, replace it.

⑤ Operation error, check whether it is in the repair position.

2. The 172 ° low position often deviates. Check whether the eccentric chuck is clamped.

3. The presser foot does not come up when parking.

① If the electromagnet fails, clean or replace it.

② Broken wire detection board fault, check the plug, detection line, and broken wire detection board.

③ The power board is damaged, the fuse is burnt out, or the bridge pair is burnt out. Exchange.

④ The needle bar spring is not good, replace the spring.

（8） Color change failure

1. Parking is not in place, unable to change colors. Correct the parking problem.

2. The nose bites and cannot be changed color. Eliminate head faults.

3. The color change lever is damaged and cannot be changed. Troubleshooting the lever.

4. The color change lamp does not light up and cannot be changed. Check whether the needle position plate is damaged. Whether the installation is in place, whether the color changing cam and bearing are damaged, whether the pull rod is jammed, and whether the color changing cam ball is broken.

5. There is a problem with the color changing motor and the color cannot be changed. Eliminate the fault with the color changing motor.

6. The thread take-up lever gear does not fit properly. Adjust the thread take-up lever.

（9） Complete machine failure (main shaft cannot rotate)

1. If the crankshaft rod of the machine head is seized (caused by oil cut-off), replace the crankshaft rod bearing and the crankshaft rod.

2. If the small spindle of the rotary hook is stuck (caused by oil cut-off), replace the small spindle and shaft sleeve of the rotary hook and add oil.

3. If the swing block and center shaft are stuck (caused by fuel cut-off), replace the swing block and center shaft and refuel.

4. If the needle rod transmission rod bolt is broken, replace the needle rod transmission rod bolt, and if necessary, replace the needle rod transmission rod shaft.

5. Two components (gear box) bite, check the chain and gear box)

（10） Abnormal noise occurs during operation

1. The prismatic bearing is damaged. Replace the bearings.

2. The support guide wheel of the Y-direction connecting plate is not slippery and worn. Add oil or replace the guide wheel.

3. The Y-direction connecting plate touches the wrapping strip. Adjust the bedplate.

4. The needle bearing of the guide rail seat in the X and Y directions is damaged. Replace the bearings.

5. The tension frame guide pulley assembly is damaged. Replace the guide wheel assembly.

6. There is a problem with the lower shaft support bearing sleeve. Adjust the bearing sleeve.

7. The thread take-up lever shaft is dry. come on.

8. The rotary shuttle is not correct, making a noise. Add oil or replace the rotary shuttle.

（11） Thread cutting part

1. Cutting thread without thread

① The thread trimming electromagnet does not work or the thread trimming cam angle is incorrect. Adjust the thread trimming box.

② There is debris at the scissors. Remove debris.

③ The scissors are in the wrong position. Adjust the position of the scissors.

④ The fixed knife and the movable knife are damaged or the gap is incorrect. Adjust or replace the blade.

2. The thread cutting is too short (flying thread, after the thread cutting action is completed, the surface thread comes out from the needle hole

① The thread trimming cam operates in advance. Adjust the working time of the thread trimming cam.

Adjust computer parameters or replace computer chips.

3. Unable to lift the bottom thread after thread cutting ① Damaged snap spring. Replace the spring plate; ② The shuttle shell is not good. Replace the shuttle shell.

4. The thread cutting is too long ① The fixing knife is too close to the outside. Adjust the fixed knife; ② Computer parameters are incorrect. Adjust computer parameters.

5. After thread cutting, the thread angle of the start-up rolling line is incorrect, and the thread is not returned to its original position after operation. Adjust the thread.

6. Thread cutting does not work ① The scissors are not in place and the proximity switch light does not light up; ② The computer thread cutting signal is not turned on.

7. The hooking line is not in place ① The hooking line position is incorrect, and the wire clamp is stuck on the hook. Adjust the hooking device; ② The proximity switch light does not light up, and the angle of the centralized hook motor is incorrect. Adjust the position angle of the hook motor and computer parameters.

（12） Basic fault of electric control part

1. Spindle rotation or non rotation (possible fault at 380V voltage)

① To reverse the spindle, simply insert the plug in reverse or replace the wiring pile head.

