How to fault analyze and troubleshoot a brushless motor motor automatic skimmer?
Brushless motor motor automatic skimmer fault analysis and troubleshooting can be carried out according to the following steps:
First, fault information collection
Operator communication: Communicate with the employees who are operating the skimmer to understand the specific time of the failure, the operating status of the equipment before the failure, and whether there is any abnormal sound, odor, or prompt information. For example, ask the employee if he or she heard an unusual humming sound from the motor or saw an error code appear on the equipment's display before the failure occurred.
Observe the operation: Under the premise of protection, observe the operation process of the skimmer, note whether the equipment moves normally, and whether the material is conveyed and collected smoothly. For example, check whether the conveyor belt runs off, whether the speed of the motor is stable and so on.
Check the appearance of the equipment: check the appearance of the reclaimer whether there is obvious damage, deformation or loose. For example, check whether there are cracks in the frame, whether there are broken electrical lines, and whether the bolts in the connection parts are loose.
Second, fault classification and common cause analysis
1、Electrical faults
Power supply problems: may be a loose power plug, power cord damage, power switch failure or power module burned, resulting in equipment can not be normal power supply. For example, use a multimeter to measure whether the voltage of the power socket is normal, check whether the power plug is inserted tightly and whether the power cord is broken.
Motor Failure: Brushless motors may have short-circuited windings, broken circuits, damaged bearings, jammed rotors, etc., resulting in the motor failing to operate normally. You can determine whether the motor is faulty by measuring the resistance value of the motor winding, checking the temperature and vibration of the motor.
Controller failure: The circuit components inside the controller may be damaged, such as capacitors, resistors, chips, etc., or the control program is wrong, resulting in abnormal operating parameters or the inability to control the equipment normally. You can use professional testing equipment to test the controller, or reload the control program.
Sensor failure: photoelectric sensors, Hall sensors, etc. may be damaged, contaminated or installed position offset and other problems, resulting in the equipment can not accurately detect the location and state of the material. You can clean the sensor's sensing surface, check whether the sensor's installation position is correct, or use the replacement method to determine whether the sensor failure.
2、Mechanical failure
Transmission parts failure: chain, belt, gears and other transmission parts may be worn, broken, loose or jammed and other problems, resulting in a decline in the transmission efficiency of the equipment or can not be normal transmission. You can check the wear and tear of transmission parts, adjust the chain tension or belt tension, and replace the damaged transmission parts.
Mechanical structure failure: Mechanical structure parts such as frame, receiving roller, conveyor belt may be deformed, damaged or loose and other problems, resulting in unstable operation of the equipment or can not work properly. You can check the connection of the mechanical structure parts and repair or replace the damaged parts.
Poor lubrication: The lack of lubrication of all transmission parts and moving parts will lead to increased wear and tear, increased running resistance, and even jamming. You can check whether the lubricant or grease in the lubrication part is sufficient, add or replace the lubricant in time.
3、Software failure
Program error: the control software may have loopholes or errors, resulting in problems with the operating logic of the equipment. You can contact the equipment manufacturer to get a new software version for updating, or debugging and repair of the software.
Parameter setting error: The operator may have mistakenly set the running parameters of the equipment, such as take-up speed, take-up length, tension control, etc., resulting in poor operation of the equipment. You can recheck and set the parameters of the equipment to ensure that the parameters meet the production requirements.
Third, troubleshooting methods
Intuitive inspection method: through observation, listening to the sound, smell, etc., to directly determine whether there is an obvious failure of the equipment. For example, smell the burning odor may indicate that the electrical line or motor has a short-circuit phenomenon; hear abnormal noise may indicate that the mechanical parts are worn or loose.
Replacement method: For some parts that are difficult to determine the cause of the failure, you can use the same specifications of the normal parts to replace, to determine whether the failure is in the part. For example, suspect that the sensor failure, you can use a new sensor to replace the original sensor, and observe whether the equipment to return to normal operation.
Measurement method: the use of multimeters, oscilloscopes and other professional testing equipment, electrical components of the voltage, current, resistance and other parameters to measure, to determine whether the components are working properly. For example, measure the resistance value of the motor winding, if the resistance value is abnormal, it means that the motor may be faulty.
Debugging method: For software failure or parameter setting problems, you can reset the parameters, adjust the program and other ways to debug the equipment to return to normal operation. For example, according to the instruction manual of the equipment, reset the parameters such as receiving speed and receiving length.
Fourth, fault records and summarize
Detailed records: the occurrence of the fault time, phenomena, analysis process, troubleshooting methods and other detailed records, the formation of fault files. This will help the subsequent maintenance and management of the equipment, but also for similar troubleshooting to provide reference.
Summarize experience: Regularly analyze and summarize the fault records to find out the pattern and common causes of equipment failure, and take corresponding preventive measures, such as strengthening the maintenance of equipment, optimizing the operating parameters of the equipment, etc., in order to reduce the occurrence of failures.
※ If you still can not solve the equipment failure through the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
