Defective products and waste products of bundled wire and stranded wire, the main problems are over-twisting, inner or outer single wire breakage, lack of strands, single wire or stranded wire surface abrasion, single wire dorsal strand, single wire peeling, scarring, brittle breakage, arching, inclusions, wire diameter is out of tolerance or adulteration, stranding direction is wrong, snake, large stranding pitch, unqualified length, stranded loose strand, wire mess and crush, scratches, bumps, wire and cable conductive core DC resistance is unqualified, etc. 　 1. Over-twist 　 Overtwisting refers to the twisting-shaped phenomenon of excessive twisting during the stranding process. 　 Causes: First, the twisted wire is not enough turns around the traction wheel, generally less than 4 turns, and the friction is too small and slipping, resulting in excessive twisting. The second is that the take-up tension is loose or the take-up reel does not rotate, and the turning body is still rotating, resulting in excessive twisting. 　 Elimination method: If the outer single line has been violently deformed and seriously damaged, there is no possibility of repair, only shearing. If the single line is not seriously damaged, the rotating part of the equipment and the traction part can be separated, and it can be rotated in the opposite direction of the twisting, so that the local twisted part is returned, and then the wire core is repaired by hand, and the excess single wire is wound to the take-up reel, and the equipment and the rotating body are traction into one, after the looser overpressure wire die, press the wire forcefully, and manually repair it with another mold, so that the production can be restarted. 　 2. The single wire is broken when stranded, and the reasons for the lack of single wire breakage: 　 l) Pull the broken core due to excessive pay-off tension. 2) The single wire is loose when drawing, the wiring is not good, and the crimping line crosses the line, causing the core to break. 3) The material of the single wire itself has cracks, and the mechanical properties are not good and brittle. 4) The installation position of the pay-off reel is improper, and the axial shaking causes the wire to break. 5) Single wire jumps out of the pulley groove, mechanical jamming. 　 Elimination method (1) Adjust the pay-off tension to make it appropriate. (2) Pay attention to the selection of the incoming line, find that there is a loose phenomenon when pulling the wire, and must be rewound before you can get on the machine. (3) Pay attention to the operation method, carefully check the position of the pay-off reel, so that the released line does not swing or jump, and check whether the single line passes through whether there is a phenomenon of jumping out of the guide wheel groove. (4) Check the surface quality of the wire core to see if there are cracks, slag inclusions, scars and other defects. If the broken wire occurs in the inner layer, and the broken head has gone too long, it cannot be repaired, only cut this missing core of the wire, if the broken wire occurs in the outer layer, the wire should be repaired before turning on. 　 3. The surface of the stranded wire is scratched and the wire core is scratched 　 Causes: usually one is the wear of the wire nozzle on the distribution reel, the second is the single line jumping out of the pulley, the third is the grinding of the wooden pipe or plastic pipe for threading, the fourth is the damage to the positioning pin on the pushing plate of the traction equipment, and the fifth is the foreign matter in the pressing mold. 　 The method of elimination: replace the threading nozzle on the distribution reel and the wooden pipe and plastic pipe used for threading, check whether the direction of the wire core is normal, protect the wire core from direct wear with the equipment, and check whether the pressing die is intact at any time, and pay attention to the operator, method. 　 4. Single wire back strands and loose strands in bundled wires and stranded wires 　 Causes: first, the uneven tension of the pay-off, loose and tight, the loose tension of the core goes more, resulting in the back strand, the second is that the mold hole type is too large, can not play the role of proper adjustment of tension, the third is the improper position of the mold, the twisting angle is unreasonable, and the fourth is that the pitch is relatively large. 　 Bundle wire machine harness 19 strands and above single core, because the bundle line has no difference in direction, can only be the same direction bundle system, so the core combination is irregular state, the current manufacturers mostly use double pitch bundle system, so the harness harness more than 19 strands of the core, back strand, loose strands phenomenon is more serious than stranded wire. 　 Elimination method: For bundle lines (bundled products above L strands), the first is to improve the pay-off device of the bundle line, and adopt a more advanced single-wire tension pay-off, so that the tension of each single wire can be adjusted and controlled. The second is to use the guide mode, and the aperture of the guide die is 97% of the outer diameter calculated for the bundle line. In this way, the guide mode can adjust the tension appropriately. The third is to switch to a single-pitch wire bundle machine, and the bundle products of this wire bundle machine can reach the level of stranded wire. The fourth is the back strand, loose strand serious bundle core, using the method of overmold rewinding repair, can also meet the requirements of use. Fifth, adjust the pitch ratio appropriately. 　 