What are the common mechanical failures and solutions for brushless motor motor automatic lock screw machine?
Brushless motor motor automatic locking screw machine common mechanical failures and solutions are as follows:
First, the screw feeding system failure
1, screw card material
l Failure performance: screws in the feed track, vibration plate or feed tube stuck, can not be properly transported to the batch nozzle position, resulting in the interruption of the locking screw action.
l Failure causes
Screw specifications are inconsistent, there are size deviations, such as head size, screw length differences.
There are debris and dust accumulation in the feeding track or feeding tube, which affect the smooth movement of the screws.
The vibration frequency or amplitude of the vibration disk is not suitable, and it can not drive the screw forward effectively.
The bending angle of the feeding tube is too large or the diameter of the tube does not match the screw.
l Solution
Strictly screen the screws to ensure that their specifications meet the requirements of the equipment, and remove the unqualified screws.
Regularly clean the feeding track and feeding tube, use compressed air to blow away the debris, and use detergent to clean if necessary.
Adjust the vibration frequency and amplitude of the vibrating disk, find the excellent parameters through the test, so that the screws can be transported smoothly.
Check the installation of the feeding tube to avoid excessive bending, according to the size of the screws to replace the appropriate diameter of the feeding tube.
2、Screw leakage
l Failure performance: No screws are available for locking after the batch nozzle reaches the locking position, and there is a leakage of locking phenomenon.
l Failure causes
The sensor on the feeding track fails to detect the position of the screws accurately, resulting in abnormal feeding action.
The mechanical parts of the feeding mechanism are worn out, such as feeding slider, push rod, etc., affecting the accuracy of feeding.
Uneven distribution of screws in the vibration disk, some areas have too few screws, resulting in failure to supply in time.
Insufficient feeding air pressure (in case of pneumatic feeding method).
l Solution
Detect and repair or replace the faulty sensor to ensure that it can work properly.
Check the mechanical parts of the feeding mechanism, replace the parts that are badly worn and lubricate them appropriately.
Adjust the parameters of the vibrating disk to make the screw distribution more uniform, or manually assist in adjusting the screw distribution.
Check the air pressure system to ensure that the feeding air pressure reaches the specified value, if there is any air leakage timely repair.
Second, locking actuator failure
1, batch mouth wear or damage
l Failure performance: The head of the screw is twisted by the batch nozzle, and can not be tightened normally, or the batch nozzle can not accurately set the head of the screw.
l Reason
The head of the batch nozzle is worn out due to long time use, and the edge of the batch nozzle becomes blunt.
The material of the nozzle is not of good quality and is easy to wear out.
Too much impact during the locking process, so that the batch nozzle deformation.
l Solution
Regularly check the wear of the batch nozzle and replace it with a new one when it is worn to a certain extent.
Choose good quality and high hardness nozzle material to improve the service life of the nozzle.
Adjust the locking parameters to avoid excessive impact, such as reducing the locking speed, adjusting the torque.
2, locking torque instability
l Failure performance: the degree of screw tightening is inconsistent, some too loose, some too tight, affecting product quality.
l Failure causes
The control parameters of the brushless motor are not set accurately, resulting in unstable output torque.
The transmission parts (such as gears, couplings, etc.) are worn or loose, affecting the transmission of torque.
Poor matching accuracy of screws and screw holes, resulting in large changes in resistance during locking.
Poor contact between the batch nozzle and the screw head, part of the torque is lost.
l Solution
Re-calibrate the control parameters of the brushless motor to ensure stable torque output, which can be adjusted by a professional torque tester.
Check the transmission parts, replace the worn parts, tighten the loose connection parts and lubricate them appropriately.
Improve the machining precision of screws and screw holes to ensure a good fit.
Adjust the position and angle of the batch nozzle to ensure that it is in full contact with the screw head.
Third, the mechanical structure is loose or deformed
1, the overall vibration of the equipment is too large
l Failure performance: In the process of locking screw machine operation, the overall vibration of the equipment is obvious, affecting the locking precision, and may even lead to damage to other components.
l Failure causes
The installation foundation of the equipment is not solid, and the ground bolts are loose.
The fastening screws of the internal mechanical parts are loose, such as the fixing screws of the motor and transmission mechanism.
Insufficient lubrication of moving parts (e.g. screws, guide rails, etc.) and increased friction.
Poor dynamic balance of the brushless motor.
l Solution
Check the installation foundation of the equipment, tighten the ground bolts and reinforce the foundation if necessary.
Check all the fastening screws inside the equipment and tighten the loose screws one by one.
Regularly lubricate the moving parts and add suitable lubricants according to the requirements of the equipment.
Carry out dynamic balance test and adjustment for the brushless motor, and can contact the motor manufacturer for professional treatment.
2、Wear of guide rail slider
l Failure performance: The actuator is stuck and not smooth when moving on the guide rail, resulting in inaccurate locking position.
l Cause
Wear on the surface of guide rail and slider due to long time use.
The working environment is dusty, and the dust enters between the guide rail and the slider, aggravating the wear.
Insufficient lubrication, so that the friction between the guide rail and the slider increases.
l Solution
Check the wear and tear of the guide rail and slider, light wear can be repaired by grinding, serious wear and tear need to replace the guide rail and slider.
Improve the working environment, install dust cover and other protective devices to reduce the entry of dust.
Regularly lubricate the guide rail and slide to ensure smooth movement.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Ltd. through the page chat tool to seek help.
