Coil Packaging Line Maintenance Guide (Updated 2025)

In the processing and logistics system of modern metal materials such as steel coils, copper coils, and aluminum coils, the coil packaging line is not only the endpoint of the packaging process, but also the "last quality checkpoint" before products enter the market.The coil packaging line system covers multiple complex process steps such as unloading, centering, winding, wrapping, weighing, labeling, and palletizing, with frequent daily operation, precise structure, and strong systematicity.
If there is a lack of scientific maintenance, the following problems are prone to occur:
● Frequent malfunctions affecting production capacity and delivery time
● The cost of spare parts consumption has increased, and maintenance manpower is difficult to control
● Key components are aging prematurely, resulting in a shortened overall lifespan of the equipment
● Unqualified product packaging leads to transportation losses and brand risks

Frequency suggestion: Before work every day+after each device shutdown
This type of inspection is carried out by equipment operators, with a focus on timely detection of abnormal symptoms and avoiding the amplification of potential hazards:
Inspection items:
● Main power and gas supply system: Confirm whether the voltage, current, and air pressure are stable and have no abnormal fluctuations.
● Status of moving parts: Check whether the belt, chain, bearing, and slide rail are loose, stuck, dry, or asymmetrically worn.
● Winding and film material mechanism: Check whether the winding arm moves smoothly, whether the sensitivity of the tension adjustment device is normal, and whether the film roll is deformed.
● Sensors and photoelectric components: Test the sensitivity of the detector with a manual switch to check for dust or obstruction.
● Control panel response: operate start/stop/manual functions, confirm that touch screen/button response is timely, without lag or error feedback.
● Security system: including safety light barriers, emergency stop buttons, warning lights, and buzzers must be fully functional and effective.
Tool suggestion:
● Equipped with simple tools such as cleaning brushes, air guns, and wiping cloths for quick daily maintenance.
● Use digital inspection forms to record daily maintenance results and create traceability documents.

Weekly maintenance points:
● Clean the equipment casing and moving parts to prevent the accumulation of metal dust.
● Tighten moving and stationary components, such as brackets, base plates, cylinder fixing points, etc.
● Check the equipment alignment system to ensure that the coil feed path is consistent with the packaging positioning and prevent misalignment.
● Check the operation trajectory of all rollers and capsule arms. If there is any abnormal noise or synchronization, it should be immediately investigated.
Monthly maintenance points:
● Replace or add lubricating grease to guide rails, rollers, gearboxes, and cylinders.
● Check whether the switch power supply, relay, and contactor are overheating or aging, and whether the cable terminal screws are loose.
● Review the mechanical accuracy of the tensioning mechanism and the guide system of the tape guide.
● Re calibrate the positioning sensor/barcode reading device to maintain accuracy.
Quarterly maintenance focus:
● Conduct a no-load operation test on the entire line to check if all submodule interlocking actions are smooth.
● Clean and inspect all modules inside the electrical control box, remove static dust, and check the grounding circuit.
● Verify the versions of the main PLC and HMI programs, and backup the operating parameters.
● Assess whether some vulnerable parts need to be purchased in advance based on the cumulative operating time.
Annual major maintenance:
● PLC system diagnosis and program optimization: detect I/O response speed, update human-machine interface HMI function menu.
● Structural component precision adjustment: Use a laser alignment instrument to correct the installation deviation of the alignment guide rail and drive system.
● Disassembly and inspection of bearings, reducers, and guide components: replace transmission components with abnormal wear.
● Debugging of servo and variable frequency control system: Optimize acceleration and deceleration curves to improve smooth operation.
● Energy consumption statistics and optimization suggestions: Evaluate the annual power consumption situation and propose energy-saving renovation plans (such as replacing stepper motors with servos).

The common types of problems are as follows:

Fault phenomenon	Potential reasons	Quick troubleshooting suggestions
Misplaced packaging or wrinkled film	Insufficient packaging tension, tape deviation, and abnormal noise from the winding arm	Re tension the guide belt, replace the tension spring, and check the motor bearings
The system does not start	Safety photoelectric not closed, PLC stuck, contactor damaged	Restart PLC, reset safety circuit, check I/O module
Automatic feeding failed	Damaged feeding motor, encoder malfunction, signal interruption	Check the motor driver, replace the encoder, and verify the PLC logic
local overheating	Fan stalling, frequency converter overload, power module overheating	Replace the fan, install ventilation holes, and replace the derating components
Suggest combining visual status panels with sound and light alarms to improve on-site problem response speed.

Maintain the project	Suggested frequency	Responsible personnel	Inspection methods/tools	Remarks/Objectives
Check the power supply voltage and air pressure	Daily (before startup)	Equipment operator	Multimeter, Barometer	Ensure stable operating conditions before system startup
Check the wear status of the conveyor belt and rollers	daily	Equipment operator	Visual inspection, manual rotation	Prevent slipping during transportation or damage to the coil during transportation
Clean the dust on the sensors and photoelectric eyes	daily	Equipment operator	Brush, wiping cloth	Maintain detection accuracy and prevent misjudgment
Check the tension device of the wrapping film	daily	Equipment operator	Manual tensile testing	Prevent film wrinkling, loose wrapping, and insufficient tension
Check the emergency stop button and safety light barrier	daily	Equipment operator	Button testing and sensor alignment inspection	Ensure personal and equipment safety
Add lubricating grease to the guide rail and linear bearing	every week	Maintenance technician	Lubrication gun, lithium based grease	Reduce mechanical friction and eliminate noise
Tighten bolts of vibration prone components	every week	Maintenance technician	Torque wrench	Prevent structural loosening caused by long-term vibration
Clean the ventilation system of the control cabinet	every week	Maintenance technician	Air gun, dry cloth	Avoid overheating of electronic control components caused by dust
Calibrate the positioning sensor	monthly	Automation engineer	Specialized calibration tools, software interface	Ensure accurate alignment of the coil and the position of the envelope
Check if the tension spring has failed	monthly	Maintenance technician	Spring tension meter	Maintain packaging tension within the set range of the equipment
Check PLC input/output response and delay	every quarter	Automation engineer	Industrial control laptop, PLC software	Optimize signal stability and instruction execution efficiency
Replace worn parts (belts, seals, bearings, etc.)	every quarter	Maintenance technician	Original spare parts, dismantling and inspection	Prevent sudden shutdowns and extend equipment lifespan
Repair the winding arm and rotating component	every year	Original factory engineer or certification team	Complete disassembly, measurement, and positioning calibration	Restore torque balance and ensure structural stability during high-frequency operation
Backup PLC and HMI operating programs	every year	Automation engineer	USB/Cloud Backup	Prevent system data loss and facilitate fault recovery
Full line no-load trial operation+operation data recording and analysis	every year	Maintenance supervisor	Vibration tester, operation log system	Detecting linkage logic and system coordination
Analyze annual energy consumption data and propose energy-saving suggestions	every year	Energy Efficiency Specialist/Original Factory Consultant	Electric energy meter, energy-saving analysis software	Explore the potential for energy conservation and assist in green manufacturing

The maintenance and upkeep of the coil packaging line is a necessary process to ensure the normal operation of the equipment and extend its lifespan.Whether it is lubrication inspection of the chain drive system, periodic testing of the electronic control module, or regular maintenance of dust prevention and safety protection mechanisms, as long as a reasonable maintenance plan is formulated and implemented properly, the operational stability and service life of the equipment can be significantly improved.
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