What are the common control unit failures and solutions for brushless motor motor automatic load tester?
The common control unit faults and solutions of brushless motor motor automatic load tester are as follows:
1、Controller power supply failure
l Failure phenomenon
No response of the tester: the control unit has no response at all, the screen does not light up, and all functions cannot be operated.
Some functions are abnormal: some control functions can work, but some functions fail, probably due to unstable power supply voltage causing some circuits to work abnormally.
l Failure causes
Power input problem: The external power socket is loose, the power cord is damaged or the power supply voltage is abnormal, resulting in failure to provide stable power supply for the control unit.
Power module failure: the power module inside the control unit is faulty, such as power chip damage, capacitor aging, short circuit, etc., affecting the normal output of power supply.
l Solution
Check the external power supply: check whether the power socket is energized, whether the power cord is firmly connected, use a multimeter to measure whether the power supply voltage is within the normal range, if there is any problem, replace the power cord or repair the power socket.
Repair or replace the power supply module: open the control unit and check whether the components of the power supply module show obvious signs of damage, such as bulging capacitors and burnt chips. Use professional tools to test the power module, if faults are found, repair or replace the damaged components, if not repairable, then replace the entire power module.
2、Control signal transmission failure
l Failure phenomenon
Motor does not move: the control unit sends the command to start the motor, but the motor does not have any response.
Abnormal motor action: The motor runs unstably, jerks, rotates abnormally or fails to run according to the set parameters, which may be due to the interference or loss of control signals during transmission.
l Failure causes
Cable problem: the cable connecting the control unit and the motor driver or sensor is broken, short-circuited or poorly contacted, resulting in the control signal can not be transmitted normally.
Interface damage: the signal output interface of the control unit or the signal input interface of the motor driver is damaged due to frequent plugging and unplugging, static electricity and other reasons, affecting signal transmission.
Electromagnetic interference: Strong electromagnetic interference sources in the test environment, such as frequency converters, welding machines, etc., interfere with the control signals, making the signals distorted or lost.
l Solution
Check the cable: carefully check the signal transmission cable to see if it is broken, fractured or loose joints. For the problematic cables, replace or repair them; for the loose connectors, re-insert and make sure that they are firmly connected.
Repair or replace the interface: Use professional tools to check whether the pins of the interface are bent, broken or oxidized, and if damaged, repair or replace the interface.
Anti-interference measures: adopt shielding measures for signal cables, such as using shielded wires, and ground the shield reliably. Set up electromagnetic shielding devices around the control unit and motor drive to reduce the impact of electromagnetic interference. You can also add filters in the control signal transmission line to filter out the interference signal.
3, control program failure
l Failure phenomenon
Chaotic test process: During the test process, the test steps are not carried out in accordance with the preset program, and there are skipped steps, repeated steps or incorrect test items are executed.
Abnormal parameter setting: the test parameters cannot be set or saved correctly, and the parameters are automatically changed or lost in the test process, resulting in inaccurate test results.
l Failure causes
Program error: the control program itself has loopholes, errors or incompatible versions and other problems, affecting the normal operation of the tester.
Storage Problems: Failure of the storage chip of the control unit or damage to the storage media, resulting in program data or test parameters not being stored or read correctly.
Human misoperation: When setting parameters or running the program, the operator mistakenly inputs wrong instructions or carries out inappropriate operations, resulting in program abnormalities.
l Solution
Update or repair the program: Contact the manufacturer of the tester to obtain a new version of the control program or a patch to repair the program vulnerability, and update or repair the program according to the operation instructions.
Check the storage device: Use professional software to test the storage chip of the control unit to see if there are bad blocks or data errors. If there is any problem, try to format or repair operation on the storage device, if it cannot be repaired, then replace the storage chip.
Restore the default settings: After eliminating the program and storage problems, try to restore the parameters of the test machine to the default settings, re-parameterization and testing, and at the same time strengthen the training of operators, standardize the operating procedures to avoid misuse.
4、Driver module failure
l Fault phenomenon
The motor cannot be driven: the control unit sends out a drive signal, but the drive module is unable to convert the signal into the electrical energy required by the motor, resulting in the motor cannot run.
Motor drive abnormality: abnormal sound, vibration or overheating phenomenon occurs during the operation of the motor, which may be due to the unstable voltage, current or abnormal waveform output from the drive module.
l Failure causes
Damage to power devices: The power transistors, IGBTs and other power devices in the driver module are damaged due to overcurrent, overvoltage, overheating, etc., and the drive current of the motor can not be properly controlled.
Driver circuit failure: the driver module internal driver circuit failure, such as driver chip damage, capacitance and resistance failure, short circuit, etc., affecting the transmission and amplification of the drive signal.
Heat dissipation problem: the driver module generates a lot of heat in the working process, if the heat dissipation is poor, it will lead to high temperature of the power device, performance degradation or even damage.
l Solution
Replacement of power devices: use professional instruments to test the performance of power devices, such as found damaged, choose the same type, the same specifications of the power device to replace, and ensure that the welding quality is good.
Repair the drive circuit: Check all the drive circuits, find the faulty components and replace or repair them. You can use an oscilloscope and other tools to detect the waveform and amplitude of the drive signal to determine whether the circuit is working properly.
Improve the heat dissipation conditions: Clean the dust on the heat sink of the driver module and make sure that the heat dissipation fan operates normally. If the heat sink is aging or poor heat dissipation, you can consider replacing the heat sink or increase the cooling fan to improve the cooling efficiency.
※ 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.
