Analysis of common problems of computerized quilting machines
● Thread breakage
○ Needle problem
Reason: Needle bending or needle tip blunting is a common cause. When the needle is bent, the thread is subjected to uneven friction during the process of passing through the fabric, which can easily lead to thread breakage. Needle tip blunting will increase the resistance to passing through the fabric, causing the thread to break due to excessive tension.
Solution: Check the needle regularly and replace the bent or blunt needle in time. It is also important to choose a needle of good quality that is suitable for the machine model.
○ Thread quality problem
Reason: If the thread is not strong enough, uneven in thickness or rough in surface, it is easy to break during high-speed quilting. For example, low-quality threads may have uneven twist during the production process, resulting in partial breakage when subjected to force.
Solution: Choose threads with reliable quality and check whether the thread specifications meet the machine requirements and quilting process. When using a new batch of threads, it is best to conduct a small-scale test first.
Hook component failure
Reason: The hook is a key component that affects the normal needle movement of the thread. If the hook tip is worn, has burrs, or there are debris in the hook, the thread will be broken. For example, after long-term use, the hook tip may be worn due to friction with the thread, making it unable to guide the thread normally.
Solution: Clean the inside of the hook regularly to remove debris and dust. Check the wear of the hook tip. If there is wear, replace the hook in time or repair the hook tip.
○ Improper tension adjustment
Cause: If the tension of the upper and lower threads is set improperly, excessive thread tension will cause thread breakage. For example, excessive tension of the upper thread will cause the thread to be pulled beyond its limit when passing through the fabric and the hook.
Solution: Reasonably adjust the tension of the upper and lower threads according to the quilting material and thread type. You can refer to the machine manual, gradually adjust the tension through the tension adjustment knob, and observe the stitching of the thread to find the best tension setting.
● Pattern movement problem
○ Loose mechanical parts
Cause: After the machine is used for a long time or is vibrated, the transmission parts (such as belts, screws, etc.) in the X-axis or Y-axis direction may become loose. This will cause the machine head to move inaccurately and cause the pattern to move out of position. For example, a loose belt will cause a slight displacement deviation of the machine head during movement, which will cause the pattern to be significantly deformed when accumulated.
Solution: Check and tighten the transmission parts of the machine regularly. For loose belts, you can tighten them by adjusting the belt tensioner; for parts such as screws, check whether their connecting nuts are loose, and tighten them with tools if necessary.
○ Computer program failure
Cause: Computer programs may fail due to virus infection, software conflict, or damage to the data storing the pattern. For example, when the computer system is infected with a virus, it may interfere with the normal operation of the quilting machine control program, resulting in pattern instruction errors.
Solution: Install genuine antivirus software and system maintenance software, and scan and maintain the computer system regularly. If you suspect that the pattern data is damaged, you can reload the correct pattern data, or re-edit and store the pattern.
○ Sensor failure
Cause: Computer quilting machines usually rely on sensors to determine the position of the machine head. If the sensor fails, such as the displacement sensor accuracy decreases or the signal transmission is interrupted, the machine will not be able to accurately sense the position of the machine head, causing the pattern to move.
Solution: Check whether the sensor connection line is loose or damaged. If there is a problem, repair or replace the line in time. Calibrate the sensor to ensure that it can accurately measure and transmit the position signal. If the sensor is damaged, you need to replace the sensor of the same model.
● Uneven quilting thickness problem
Uneven presser foot pressure
Cause: Uneven presser foot pressure will cause inconsistent fabric feed speed at different positions during quilting. For example, if the pressure on one side of the presser foot is too high, the movement of the fabric on that side will be hindered, resulting in differences in quilting thickness.
Solution: Check the pressure adjustment device of the presser foot to ensure that the pressure on both sides of the presser foot is uniform. You can test quilting on the fabric to observe the fabric feeding situation and fine-tune the presser foot pressure as needed.
○ Feed dog wear or height inconsistency
Cause: The feed dog is responsible for conveying the fabric forward. If the feed dog is severely worn or the height is inconsistent, the fabric conveying will be unstable, resulting in uneven quilting thickness. For example, after some feed teeth are worn, their ability to grab the fabric decreases, resulting in a decrease in the amount of fabric delivered in this area.
Solution: Check the wear of the feed teeth and replace the ones with severe wear. At the same time, use a measuring tool to check the height of the feed teeth and adjust them to make them consistent to ensure that the fabric can be evenly delivered.
● Machine operation noise problem
○ Mechanical parts lack oil
Cause: The transmission parts of the machine (such as screws, guide rails, gears, etc.) will increase the friction coefficient and produce noise when there is a lack of lubricating oil. For example, when the screw rotates without sufficient lubricating oil, it will make a harsh sound due to dry friction.
Solution: Regularly add lubricating oil to the transmission parts of the machine. According to the machine's instruction manual, select the appropriate lubricating oil and lubricate it according to the prescribed cycle and method. Pay attention to cleaning the oil and impurities on the surface of the parts to prevent them from entering the machine and affecting normal operation.
○ Wear or damage of parts
Cause: Long-term use or overload impact on the machine may cause wear or damage to the parts, such as bearing wear and gear tooth surface damage. These damaged parts will produce abnormal noise during operation.
Solution: Carefully check the operation of each part of the machine and determine the source of the noise by listening to the sound, observing the vibration, etc. For worn or damaged parts, replace them in time to restore the normal operation of the machine.
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