What are the common control unit failures and solutions for brushless motor motor automatic needle bearing press-in machine?
Brushless motor motor automatic needle bearing press-in machine common control unit failure and solutions are as follows:
1、Controller failure
Failure performance
Abnormal program operation: The controller of the equipment has a program crash, program loss or program operation chaos, resulting in the press-in machine can not work in accordance with the preset process and parameters, such as press-in speed, pressure and other parameters appear abnormal changes.
Communication failure: the controller and other equipment components (such as sensors, drives, etc.) can not be normal communication between the controller can not receive the sensor feedback signals, or can not send control instructions to the drive, so that the overall operation of the equipment malfunction.
Failure causes
Hardware failure: the controller's internal electronic components, such as chips, capacitors, resistors, etc., appear to be damaged, may be due to aging caused by long-term use, or the power supply voltage instability, static electricity and other factors.
Software problems: the controller's program may have loopholes, errors, or attacked by viruses, malware, or incompatible versions of the program and other reasons leading to abnormal program operation.
Environmental factors: the controller is located in the working environment of too high a temperature, too much humidity, too much dust, etc., may affect its normal operation, resulting in failure.
Solution
Hardware Inspection and Replacement: Use professional testing tools, such as multimeter, oscilloscope, etc., to test the hardware of the controller, determine the damaged components and replace them. If the overall damage of the controller is serious, it is recommended to replace the controller with a new one.
Software repair and update: Check and repair the program of the controller, and clear out the virus or malware. If the problem is with the program version, update to a new, compatible program version in a timely manner. Technical support and program update documentation can be obtained by contacting the equipment manufacturer.
Improve the working environment: Provide a suitable working environment for the controller, install air-conditioning equipment, etc., to keep the ambient temperature and humidity within the normal range, and clean the dust on the surface of the controller on a regular basis to ensure that it dissipates heat well.
2、Drive failure
Failure performance
Motor does not rotate or abnormal speed: the driver cannot drive the brushless motor normally, resulting in the actuator of the needle bearing press-in machine not being able to act, or the motor speed is unstable, sometimes fast and sometimes slow, affecting the precision and efficiency of press-in.
Overheating alarm: The drive becomes overheated during operation, triggering the overheating protection mechanism and causing the equipment to shut down.
Failure causes
Overload operation: During the working process of the press-in machine, the load exceeds the rated load capacity of the drive, and prolonged overload operation leads to overheating and failure of the drive.
Improper parameter setting: The parameters of the driver, such as the number of motor poles, voltage, current, etc. are not set correctly and do not match with the brushless motor, resulting in abnormal motor operation.
Poor heat dissipation: Failure of the heat dissipation fan of the drive, blockage of the heat sink or improper installation position, etc., leading to poor heat dissipation and high temperature of the drive.
Solution
Reasonable adjustment of load: Check the working load of the press-in machine to ensure that it runs within the rated load of the drive. If the load is too high, the process needs to be adjusted or the drive needs to be replaced with a higher power drive.
Reset parameters: According to the actual parameters of the brushless motor, readjust the parameters of the drive to ensure that they match. You can refer to the manuals of the motor and the drive for parameter setting, or consult professional technicians.
Improve the heat dissipation conditions: Check whether the heat dissipation fan is functioning normally, clean up the dust and debris on the heat sink to ensure that the heat dissipation channel is smooth. Adjust the installation position of the drive to ensure that there is enough space around it for heat dissipation.
3、Relay failure
Failure performance
Contact sticking: the contacts of the relay can not be normally disconnected after closing, resulting in the circuit has been in the state of conduction, which may cause the equipment to continue to run, can not be stopped, or cause a short circuit and other problems.
Contact erosion: the contacts of the relay in the frequent on and off process, due to the arc and other reasons lead to contact surface erosion, contact resistance increases, so that the circuit conduction is poor, unstable operation of the equipment.
Failure causes
Excessive current: The current through the relay contacts exceeds its rated current, and the long time high current passage leads to contact heating, sticking and erosion.
Service life expiration: After long time use, the contacts of the relay will be naturally worn and aged, and will be prone to malfunction after reaching the service life.
Abnormal control signal: unstable control signal, too low or too high voltage of the relay may cause the relay to malfunction or fail to operate normally.
Solution
Replacement of relays: For relays with sticky or badly abraded contacts, replace them with new ones in time, and choose relays with appropriate rated current and specifications for replacement.
Control current: Check the current in the circuit to ensure that the current through the relay is within its rated range. Current limiting measures can be added, such as installing suitable fuses or reactors.
Checking the control signal: Use a tool such as a multimeter to check the control signal of the relay to ensure that the signal voltage is stable and normal. Repair or replace the control signal transmission line to ensure the accuracy and stability of signal transmission.
4、Power module failure
Failure performance
Abnormal output voltage: The voltage output from the power supply module is unstable, with high, low or excessive voltage fluctuations, resulting in the control unit and other equipment components not working properly.
No power output: the power supply module has no voltage output at all, and the equipment as a whole is disconnected and cannot start operation.
Failure causes
Power overload: the load carried by the power supply module exceeds its rated power, resulting in overheating of the power supply, abnormal output voltage or even damage.
Component damage: the rectifier diode, filter capacitor, switching tube and other components inside the power supply module are damaged, affecting the normal operation of the power supply.
Input power problem: The unstable voltage, abnormal frequency or harmonic of the input power supply may cause the power supply module not to work normally.
Solution
Adjust the load: Check the load condition carried by the power supply module, distribute the load reasonably and make sure that it does not exceed the rated power of the power supply module. If the load is really too large, consider replacing the power supply module with a higher power.
Repair or replace the power module: Use professional tools to inspect the power module, determine the damaged components and repair or replace them. If the power supply module is severely damaged, it is recommended to directly replace it with a new one.
Stabilize the input power supply: Install voltage regulators, filters and other equipment to process the input power supply to ensure that the voltage and frequency of the input power supply are stable and the harmonic content meets the requirements.
※ If the above ways and means still can't solve the equipment failure, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
