How to Troubleshoot and Troubleshoot Brushless Motor Motor Manual 4-station External Winding Machine?
Brushless motor motor manual four-station external winding machine fault analysis and troubleshooting:
First, the basic steps of fault analysis
Observe the fault phenomenon
The equipment does not work at all:
Check whether the power indicator light is on, whether there is a display on the operation panel, and whether the equipment has any signs of starting, such as whether there is vibration of the motor and whether there is any abnormal sound.
Check whether the control unit of the winding machine starts normally, and whether there is any error message or fault code display.
Abnormal winding function:
Observe whether the winding speed is stable, whether it is too fast or too slow, and whether it can wind normally according to the set parameters.
Pay attention to whether the winding position is accurate, whether the wire turns are arranged neatly, and whether there are problems such as winding deviation, overlap or leakage.
Check whether the tension during winding is stable, whether there is loose or tight wire, and whether there is wire breakage.
Abnormal operation panel:
Check whether the buttons on the operation panel respond normally, and whether they can input and modify the winding parameters normally, such as the number of turns, speed, tension and other settings.
Observe whether the display is normal display, whether there is a black screen, screen, garbled code or display information error.
Second, the common faults and troubleshooting methods
1, mechanical failure
Transmission components failure
Belt transmission problems (if using belt transmission):
Failure phenomenon:
The belt slips, resulting in unstable winding speed, the winding machine can not work properly.
The belt is badly worn, cracked or even broken, affecting power transmission.
Cause analysis:
Insufficient belt tension, possibly due to long-term use, improper installation or failure of the tension adjustment mechanism.
Pulley wear, resulting in reduced friction with the belt.
Overload operation, so that the belt is subjected to excessive tension.
Ruling out method:
Adjust the belt tension, use the tension adjusting device to tension the belt to a suitable degree to ensure that there is sufficient friction between the belt and the pulley.
Check the wear of the pulleys, and replace the pulleys that are badly worn.
Check the load on the winder to avoid overloading the machine and adjust the winding process or load if necessary.
Gear drive problem (if gear drive is used):
Fault phenomenon:
Gears mesh poorly, producing abnormal vibration and noise, affecting the winding accuracy.
Gear teeth wear, resulting in reduced transmission efficiency and inaccurate winding.
Gear teeth break, interrupting the transmission.
Cause analysis:
Inaccurate center distance or non-parallel axes when gears are installed, resulting in poor meshing.
Frictional wear under long-term use and high loads causes tooth wear or breakage.
Poor lubrication accelerates gear wear.
Ruling out method:
Check the installation accuracy of the gears, adjust the center distance and axis parallelism to ensure good meshing.
For worn or broken gears, replace them according to specifications and check the related load and lubrication.
Ensure lubrication of gears by adding or replacing suitable grease or oil.
Failure of winding components:
Failure phenomenon:
Inaccurate position of the winding head, resulting in shifted winding position and untidy winding.
Damage to the bobbin winding head, such as bending of the guide pin and failure of the crimping device, affecting the bobbin winding operation.
The bobbin is jammed or rotates inflexibly, preventing the winding from proceeding smoothly.
Cause analysis:
The positioning mechanism of the bobbin winding head is loose, worn or improperly adjusted.
The bobbin winding head is damaged by mechanical collision or long-term use.
The bearing of the bobbin is damaged, or there is a foreign object or poor fit between the bobbin and the bracket.
Remedy:
Check the positioning mechanism of the bobbin winding head, readjust and tighten the loose parts, and replace the worn out positioning parts.
Repair or replace damaged bobbin winding head parts, such as replacing the needle guide and wire presser device.
Check the bearings of the bobbin, clean up the foreign matter, adjust the fit between the bobbin and the bracket, and replace the bearings if necessary.
2、Electrical fault
Power failure
Fault phenomenon:
The equipment can not be started, the power indicator does not light up.
Power interruption, flashing and other unstable conditions occur during the operation of the equipment.
Cause analysis:
The power supply is not plugged in properly, the socket is faulty or the power cord is damaged, resulting in the power supply being inaccessible.
The fuse inside the device is blown, possibly due to short circuit, overload or power surge.
The power switch or power module is faulty and cannot supply power normally.
Troubleshooting method:
Check the power plugs and outlets to make sure they are securely connected and replace damaged power cords.
Locate and replace blown fuses and check the circuit for short circuits or overloads.
Check the conductivity of the power switch, use a multimeter to measure the output voltage of the power module, replace the damaged switch or power module.
