Precision Wire Cutting Machine Standard Operating Manual

2025-04-16

Chapter 1: Operational Standards

1.1 Pre-Operation Preparation

Checklist	Specifications	Testing Tools
Power Supply	220V ±5%	Multimeter
Cutting Wire Tension	0.15–0.25 N/mm²	Tension Gauge
Coolant Concentration	5–8% pH-balanced	Hydrometer/pH Test Strips
Grounding Resistance	≤4Ω	Megohmmeter

Pre-Start Verification:

① Wear ANSI Z87.1-certified splash-proof goggles and cut-resistant gloves.

② Remove flammable materials within a 1m radius.

③ Conduct a no-load test run (≥3 minutes).

Chapter 2: Process Control

2.1 Standard Operating Procedure

Step	Operation Guidelines	Safety Alerts
Workpiece Clamping	Use 3-point fixture (clamping force ≤80N·m)	Never adjust unsecured parts manually.
Parameter Setup	Select wire speed based on material hardness*	Enable anti-electrolysis mode for copper.
Cutting Initiation	Maintain 45° feed angle (initial speed ≤5mm/s)	Emergency stop if abnormal vibration.
Process Monitoring	Coolant flow: 2–3L/min	Activate secondary cooling at >60°C.

*Refer to Appendix A for material-specific parameters.

Chapter 3: Emergency Protocols

3.1 Critical Incident Response

Fault Action Plan Containment Measures

Wire Break Alarm 1. Cut power Establish 10cm exclusion zone

2. Mark breakpoint

3. Relieve tension before replacing wire

Coolant Leakage 1. Activate backup pump Cut power to affected area

2. Deploy absorbent mats

3. Inspect seals

System Freeze 1. Press physical E-stop Do NOT force slider movement

2. Backup programs

3. Recalibrate after reboot

Chapter 4: Maintenance Schedule

Task Daily Weekly Monthly

Guideway Cleaning ✓

Bearing Lubrication ✓

Pulse Power Check ✓ (Laser interferometer)

Precision Calibration ✓

Integrated with Wire Bending & Welding Systems

Wire Bending Machine Compatibility: Ensure tension settings align with downstream bending processes.

Wire Welding Machine Synergy: Maintain coolant purity to prevent residue interference during welding.

Cross-Platform Safety: Use identical ANSI-rated PPE when operating adjacent wire bending machines or wire welding machines.

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