What are the common control unit failures and solutions for brushless motor motor manual four-station external winding machine?
Brushless motor motor manual four-station external winding machine common control unit failure and solutions:
First, the controller hardware failure
1, control chip failure
Failure phenomenon:
The winding machine can not start normally, the operating panel does not display, or display messy code, error code and other abnormal information.
The winding function of the winding machine fails completely, unable to perform any winding operation, including manual and automatic winding mode.
Some functions are abnormal, such as some control buttons or parameter setting functions are invalid, but other parts still work normally.
Cause Analysis:
The chip may be damaged in the internal circuit due to power surge, static electricity, overheating and other reasons.
Long-term use of the chip leads to aging, performance degradation, can not properly process the control signal.
Chip pin false welding, short circuit or broken circuit, affecting the normal input and output of the signal.
Solution:
First check whether the power supply of the control chip is normal, use a multimeter to measure the power pin voltage of the chip to ensure that it is within the normal range. If the power supply is abnormal, check the power supply circuit and repair or replace the damaged power supply components.
For aging chips, it is necessary to replace the chip with the same model. When replacing the chip, pay attention to anti-static operation to avoid damage to the new chip.
Check the welding of the chip pins, for false welding pins, use a soldering iron to re-weld; if you find that the pins are short-circuited or disconnected, you need to find out the failure point, clean up the short-circuited part or repair the disconnected line.
2, circuit board failure
Failure phenomenon:
Intermittent failure of the winding machine during operation, sometimes it can work normally, sometimes it will suddenly stop or abnormal operation.
Some components on the circuit board appear overheating phenomenon, and even burnt odor, may affect the performance and stability of the winding machine.
The indicator lights on the circuit board are abnormal, such as not lighting up, blinking with abnormal frequency or displaying wrong color.
Cause analysis:
Components on the circuit board such as capacitors, resistors, inductors, etc. may be damaged due to over-voltage, over-current, overheating or long-term use.
Disconnection, short circuit or corrosion of the printed circuit of the circuit board may be caused by moisture, dust, chemical corrosion or physical damage.
Loose or desoldered solder joints result in unstable circuit connections, affecting signal transmission and circuit function.
Solution:
Use a multimeter to check whether the parameters of capacitors, resistors, inductors and other components on the circuit board are normal, and for damaged components, replace them according to the specifications and markings of the components.
Carefully check the printed wiring of the circuit board and look for any breaks, shorts, or corrosion. For broken lines, use wires to repair; for short-circuited parts, use insulating materials to isolate or repair damaged lines; for corroded lines, professional circuit board cleaners and restorers can be used.
Check the solder joints, for loose or desoldered solder joints, use the soldering iron to re-weld to ensure that the solder joints are firm and reliable.
Second, the control software failure
1, software crash or crash
Failure phenomenon:
The operating software of the winding machine suddenly stops responding during operation, and the interface is stuck and cannot be operated.
The software automatically shuts down during operation and may pop up error message.
Cause analysis:
The software may have loopholes or compatibility problems, such as incompatibility with operating system updates, or program errors in the development process of the software.
Insufficient resources in the computer system, such as insufficient memory, CPU occupancy is too high, resulting in the software can not run normally.
The software is attacked by virus or malware, which affects its normal function.
Solution:
First try restarting the bobbin winder and control software to see if the problem can be solved. If the problem still exists, check if there is an updated version of the software, download and install new software patches or updates from official channels.
Close other unnecessary programs, free up system resources, increase the computer's memory or optimize CPU performance to improve the environment in which the software runs.
Use antivirus software to scan your computer system to clean out viruses and malware. If the software crashes frequently, contact the software developer to provide error information and operating environment information so that they can repair.
2、Parameter setting fault
Fault phenomenon:
When setting winding parameters (e.g. number of winding turns, winding speed, tension, etc.), the software is unable to save or read the set parameters correctly, resulting in the winding machine failing to work as expected.
The input parameter range does not meet the requirements, and the software is unable to carry out correct parameter checking and limitation, which may lead to abnormal operation of the winding machine.