Motor Failure
Failure phenomenon:
The motor does not rotate or rotates weakly, and cannot drive the winding action.
The motor speed is abnormal, does not match the set speed and cannot be adjusted.
Cause analysis:
The motor winding is short-circuited or disconnected, resulting in the motor not working properly.
The driving circuit of the motor is faulty, such as the driving chip is damaged, the power tube is invalid, and it cannot provide enough current for the motor.
Failure of the connection line between the motor and the drive circuit, including loose, broken or poor contact of the connection line.
Troubleshooting method:
Use a multimeter to check the resistance of the motor winding to determine whether it is short-circuited or disconnected, and repair or replace the motor for the damaged winding.
Check the driver chip, power tube and other components of the drive circuit, replace the damaged components to ensure that the drive circuit works properly.
Check the connection line between the motor and the driving circuit, reconnect or replace the damaged wires.
Sensor failure
Fault phenomenon:
Position sensor failure causes inaccurate winding position, unable to realize precise winding.
Tension sensor failure causes unstable winding tension, affecting the quality of winding.
Failure of the speed sensor makes the winding speed measurement inaccurate or unable to measure.
Counting sensor failure causes winding turns counting error or can not count.
Cause analysis:
Improper position of the sensor probe and the measured object, unable to sense the signal properly.
Damage to the internal components of the sensor, such as photoelectric components, Hall components, strain gauges, etc..
Problems with the connection line between the sensor and the control circuit, including broken, shorted or poor contact.
Troubleshooting method:
Adjust the position of the sensor probe to ensure the proper distance and angle from the object to be measured.
Use a multimeter or oscilloscope to check the electrical parameters of the sensor's internal components and replace the damaged sensor.
Check the connection line of the sensor, repair or replace the faulty line.
3、Control unit failure
Control chip and circuit board failure
Fault phenomenon:
The winding machine can not start normally, the operation panel does not display or display error messages.
Some of the functions of the winding machine fails, such as not being able to control the winding parameter settings, not being able to start the winding program.
Cause analysis:
The control chip is damaged due to abnormal power supply, overheating, static electricity, etc., and cannot work normally.
Components on the circuit board (such as resistors, capacitors, integrated circuits, etc.) are damaged, affecting the function of the circuit.
The solder joints of the circuit board are desoldered, short-circuited or broken, resulting in abnormal signal transmission.
Troubleshooting method:
Check the power supply of the control chip, use an oscilloscope to observe the input and output signals, and replace the damaged chip.
Use a multimeter to check the components on the circuit board, find out the damaged components and replace them.
Check the solder joints of the circuit board, re-solder the desoldered solder joints, and repair the short-circuited or disconnected lines.
Software Failure
Failure phenomenon:
The software crashes or dies, and the operation interface is unresponsive.
The software cannot set or save the winding parameters correctly, resulting in abnormal winding function.
The software displays error messages, such as parameter error, function conflict, etc.
Cause analysis:
The software may have loopholes or compatibility problems, incompatible with the operating system.
The software runs with memory leakage or excessive resource occupation, resulting in system crash.
There is an error in the parameter setting module or storage module of the software.
Troubleshooting method:
Check the update information of the software, update to a new version and solve the compatibility problem.
Close other programs that occupy system resources, check the resource usage of the software, and optimize the software performance.
Contact the software developer to give feedback on the software problem and wait for repairing the parameter or storage module error of the software.
4、Operating panel failure
Key failure
Failure phenomenon:
The keys on the operation panel are out of order, and there is no response when they are pressed.
The keys are slow to respond and need to be pressed several times to realize the operation.
Cause analysis:
The microswitch under the pushbutton is damaged, probably due to long-term use or mechanical wear.
The wiring between the pushbuttons and the control unit is faulty, such as broken circuit, short circuit or poor contact.
Content:
Replace the damaged microswitch and ensure that the mechanical structure of the keypad is normal.
Check the wiring of the keys and repair or replace the faulty wiring to ensure normal signal transmission.
Display screen failure
Fault phenomenon:
The display screen is black and cannot display information.
The display shows fuzzy, splash screen or garbled code.
Cause analysis:
Power supply problem of the display, such as power line failure or power module damage.
The wires of the display are loose, damaged or display driver circuit failure.
Troubleshooting method:
Check the power line of the display and replace the damaged power line or power module.
Check and re-plug the wires of the display, replace the damaged wires or repair the display driver circuit.
※ If the above ways and means still can't solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
