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During the winding process using a fork-type winding machine, many operators of such machines encounter the problem of the wire not catching on the hook. Below, the manufacturers of fork-type winding machines explain the reasons behind this issue as well as the solutions: 1. The distance between the fork and the wire sleeve is too great: When trying to hook the wire, it fails to catch on the bottom of the hook and instead gets caught on the outer edges of the hook, resulting in it falling off when the hook is moved. The thread can be seen when hooked. Solution: Adjust the distance between the flying fork and the hook line sleeve. 2: Inappropriate use of springs in the tensioning mechanism: When the spring force is weak, the wire becomes loose; it cannot reach the bottom of the hook and thus tends to come loose easily. When the spring force is strong, the line tends to get caught on the outer edge of the hook; when the inner sleeve of the hook moves, the connection breaks and the line can get scratched. Solution: Choose the appropriate spring. 3. Poor tension setting: The thread appears very loose when hooked. At the hooking point of the wound rotor wire, when the hook is not tightened, the spring in the tension mechanism pulls the magnetic powder tensioner to tighten the copper wire at that point so that hooking can take place. If the tension setting is incorrect, the magnetic powder tensioner cannot hold the copper wire tightly when the spring exerts force, and the wire slips out of the wire reel, resulting in missed hooks; many hooks are missed in a row. Solution: Adjust the tension setting; if the value is set too low, the hook will not be properly secured, the thread won’t reach the bottom of the hook, and the thread will come loose. If the value set is too high, it can cause the copper wire to be cut by the sharp edges of the hooks or scratched. 4. Variation in indexing during the winding process: The positions of the commutator hooks and the openings in the hook wire sleeves also change; the greater the offset, the more likely it is that the wire will not be properly hooked. The last few hooks missed their targets. Ear guards with hook wires can damage the commutator hooks, resulting in missing hooks. Solution: Adjust the distance between the two (the thicker the line, the greater the distance should be); a normal value is 2-3 mm. 5. The distance between the wire mold and the hook wire sleeve is too large: Care was not taken when changing the model; when adjusting the hook wire sleeve, only attention was paid to the distance between the outer sleeve and the wire mold, without considering the distance between the inner sleeve and the wire mold. From the outlet of the flying fork to the wire die, the copper wire forms an inclined line; the farther the hooking sleeve is from the wire die, the farther it is as well from the copper wire. Solution: Increase the distance between the two; the thicker the distance line, the greater the distance should be, with a normal value of 2-3 mm. The length of the wire guard must be 1-2 mm longer than that of the hook guard. 6. Improper parameter setting: 1. The indexing speed is not in harmony with the hooking speed – the indexing speed is fast while the hooking speed is slow; as a result, the indexing occurs before the hooking action is complete, making it easy for the line to come loose from the hook. The hooking speed is fast while the indexing speed is slow; the rotor hooks before reaching the proper position, making it easy to fail to hook at the bottom of the hook, thus leading to easy disengagement. 7. If the angle at which the fork moves to the hooking position and the angle at which it moves to the winding position are not set properly, the wire needs to be rotated by an appropriate amount after one slot has been wound. If the angle for moving the fork to the hooking position is set too small, the wire will move towards the commutator and tighten under tension, thus hooking onto it. Repeating this process causes the wire coil around the rotor’s neck to thicken, and as the wire moves further away from the hooking sleeve, hooking failures occur. After winding the wire, if the angle at which the fork moves to the hooking position is set too high, the wire will be pulled into the wire guide; when trying to hook it, the wire emerges from the guide, resulting in missed hooks. If the angle setting for hooking to the winding position is too small, the wire cannot reach the bottom of the hook and is prone to coming loose; if the angle setting is too large, the wire will move the wire guide, causing imbalance in it, and this can lead to damage to the steel plates during indexing and closing. 8. Poor adjustment of the ear guards: The cylinder mechanisms for the ear guards on both sides of the flying fork winding machine do not operate in coordination; on one side, two cylinders work simultaneously, which leads to inconsistencies. The position of the ear guards is not aligned with those of the commutator hooks, and the distance between the movement of the ear guards and the commutator is too small, preventing the wire from passing through.