Criteria Based on Precision and Performance
Significant Degradation of Core Precision:Dial indicator tests reveal tufting head positioning deviations exceeding 0.1mm; brush roller radial runout exceeds factory standards by twofold; tufting hole offsets and filament distribution uniformity errors exceed 15%; and standard calibration fails to restore precision.
Drastic Drop in Production Efficiency: Rated capacity drops by over 30%; single-shift output consistently falls short of design specifications despite replacing wear parts or adjusting parameters; and production cycle times lag significantly behind line requirements.
Sustained Decline in Finished Product Yield: Filament retention fails to meet standards; filament shedding rates exceed industry norms by twofold; defects such as inconsistent filament lengths or densities recur frequently; and minor repairs fail to ensure stable product quality.
Criteria Based on Mechanical Operating Condition
Severe Wear of Core Components: Fundamental parts (spindles, guide rails, lead screws) exhibit deep scoring or exceed form and position tolerances; transmission gear tooth wear exceeds one-third of the tooth thickness; bearing clearance exceeds limits by more than threefold; and routine lubrication or clearance adjustments fail to resolve the issues.
Chronic Abnormal Operating Conditions: Violent vibration or abnormal noise occurs even during no-load operation; motor load current consistently exceeds the rated value by 20%; bearing temperatures exceed 70°C after one hour of continuous operation; and routine troubleshooting fails to identify the root cause.
Sharp Increase in Failure Frequency: Unplanned monthly downtime due to breakdowns exceeds five incidents; the same component fails repeatedly despite repeated repairs; stable operation lasts less than 72 hours after minor repairs; and maintenance costs escalate sharply.
Criteria Based on Electrical and Safety Systems
Widespread Electrical System Aging: Extensive cracking in wire insulation layers; insulation resistance drops below 0.5 MΩ; control system components age, leading to frequent missed steps or system crashes during program execution; and replacing individual components fails to resolve systemic issues.
Total Failure of Safety Functions: Safety devices-such as emergency stop switches, protective guard interlocks, and overload protection-fail completely or largely; safety performance cannot be restored despite multiple repair attempts; and equipment operation poses significant safety hazards.
