How to analyze and troubleshoot the brushless motor-motor automatic screwdriver?
Brushless motor motor automatic locking screw machine fault analysis and troubleshooting can be carried out according to the following steps and methods:
First, fault information collection
1, on-site observation: after the equipment failure, the first thing to do is to observe the operating status of the equipment. Check whether the equipment has abnormal noise, vibration, smoke and other phenomena; observe the status of the indicators on the operating panel to determine whether the equipment has alarm information display.
2, operator communication: detailed communication with the equipment operator to understand the time of failure, frequency, failure occurred before the operation and other information. For example, the fault is in the equipment startup, or in the operation of a period of time before the emergence of the operator in the fault occurs before whether the special operation and so on.
3, historical records access: access to equipment maintenance records and failure history files, to understand the equipment in the past whether similar failures, as well as the cause of the failure at that time and the solution. This helps to quickly locate possible problems.
Second, fault classification analysis
1、Mechanical failure
l Screw feeding system failure
Jamming problem: If the screws are jammed in the feeding track, vibration disk or feeding tube, first check whether the specifications of the screws are the same, and whether there are screws with too large a deviation in size. If the screw specification is not a problem, clean up the debris in the feeding track and feeding tube, adjust the vibration frequency and amplitude of the vibration disk to ensure that the screws can be transported smoothly.
Poor feeding: Check whether the mechanical parts of the feeding mechanism are worn, such as feeding slider, pusher, etc., if the wear is serious, then replace it. At the same time, check whether the feeding tube is installed correctly, whether there is excessive bending or the tube diameter is not suitable.
l Failure of locking actuator
Problems with the batch nozzle: If the head of the screw is screwed or the batch nozzle can not accurately set the head of the screw, check whether the batch nozzle is worn or damaged. If it is seriously worn, replace the nozzle in time and make sure the specification of the nozzle matches the screw.
Unstable locking torque: Check whether the control parameters of the brushless motor are set accurately, and whether the transmission parts (such as gears, couplings, etc.) are worn or loose. If the parameter setting is wrong, recalibrate the parameter; if the transmission parts are faulty, repair or replace them.
Mechanical stalling: Check whether the moving parts of the equipment, such as screws, guide rails, etc., are stuck with foreign objects, or whether the friction increases due to insufficient lubrication. Clean up the foreign matter, lubricate the moving parts, and adjust the fit gap of mechanical parts if necessary.
2、Electrical failure
l Power failure
The equipment can not start: check whether the power plug is plugged in properly, whether the power cord is broken. Use a multimeter to measure the power input voltage is normal, if the voltage is abnormal, check the power socket and power supply line. At the same time, check whether the power switch inside the equipment is damaged and whether the fuse is blown.
Unstable voltage: Install a voltage regulator to stabilize the input voltage, check whether the power filter is working properly, and replace it if it is faulty. Check whether the internal components of the power supply module are aging, and repair or replace them promptly if there is any problem.
l Motor and driver failure
Motor does not rotate: check whether the motor drive board is faulty, whether the motor winding is short-circuited or disconnected, and whether the connection line between the motor and the drive board is loose or damaged. Use professional tools to test the driver board and motor winding, repair or replace the damaged parts.
Abnormal motor speed: Check whether the motor drive parameters are set correctly and whether the potentiometer on the drive board is damaged or improperly adjusted. Reset the parameters and replace the damaged potentiometer.
l Sensor failure
Mis-detection or no signal output: For screw detection sensors, position sensors, etc., check whether the installation position is accurate and whether the surface is covered with dust or debris. Clean the sensor surface and adjust the mounting position. If the sensor still can not work properly, it may be the internal components are damaged and need to be replaced.
3、Software failure
l program running error
Process error: If the device does not perform according to the preset program, check whether there are loopholes or errors in the control program. You can try to restart the device, if the problem still exists, contact the equipment manufacturer to get a new version of the program for upgrading.
Parameters are lost or settings are invalid: check if the database or file storing the parameters is corrupted, if it is corrupted try backing up and restoring the data. At the same time, check whether the authority setting of the software is correct, make sure the software has enough authority to save and read the parameters.
l Communication Failure
Abnormal communication with other devices: If the device supports communication with the host computer, PLC, etc., check whether the communication protocol matches and whether the communication line is connected normally. Reset the communication protocol, check and repair the communication line.
4、Troubleshooting implementation
Step-by-step troubleshooting: According to the results of the fault analysis, in accordance with the principle of first easy and then difficult, step by step on the possible problematic components for investigation and repair. For example, check the external connection lines and easily observable parts first, and then check the internal electrical components and mechanical structure in depth.
Replacement method: For some parts that are difficult to determine whether they are damaged or not, the replacement method can be used for troubleshooting. Will be suspected of problematic parts with the same specifications of the normal parts for replacement, if the fault disappears, it means that the replaced parts have problems and need to be repaired or replaced.
Professional Repair: For some complicated faults, such as control board faults, internal motor faults, etc., professional repairers may be required. In this case, you should contact the equipment manufacturer's after-sales service department or a professional maintenance organization in time to avoid greater damage caused by self-maintenance.
5, fault summary and prevention
Fault summary: After troubleshooting, summarize the entire troubleshooting process. Record the fault phenomenon, the cause of the fault, the solution and the measures taken in the maintenance process and other information, in order to provide a reference for future troubleshooting.
Formulation of preventive measures: according to the cause of the failure, develop corresponding preventive measures. For example, strengthen the daily maintenance of equipment, regular inspection and replacement of wearing parts; training of operators to improve their operating skills and troubleshooting capabilities; optimize the operating environment of the equipment to reduce the impact of external factors on the equipment.
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※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
