What are the common electrical failures and solutions for brushless motor motor automatic needle bearing press-in machine?
Brushless motor motor automatic needle bearing press-in machine's electrical system is more complex, common electrical faults and solutions are as follows:
First, power-related failures
1, the equipment can not start
Failure performance: press the start button, the press-in machine does not have any response, the indicator light does not light, the motor does not run.
Fault causes
The power plug is loose, detached or the power cord is damaged, resulting in power supply interruption.
The power switch is damaged and cannot connect the circuit normally.
Fuse is blown, which may be caused by short circuit or overload.
The power module is faulty and cannot provide stable voltage output.
Solution
Check whether the power plug is plugged in properly, whether the power cord is broken or fractured, and replace it promptly if it is damaged.
Use a multimeter to detect the on-off condition of the power switch, if the switch is damaged, replace it.
Check the fuse, if it is blown, first check whether there is a short-circuit point in the circuit, and replace the fuse with the same specification after troubleshooting.
Detect the output voltage of the power module, if the voltage is abnormal, contact a professional to repair or replace the power module.
2、Voltage instability
Failure performance: abnormalities in the operation of the equipment, such as motor speed fast and slow, flashing lights, the display is unstable.
Failure causes
Grid voltage fluctuations, affecting the normal power supply of the equipment.
Failure of the power filter, unable to effectively filter the stray waves and interference signals in the power grid.
The internal components of the power supply module are aging or damaged, resulting in unstable output voltage.
Solution
Install a voltage regulator to ensure that the voltage of the input equipment is stabilized within the specified range.
Check the power supply filter and replace it if it is faulty.
Test and repair the power supply module and replace the aging or damaged components; if it cannot be repaired, replace the power supply module.
Second, the motor drive failure
1, the motor does not rotate
Failure performance: After starting the device, the motor does not have any action, and the press-in operation cannot be carried out.
Fault causes
Motor drive board failure, such as power tube damage, control chip failure, etc., can not provide normal drive signal for the motor.
The motor winding is short-circuited or disconnected, resulting in the motor not working properly.
The connection line between the motor and the driver board is loose, poorly contacted or damaged, and signal transmission is blocked.
The controller does not output the correct drive signal, which may be due to program error or improper parameter setting.
Solution
Test the components on the driver board, use a multimeter to measure the conduction of the power tube, check the working status of the control chip, and replace the damaged components, if any.
Use insulation resistance meter to measure the resistance value of the motor winding to determine whether it is short-circuited or disconnected, if there is any problem, replace the motor.
Check the connection line, re-insert and pull out the loose connector, repair or replace the damaged line.
Check the program and parameter settings of the controller, reset the correct parameters, if there are problems with the program, contact the manufacturer to update or repair.
2、Abnormal motor speed
Failure performance: the motor speed is too fast or too slow, unable to reach the set speed, affecting the precision and efficiency of the press-in.
Failure causes
The motor drive parameters are set incorrectly, such as frequency, voltage and other parameters do not match the motor.
The potentiometer on the drive board is damaged or improperly adjusted, resulting in unstable output signal.
Excessive load on the motor, which may be due to mechanical parts stalling or excessive bearing press-in resistance.
Faulty encoder (if an encoder is used), the feedback speed signal is inaccurate, resulting in the controller not being able to adjust the motor speed correctly.
Solution
Reset the motor drive parameters and adjust them according to the specifications and requirements of the motor.
Check the potentiometer on the drive board, if it is damaged, replace it; if it is not properly adjusted, re-adjust it.
Check the mechanical parts, eliminate the phenomenon of stagnation, and ensure that the bearing is pressed in smoothly; if the bearing is pressed in with too much resistance, check the fit between the bearing and the workpiece.
Detect the working status of the encoder, if there is a fault, replace the encoder.
Third, sensor failure
1、Position sensor failure
Failure performance: the equipment can not accurately detect the position of the bearing, resulting in the press-in position deviation, affecting product quality.
Failure causes
The sensor installation position is shifted, the detection range changes, and the bearing position cannot be accurately detected.
Dust, oil and other contaminants on the sensor surface, affecting the normal detection of the sensor.
The sensor is damaged, such as internal component failure, circuit breakage, etc..
The connecting lines of the sensor are loose, poorly contacted or damaged, and the signal transmission is unstable.
Solution
Re-adjust the installation position of the sensor, use a gauge for accurate measurement and positioning to ensure that the sensor can accurately detect the bearing position.
Clean the surface of the sensor, wipe it with a clean cloth to remove dust and oil.
Use multimeter and other tools to detect the output signal of the sensor, if the sensor is damaged, replace it.
Check the connection line, re-insert the loose connector, repair or replace the damaged line.
2、Pressure sensor failure
Failure performance: The pressure value displayed by the device is inaccurate, and it is impossible to monitor the pressure changes in the bearing press-in process in real time, which may lead to too large or too small press-in force, affecting product quality.
Failure causes
The zero point of the pressure sensor has drifted, and after a long time of use, the zero point of the sensor has changed, resulting in inaccurate measurement values.
Improper selection of the range of the sensor, the actual pressure exceeds the measurement range of the sensor, resulting in increased measurement error.
Damage to the internal components of the sensor, such as strain gauge damage, amplification circuit failure.
The connecting lines of the sensor are loose, poorly contacted or damaged, and the signal transmission is interfered.
Solution
Perform a zero calibration of the pressure sensor, following the sensor's instruction manual.
Check the range of the pressure sensor, and select the appropriate range of the sensor according to the size of the actual indentation force.
Check the internal components of the sensor, if there is damage, replace it; if it is not repairable, replace the whole sensor.
Check the connection line to ensure that the connection is firm, to exclude interference factors; if the line is damaged, replace it.
Fourth, the controller failure
1, the program running error
Failure performance: the device's operating procedures appear chaotic, such as skipping some steps, repeat the implementation of a step, the implementation of the wrong action, etc..
Failure causes
The controller program is subject to interference, such as electromagnetic interference, power fluctuations, etc., resulting in errors in program operation.
There are loopholes or errors in the program itself, and all possible scenarios were not considered during the writing process.
The memory of the controller is faulty, data is lost or read/write error, affecting the normal operation of the program.
The input/output interface of the controller is damaged and cannot receive or send signals normally.
Solution
Add an electromagnetic shielding device, such as a metal shield, to the controller and ground it reliably to reduce the impact of electromagnetic interference; at the same time, ensure that the power supply is stable to avoid power fluctuations affecting the controller.
Contact the equipment manufacturer to obtain a new version of the program for updating, and fix the loopholes and errors in the program.
Test the memory of the controller, if there is any fault, repair or replace the memory module.
Check the input and output interfaces of the controller, if there is damage, replace or repair.
2, communication failure
Failure performance: the device and the host computer or other devices can not communicate normally, data transmission failure, can not realize remote monitoring and control.
Failure causes
The communication line is connected incorrectly or loosely, resulting in signal transmission interruption.
Incorrect communication protocol setting, the communication protocol used by the device and other devices is inconsistent.
Communication module failure, such as serial communication module, Ethernet communication module, etc. are damaged.
Solution
Check the connection of the communication line, re-insert and pull out the loose connector to make sure the connection is correct and firm; if the line is damaged, replace it.
Check the setting of the communication protocol, make sure that the device uses the same communication protocol with other devices, and set it correctly according to the manual of the device.
Check the working status of the communication module, if there is any fault, replace or repair it.
※ If the above ways and means still can't solve the equipment failure, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