Cause Analysis:
The parameter setting module of the software may have a code error that prevents the parameters from being processed and stored correctly.
The database of the software or the file for storing parameters is damaged, resulting in the inability to correctly read and save parameters.
The permission settings of the software may be incorrect, restricting users from setting and modifying certain parameters.
Solution:
Contact the software developer to give feedback on the parameter setting problem and wait for the software update to fix it.
Try to use the database repair tool that comes with the software (if available) to repair the file that stores the parameters, or restore the software to its initial state and reset the parameters.
Check the user rights settings to ensure that the user has sufficient permissions for parameter setting operations.
Third, communication failure
1, internal communication failure
Failure phenomenon:
The different modules inside the winding machine cannot communicate normally with each other, for example, the control unit cannot exchange information with the drive unit and the sensor.
Some operations can not be performed normally, because the control unit can not pass the instructions to the corresponding execution module, or can not receive feedback information from the sensor.
Cause analysis:
Disconnection, short circuit, or poor contact in the internal communication lines (e.g., row wires, wires).
The communication protocol is set incorrectly, resulting in different modules not being able to correctly parse the information sent by the other.
The internal communication interface is damaged, which may be due to too much plugging and unplugging, external damage, etc.
Solution:
Check the internal communication lines, use a multimeter to check the through and through situation of the lines, and repair or replace the lines that are broken or short-circuited. For poor contact, re-insert or tighten the connection line.
Check and confirm the settings of the internal communication protocol to ensure that each module uses the same communication protocol, including baud rate, data bits, stop bits, parity bits and other parameters.
For the damaged communication interface, replace it according to the type and specification of the interface to ensure that the interface is connected normally.
2、External communication failure (communication with the host computer or other devices)
Fault phenomenon:
The winding machine is unable to transmit data with the upper computer or other external devices, such as unable to receive control commands from the upper computer, or unable to send the winding data to the upper computer.
External communication is interrupted, resulting in the inability to realize remote control, data monitoring and other functions.
Cause analysis:
Failure of external communication lines (e.g., network cable, serial port cable, USB cable, etc.), including circuit breakage, short circuit, poor contact, etc.
The baud rate, data bits, stop bits and other communication parameters of external communication devices are not set consistently.
The driver of the external device is not installed correctly or is damaged, affecting the communication function.
Solution:
Check the external communication lines, replace the faulty lines, and ensure that the lines are firmly connected and not damaged.
Check and adjust the communication parameters of the communication quartet to ensure that the parameters match. For the driver of the external device, reinstall or update the driver to ensure that it works properly.
Fourth, the operating panel failure
1, key failure
Failure phenomenon:
The keys on the operating panel are out of order, and there is no response when pressed.
The keys are slow to respond and need to be pressed several times to realize the operation.
Cause analysis:
The microswitch under the key is damaged, which may be caused by long-term use or mechanical wear and tear.
There is a short circuit, broken circuit or poor contact on the circuit board of the pushbutton.
The connecting circuit between the pushbutton and the control unit is faulty.
Solution:
For keys with damaged microswitches, open the operation panel and replace the microswitches with the same specifications.
Check the circuit board of the keypad to find the location of short circuit, broken circuit or poor contact, and use a multimeter to troubleshoot and repair the faulty point.
Check the connection lines between the keys and the control unit to ensure that the lines are connected properly, and repair or replace the damaged lines.
2, display failure
Fault phenomenon:
The display screen is black and cannot display any information.
The display shows fuzzy, splash screen or garbled code.
Cause analysis:
Problems with the power supply to the display, may be a power line failure or power module damage.
The wires of the display are loose, damaged or in poor contact.
The driver circuit of the display itself is faulty or the internal components are damaged.
Solution:
Check the power line of the display, use a multimeter to measure the voltage, repair or replace the damaged power line or power module.
Check the wiring of the display, re-plug or replace the damaged wiring.
For the display driver circuit or internal components damaged, contact professional maintenance personnel or equipment suppliers, according to the model and specifications of the display for repair or replacement.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. technical specialists through the page chat tool to seek help.
