What are the common sensor failures and their solutions for brushless motor motor automatic lock screw machine?
Brushless motor motor automatic locking screw machine common sensor failure and its solutions are as follows:
First, the screw detection sensor failure
1, false detection
Failure performance: the sensor frequently sends out the wrong screw detection signals, such as obviously no screws are detected but screws, or screws are not detected.
Failure causes
Sensor installation position is not accurate, resulting in detection range deviation.
The sensor surface is covered with dust, oil and other pollutants, affecting its normal detection function.
The sensitivity of the sensor is improperly set, too high or too low will cause false detection.
There is electromagnetic interference in the surrounding environment, which interferes with the signal transmission of the sensor.
Solution
Re-adjust the installation position of the sensor to ensure that it is accurately aligned with the detection area of the screws, which can be tested repeatedly to determine the excellent position.
Clean the surface of the sensor regularly, use a clean, soft cloth dipped in an appropriate amount of detergent to gently wipe to remove contaminants.
Adjust the sensitivity parameters according to the sensor's instruction manual, and find the appropriate sensitivity value through actual testing.
Add shielding devices for the sensor, such as metal shielding, and ground it reliably to reduce the impact of electromagnetic interference.
2, no signal output
Failure performance: the sensor does not output detection signals, resulting in the screw machine can not normally determine the presence or absence of screws.
Fault causes
The power supply line of the sensor is broken or short-circuited, resulting in the sensor can not work properly.
The internal components of the sensor are damaged, such as chips, capacitors and other faults.
The connection line between the sensor and the controller is loose, broken or in poor contact.
Solution
Use a multimeter to check the power supply line of the sensor, find the broken or short-circuit point, repair or replace the damaged line.
If you suspect that the internal components of the sensor are damaged, you can use professional testing equipment to test the sensor, confirm the fault and then replace the sensor with the same model.
Check the connection line between the sensor and the controller, re-plug and unplug the connection plug to ensure a firm connection. If the line is broken, replace the line in time.
Second, the position sensor failure
1, inaccurate position detection
Failure performance: the screw machine actuators (such as batch nozzle) can not accurately reach the predetermined locking position, resulting in screw tightening position deviation.
Failure causes
The installation position of the position sensor is offset, making the detected position information inconsistent with the actual position.
The accuracy of the sensor decreases, possibly due to aging of the components due to long-term use or being affected by mechanical vibration.
Environmental temperature, humidity and other factors vary greatly, affecting the performance of the sensor.
Solution
Re-calibrate the installation position of the position sensor and use a high-precision measuring tool for positioning to ensure its accurate installation.
For sensors with decreased accuracy, try calibration operation. If the calibration still fails to meet the requirements, replace the sensor with a new one.
Improve the working environment, control temperature and humidity in the sensor's normal operating range, you can install air conditioning and other equipment.
2, signal loss
Failure performance: During the operation of the screw machine, the signal of the position sensor is suddenly lost, resulting in the loss of position control of the actuator.
Failure causes
The signal transmission line of the sensor is damaged by external pulling and squeezing.
The interface of the sensor is loose, resulting in signal transmission interruption.
The sensor is subject to strong electromagnetic interference, which prevents the signal from being transmitted normally.
Solution
Check the signal transmission line, if found damaged, replace the line in time. At the same time, make reasonable wiring and fixing of the line to avoid being affected by external force.
Check the interface of the sensor to ensure that it is connected tightly. Tools such as screwdrivers can be used to tighten the screws at the interface to prevent loosening.
Take anti-interference measures, such as using shielded wires to transmit signals, install electromagnetic shielding devices near the sensor, and ground it.
Third, the torque sensor failure
1, torque measurement inaccuracy
Failure performance: The torque value displayed by the torque sensor and the actual tightening of the screw torque value there is a large deviation, affecting the screwing quality.
Failure causes
The torque sensor is not properly calibrated, resulting in inaccurate measurement results.
The elastic element of the sensor is fatigued and deformed, affecting the torque measurement accuracy.
When installing the torque sensor, its connection with the transmission components is not concentric, generating additional stress and affecting the measurement results.
The Solution
Use standard torque calibration equipment to calibrate the torque sensor and follow the calibration procedure to ensure measurement accuracy.
If the fatigue deformation of the elastic element is serious, replace the torque sensor with a new one.
Reinstall the torque sensor, use professional tools to adjust its concentricity with the transmission components to ensure installation accuracy.
2, no torque signal output
Failure performance: the torque sensor does not have any signal output, the screw machine can not get the information of tightening torque.
Failure causes
The power supply of the torque sensor is faulty and cannot provide normal working voltage for the sensor.
The internal circuitry of the sensor is damaged, such as welding points off, chip failure, etc..
The signal transmission line is broken or short-circuited, resulting in the signal not being transmitted to the controller.
Solution
Check the power supply of the torque sensor, use a multimeter to measure whether the power supply voltage is normal. If the power supply is faulty, repair or replace the power supply.
For internal circuit damage, need professional maintenance personnel to overhaul, if can not be repaired then replace the sensor.
Check the signal transmission line, find the broken or short circuit point, repair or replace the damaged line.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