For stranded wire products, the elimination method of loose strands: First, adjust the pay-off tension to make it uniform. The second is to change the pressing mold, the wire core should not be loosened in the die hole, pay attention to the horn mouth of the mold, if the horn mouth has been damaged, it can not be made. The third is to adjust the position of the pressing mold base to make the twisting angle of the stranded wire reasonable. Fourth, if the stranding pitch is large, it should be appropriately reduced. 　 5. Single wire grooving or surface defects in stranded wire 　 Cause: The defects such as pockmarks, scars, triangular cracks, and slag inclusions on the surface of the single line are mainly brought by the material, of course, there is a chipping phenomenon on the surface of the wire core, and it is not excluded that the wire die hole type is unreasonable and generated, which needs to be analyzed on a case-by-case basis. The grooving on the surface of the wire core is continuous, which is generally caused by the wire pulling, the deterioration of the lubrication conditions of the wire, the surface sticking to the aluminum, and the discontinuous grooving, may be caused by the stranded wire pressing die sticking foreign matter. 　 Elimination method: for the grooving of the aluminum wire when pulling the wire, you should first check whether the lubrication effect of the wire can meet the requirements of the wire, need to replace the lubricating oil in time, replace the wire mold, or eliminate the debris stuck to the wire mold, carefully check the incoming line, and eliminate the unqualified line entry in time, and at the same time check whether the crimping die is damaged, whether there are debris, and repair and replace it in time. 　 6. The single wire diameter is suddenly large, small or doped with the core 　 Cause: The main reason for finding that the single wire diameter is out of specification or doped with the wrong wire core in the stranding is that the process regulations are not carefully implemented, and the other reason is that there are certain problems in management. 　 Elimination method: If the length of the doped wire core is not long, it can be peeled off, re-replaced and repaired according to the wiring repair method. If the length is too long, it cannot be repaired, only get off the machine and deal with it separately. Therefore, before going on the machine, the operator should carefully check and measure. Of course, managers should also provide a guarantee method, such as whether the wire gauge is too much, whether the tolerance is reasonable, whether the production scheduling is properly arranged, and carefully consider the problems in management according to the principle of PDCA to avoid the generation of man-made defective products and waste products. 　 7. Stranded wire core loose strands 　 Causes: (l) The pitch is too large, resulting in the unstable stranded core. (2) The hole type of the pressing mold is too large and cannot play the role of compaction and adjustment. The wire mold flared mouth is too large or worn and damaged. (3) The pay-off tension is uneven, loose and tight. (4) The pitch ratio of each layer is not well matched. (5) The state of the wire core does not meet the process regulations, especially the improper position of the aluminum (6) wire splitter and die base. 　 Elimination method: first of all, strict process discipline, implement process operation procedures, appropriately reduce excessive pitch, adjust the pay-off tension and pressing mold. The position of the splitter to the mold base, according to different structures, is generally adjusted to 200~250mm. For stranding some strands with particularly large tensile strength, the method of combining molds can be used, and there are also good results, of course, the operator operates according to the method specified in the process operation regulations, which is quite important. 　 8. The twisting direction is wrong, and the stranding pitch is unqualified (mainly large) 　 Cause: The wrong direction is mainly a judgment error, the operator should strengthen the sense of responsibility when operating, strictly implement the process card, and should strengthen the flow inspection to prevent the generation of man-made defective products and waste products. 　 9. Confusing wiring and crimping 　 Cause: Stranded products are generally supplied on plates. Large section, to be lined up one by one, especially the bottom line should pay special attention to the neatness, in the line turn, because there is a stay, should pay special attention, between the upper and lower layers can not leave too large gap, the row distance should be appropriate, too large easy to cause crimping. 　 Elimination method: first of all, to adjust the cable tension, when manually arranged, one can be arranged is appropriate, the second according to the core diameter to replace the cable pitch, the first layer is the key, must be neat; In the second layer, when adjusting the layer, manual wiring should be carried out to ensure the quality of the line. The third is to strengthen the sense of operational responsibility to observe the quality of the cable at any time, adjust the problem in time, and pay attention to fixing the distance between the two wire ends and the edge.