Before equipment develops major problems, there are actually small warning signs.
The tension curve on an SZ stranding line starts fluctuating slightly. The sheath surface on a fiber optic cable sheathing line occasionally looks a bit dull. The UV lamp brightness on a fiber coloring machine isn’t what it used to be – these are all the equipment “talking.” But when operators get busy, they often don’t have time to look. By the time the equipment alarms and stops, it’s already too late.
Today, let’s share a 15-minute daily inspection route. Walk through it process by process, and eliminate faults while they’re still in the bud. As a Premier Cable Machine Manufacturer, Hongkai trains customer operators to master this inspection method during equipment delivery.
1. Inspection Route: Starting from the Fiber Coloring Machine
Station 1: Fiber Coloring Machine / Fiber Optic Coloring Line
What to check:
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Is the pay-off tension curve on the touchscreen stable? Hongkai’s fiber coloring machine has pay-off tension accuracy of ±0.05 N – the curve should be a smooth line.
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Is the UV-LED curing lamp glowing normally? After the lamp ages, curing effectiveness declines and the color rubs off easily.
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Is the take-up traverse neat? Irregular winding causes fibers to overlap on the reel, and the pay-off tension in the next process becomes unstable.
Station 2: Secondary Coating Line for Optical Fiber / Loose Tube Line
What to check:
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Are the extruder heating zone temperatures stable? If temperature deviation exceeds ±2°C, the loose tube wall thickness becomes uneven.
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Is the hot water trough temperature normal? Excess length control accuracy is ±0.2‰ – water temperature is key.
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Is the take-up tension stable? If the loose tube is wound too tightly, the fiber inside gets stretched.
Station 3: SZ Stranding Line
What to check:
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Real-time pay-off tension curve. Industry standards require fluctuation ≤ ±0.5 N; Hongkai measures ≤ ±0.4 N. If the curve jumps significantly, first check whether the dancer arm is sticking.
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Stranding unit operating sound. Uniform gear meshing sound is normal; periodic “clunking” means check the bearings.
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Binder yarn breakage switch. Simulate a yarn break once to see if the machine stops within 0.1 seconds.
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Differential gearbox oil level and quality. Oil level should be between the upper and lower marks. If the oil is black or contains metal debris, change it early.
Station 4: Fiber Optic Cable Sheathing Line
What to check:
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Is the laser diameter gauge reading stable? A dirty lens causes reading drift, and a drifting reading causes the PLC to misadjust extruder speed. Wipe the lens with an alcohol swab before startup every day.
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Sheath surface quality. Any bubbles, scratches, or dullness? LSZH material that has absorbed moisture tends to bubble during extrusion.
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Extruder heating zone temperatures. If temperature deviation exceeds ±2°C, sheath wall thickness becomes uneven.
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Is the take-up traverse even? Irregular winding causes cable to spill off the reel during delivery.
Station 5: FTTH Optical Cable Manufacturing Machine
What to check:
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Is the butterfly die discharging evenly? If cross-section dimensions are unstable, the fiber position in the butterfly drop cable shifts.
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Is the strength member pay-off tension stable? If steel wire or FRP pay-off tension fluctuates, the butterfly cross-section becomes asymmetrical.
Station 6: Indoor Optical Fiber Production Line
What to check:
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Is the tight buffer die discharging evenly? The tight buffer layer is only 0.15–0.3 mm thick – unevenness directly affects fiber performance.
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Is the pay-off tension stable? Bare fiber is fragile – pay-off tension accuracy is ±0.05 N; excessive fluctuation breaks the fiber.
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Is the take-up traverse neat?
2. Weekly Inspection: Spend an Extra 30 Minutes on These Tasks
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Grease the dancer bearings: The dancer bearings on the SZ stranding line should be greased once a week until old grease is pushed out of the seals.
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Clean electrical cabinet dust screens: Clogged dust screens raise cabinet temperature and shorten inverter lifespan.
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Check drive belt tension: Press the middle of the belt with your finger – a depression of 10–15 mm is normal.
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Check measuring wheel wear: A worn measuring wheel causes inaccurate length measurement – delivery lengths won’t match.
3. Monthly Inspection: Half a Day for These Tasks
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Calibrate tension sensors with standard weights: Hang a 5 N weight – a touchscreen display of 4.8–5.2 N is acceptable.
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Calibrate the length counter: Measure a 100-meter cable section and compare with the display. If deviation exceeds 1%, recalibrate.
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Check die concentricity: For the sheath die on the fiber optic cable sheathing line and the butterfly die on the FTTH optical cable manufacturing machine – if deviation exceeds 0.02 mm, re-grinding is recommended.
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Check heater band resistance: Measure with a multimeter – if deviation exceeds 10%, replacement is recommended.
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Check sensor connectors: For all machines on the optical fiber cable production line, connectors must be free of looseness and oxidation.
4. Inspection Records: Let the Data “Speak”
Hongkai equipment comes standard with Siemens/Mitsubishi PLC platforms, supporting automatic production data recording and MES integration. The entire fiber optic cable making machine series – including fiber optic coloring line, secondary coating line for optical fiber, loose tube line, SZ stranding line, fiber optic cable sheathing line, FTTH optical cable manufacturing machine, and indoor optical fiber production line – supports data acquisition.
Inspection records should be entered into the equipment file. Which machine, what time, what data, what action taken – write it down. Next time a similar problem occurs, there’s a reference.
5. What to Do When Inspection Finds a Problem?
Minor problems – handle them yourself: Bearing greasing, lens cleaning, terminal tightening – operators follow the troubleshooting guidance on the touchscreen.
Can’t handle it – contact Hongkai: Remote video support with a 2-hour response time during working hours. In 2024, Hongkai completed 89 overseas remote video support sessions, with an average resolution time of 32 minutes. Equipment can optionally be equipped with a remote access module (with customer authorization), allowing engineers to remotely view equipment operating status and diagnose alarm causes.
Need replacement parts: Every Hongkai machine comes with a standard wear-parts kit – belts, bearings, sensors, fuses – shipped with the equipment. For major parts, DHL delivery within three days. Major electrical components use Siemens/Mitsubishi/Schneider, with global warranty coverage and locally available replacements.
6. Overseas Factory Inspection Training: What Can Hongkai Provide?
As a Premier Cable Machine Manufacturer, Hongkai provides during equipment delivery:
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Engineers on-site for installation and commissioning: 12 to 18 days from unpacking to producing the first qualified reel.
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Operator training: Three levels – operational, maintenance, and data. Before the engineers leave, ensure operators can independently perform inspections.
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Bilingual (Chinese/English) Maintenance Manual: Daily inspection checklist, weekly maintenance items, monthly maintenance plan – all listed.
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Remote retraining: New employees can receive remote video training before starting work (2 free sessions per year).
📩 Get an Inspection Checklist Template and Training Plan
If you are procuring a fiber optic cable production line for an overseas project, or want a bilingual (Chinese/English) daily inspection checklist for your operators, feel free to contact the Hongkai technical team.
Just tell us three things:
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What type of cable do you want to make? (Loose-tube / FTTH / indoor cable)
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Where will the factory be built? (This affects operator language and voltage system)
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Approximately what capacity? (How many kilometers per month or per year)
We will provide a preliminary equipment configuration proposal, inspection checklist template, and quotation within 5 working days.
📧 Email: sales2@hkofcmachine.com
🌐 Website: https://hkofcmachine.com/