② If the main shaft does not rotate, there may be a lack of phase or a lack of zero line. If the ground wire is used as a zero line, reconnect the power line.

2. Disconnection detection lamp does not light up (no alarm or random alarm for disconnection)

① Poor contact of thread take-up spring. Readjust.

② Broken wire detection board is damaged. Replace or repair.

③ The signal wire is broken. Check for broken ends.

④ The bottom line alarm device fails, the plastic roller does not rotate, and the plastic roller teeth are broken. Adjust and repair the bottom line alarm device.

⑤ Electromagnets or other electrical components leak electricity, causing interference.

3. Parking is not in place

① The photoelectric encoder is damaged. Replace the encoder.

② The encoder adjustment parameters are incorrect. Readjust the encoder computer parameters.

③ Main motor failure, brake resistance too high or too low. Adjust the brake resistance.

④ Belt slipping. Adjust the belt tightness or replace it with a new belt.

⑤ Mechanical failure caused parking not in place. Eliminate mechanical faults.

4. Scaffold movement failure

① Abnormal stretching frame exceeds the limit. The limit switch may be damaged, or the switch may not be properly installed, so readjust it.

② Damage to the stepper driver, overheating, overcurrent, and overvoltage may cause the stepper motor to not rotate and the stretcher to not move.

③ Damage to the photoelectric encoder caused the stretcher to wander until the frame was pulled.

④ The computer frameshift parameters are incorrect. Adjust parameters.

5. Computer display failure

① The LCD screen is damaged. Replace the LCD screen.

② The display lamp tube is damaged. Replace the display lamp.

③ There is no response to the button. Replace the operation panel.

④ The display screen is not lit, and the 5V power supply may be damaged. Replace the 5V power switch

（13） The sequin embroidery device is faulty

1. No production:

① The sequin pressing spring is too loose. Tighten the spring.

② The thimble did not push into the sequin hole. Adjust the ejector pin position.

③ When in place, the ejector pin does not exit. Adjust the ejector pin position.

2. The film is not produced in place and has a tail

① The stroke of the pusher rod is incorrect. Adjust the stroke of the pusher rod.

② The sequin spring is too loose or tight. Adjust the tightness of the pressing plate.

3. Sequin Offset

① The sequin guide rail is skewed. Replace or adjust the guide rail.

② The position of the bottom plate slot and the sequin hole is incorrect and not in the center. Realign the holes.

③ The sequin pressing spring is too loose or tight. Adjust the tightness of the pressing plate.

④ The quality of the sequin tape is poor. Replace the film.

4. Do not cut sequins

① The position of the slicing moving knife and the bottom plate is incorrect. Adjust the position of the knife and the base plate.

② The slicer spring fell off. Install the spring.

③ Oil shortage, slicing knife stuck. Add oil to make the slicer flexible.

5. The sequin device goes up and down abnormally

① Air leakage, insufficient pressure. Check the air pump and the air pipe connector to plug the air leakage.

② The guide rail is stuck. Repair or replace the guide rail.

6. Skip film

① The position of the needle and the tablet is incorrect. Adjust the position of the sequin device and needle.

② The direction of the printing needle is incorrect. Revision or remaking.

Maintenance Method of Computerized Embroidery Machine

The machine repair must be equipped with tools and a set of hexagonal wrenches. One wrench is required for each of 8-10 and 10-12 wrenches. The 35cm long and medium-sized slotted screwdriver "Knife edge 1cm wide, 0.2-0.3 thick" is preferably equipped with an iron absorption function. A 20cm long cross screwdriver with a crosshead as small as possible. One vice and one pointed pliers each. A needle lever wrench.

1: There is a big difference between wool and broken yarn. Basically, there is a burr on the surface of the screw, such as "polishing with the finest sand to smooth off" or the needle position is off the mark. If it still doesn't work, it's the problem of the maximum number of spins. When paying attention to the counter rotation number, see if the needle is in the center of the needle plate. If it has tilted onto the needle plate, then the basic needle plate