What are the common sensor failures and their solutions for brushless motor motor automatic stator press end plate machine?
Brushless motor motor automatic stator press end plate machine common sensor failure and its solution are as follows:
1、Pressure sensor failure
Failure phenomenon
Abnormal pressure display: the pressure value displayed by the pressure sensor does not match with the actual pressure, and the pressure value may be high, low or fluctuating, resulting in the inability to accurately control the pressure of the end plate.
Pressure control failure: the equipment cannot carry out normal pressure adjustment according to the set pressure value, and the pressure may be too high or too low, which affects the pressing quality of the end plate and may even damage the equipment or workpiece.
Failure causes
Sensor damage: Long-term use, overload, impact and other reasons may lead to damage to the strain gauges and electronic components inside the pressure sensor, making it unable to work normally.
Wiring problems: loose, broken or short-circuited connecting wires of the sensor will lead to poor signal transmission, resulting in abnormal pressure display or control failure.
Electromagnetic interference: Electromagnetic interference in the surrounding environment may affect the signal transmission of the pressure sensor, resulting in inaccurate measurement data.
Solution
Check the sensor: use professional testing equipment to test the pressure sensor, if found damaged, replace the new pressure sensor in time.
Check the line: carefully check the connection line of the sensor to ensure that it is firmly connected and has no breaks or short circuits. If there is any problem, repair or replace the connection line.
Anti-interference processing: shielding of the sensor lines, or away from strong electromagnetic interference sources to reduce the impact of electromagnetic interference on the sensor.
2、Position sensor failure
Failure phenomenon
Inaccurate positioning: The position sensor cannot accurately detect the position of the stator or end plate during feeding and pressing, resulting in the end plate being pressed out of position or the stator and end plate being assembled in an inaccurate position.
Abnormal operation of the equipment: Failure of the position sensor may lead to malfunctioning of the equipment in the process of operation, such as pressing without feeding the material in place, or not being able to carry out the next operation normally after pressing is completed.
Failure causes
Improper installation of the sensor: Inaccurate, loose or offset installation position of the position sensor will make it unable to accurately detect the position of the object.
Sensor damage: the sensor's sensing element is aging, damaged, or the internal circuit is malfunctioning, resulting in its inability to work properly.
Problems with the detection object: The surface of the detected stator or end plate has contaminants such as oil, dust, etc., which affects the sensing effect of the sensor, or the shape or size of the detected object has changed beyond the detection range of the sensor.
Solution
Adjust the installation position: Re-calibrate the installation position of the position sensor to ensure that it is firmly and accurately installed and can correctly detect the position of the object.
Replacement of sensors: Replace the damaged position sensors, choose the right type and specification of sensors to ensure its performance and accuracy.
Cleaning and inspection: Clean the surface of the detected object regularly to ensure that there is no oil, dust and other pollutants. At the same time, check the shape and size of the detection object to see if it meets the requirements, and if there is any problem, adjust or replace it in time.
3、Speed sensor failure
Failure phenomenon
Abnormal speed display: the speed displayed by the speed sensor does not match the actual running speed of the equipment, which may lead to misjudgment of the operating status of the equipment by the operator.
Unstable speed control: during the operation of the equipment, the speed cannot be stabilized at the set value, and there are speed fluctuations or sudden acceleration or deceleration, which affects the production efficiency and product quality.
Failure causes
Sensor wear: The sensing parts of the speed sensor are in long-term contact with the rotating parts, which may be worn out, resulting in inaccurate sensing.
Signal interference: The surrounding electromagnetic environment, electrical noise, etc. may interfere with the signal transmission of the speed sensor, making the measurement results inaccurate.
Installation problems: Inadequate mounting clearance and deviation of the mounting position of the speed sensor may affect its accurate measurement of speed.
Solution
Replacement of worn parts: Check the sensing parts of the speed sensor and replace them promptly if they are worn.
Anti-interference measures: Take anti-interference measures such as shielding and filtering to reduce signal interference. For example, use shielded wires to connect the sensor, add filters to the circuit, etc.
Adjustment of installation: readjust the installation position and installation gap of the speed sensor to ensure that it can accurately measure the operating speed of the equipment.
4, proximity sensor failure
Failure phenomenon
False detection: the proximity sensor will send out a detection signal even when no object is close to it, resulting in faulty operation of the equipment, such as starting or stopping for no reason.
Missing detection: when the object is close, the proximity sensor can not send out the detection signal in time, so that the equipment can not be normal corresponding operation, such as feeding in place can not stop feeding in time.
Failure causes
Sensor sensitivity problem: the sensitivity of the proximity sensor is improperly set, too high or too low will lead to inaccurate detection.
Environmental factors: high ambient temperature, humidity, corrosive gases, etc., may affect the performance of the sensor, resulting in its failure.
Sensor aging: After long-term use, the performance of proximity sensors will gradually decline, resulting in reduced sensitivity, false detection and other problems.
Solution
Adjust the sensitivity: According to the actual situation, re-adjust the sensitivity of the proximity sensor, so that it can accurately detect the proximity and departure of objects.
Improve the environment: Improve the environment where the sensor is located, such as strengthening ventilation and heat dissipation, moisture, corrosion and other measures to ensure that the sensor works under normal environmental conditions.
Replacement of the sensor: If the sensor is aging badly and can not be adjusted and other ways to return to normal, it should be replaced with a new proximity sensor in a timely manner.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. technical specialists through the page chat tool to seek help.
