Wire breakage shutdown faults of geogrid production line equipment shall be handled by the procedure: root cause inspection → fault disposal → commissioning and resetting. Wire breakage shutdown interrupts production. Frequent occurrences cause material loss and reduce output efficiency. Therefore, during fault handling, first identify the breakage position and classify causes into raw material, mechanical, tension or temperature control issues. This is the first step of fault disposal.

Wire breakage in the unwinding zone is mostly related to raw material quality. Uneven diameter, internal bubbles or surface scratches on filaments lead to fracture under continuous tension. Inspect the unwinding stand for jamming and asynchronous rotation. Fluctuating unwinding resistance causes sudden tension and filament breakage. Stop the machine, replace defective rolls, calibrate unwinding brakes and adjust damping to stabilize unwinding speed and prevent tension spikes. Re-thread filaments and run the line at low speed to monitor filament feeding.

The stretching section has the highest failure rate. Filaments are oriented by heat and tension. Too low temperature results in insufficient ductility and brittle fracture; excessive temperature over-softens filaments and reduces tensile strength. Verify temperature readings of each oven zone, check heating modules and temperature sensors for measurement deviation, and clean oven deposits to ensure uniform temperature distribution. Check traction roll gaps. Worn roll surfaces or uneven gaps cause uneven load on individual filaments and local overload breakage. Grind and repair roll surfaces or adjust gaps to equalize tension on all filaments.

For breakage at setting and grid forming sections, focus on guide rollers and filament dividers. Damaged or burr divider teeth and seized guide roller bearings scrape filaments and cut them gradually. Stop the machine, inspect dividers and guide rollers, remove burrs, replace damaged teeth and stuck bearings, and adjust filament spacing to ensure smooth feeding without friction.

Wire breakage may also arise from abnormal tension systems. Drifted tension sensors or improper tension parameters cause sudden tension surges and filament fracture. Calibrate tension detectors, reset tension parameters to reduce fluctuation, and set over-tension early warning to mitigate unexpected shutdowns.

After fault repair, do not start full-speed operation immediately. Run the equipment at low speed with no load to confirm smooth rotation of all moving parts, then thread filaments for trial production. Continuously monitor filament conditions and record breakage frequency. For routine maintenance, regularly inspect guide, traction, temperature and tension components, replace worn parts and clean dividing mechanisms to avoid filament scratches by impurities.

Recurring wire breakage requires mechanical property testing of filament samples. Locate systematic problems with operation logs and optimize raw material and process parameters. Control raw material inspection, equipment patrol and process parameters to reduce repeated wire breakage shutdowns and ensure stable continuous production.