What are the common electrical faults and solutions for the manual six-station internal winding machine of brushless motors?
The common electrical faults and solutions for the manual six-station internal winding machine of brushless motors are as follows:
1. The motor does not rotate.
Reasons for the fault:
Power supply problem: The power plug is not properly inserted, the power cord is damaged, the power switch is faulty, or the power supply voltage is too low.
Motor fault: The motor winding is short-circuited, open-circuited, or the motor bearing is damaged, causing the motor to fail to operate normally.
Controller fault: There is a fault in the internal circuit of the controller, such as a damaged chip, a faulty capacitor, etc., which prevents it from outputting the correct control signal.
Connecting wire problem: The connecting wire between the motor and the controller is loose, open-circuited, or has poor contact.
Solutions:
Check the power supply: Ensure that the power plug is firmly inserted, check whether the power cord is damaged, and if so, replace the power cord; check whether the power switch is working properly, and measure whether the power supply voltage is within the rated range. If the voltage is too low, check the power supply system.
Check the motor: Use a multimeter to measure the resistance value of the motor winding to determine whether there is a short-circuit or open-circuit situation. If there is a problem, replace the motor winding; check whether the motor bearing is flexible. If there is any jamming or damage, replace the bearing.
Check the controller: Observe whether there are obvious signs of component damage in the controller, such as a bulging capacitor; use professional tools to detect whether the output signal of the controller is normal. If the controller is faulty, repair or replace it.
Check the connecting wire: Carefully check the connecting wire between the motor and the controller to ensure that it is firmly connected and there is no looseness or open-circuit. If there is a problem, repair or replace the connecting wire in a timely manner.
2. The winding speed is unstable.
Reasons for the fault:
Motor speed regulation system fault: The speed regulation potentiometer is damaged, or the electronic components in the speed regulation circuit are aged or damaged, resulting in inaccurate motor speed regulation.
Load change: During the winding process, due to factors such as wire diameter and material, the load is uneven, affecting the winding speed.
Improper motor parameter setting: The parameters of the motor set in the controller do not match the actual motor, such as incorrect settings of parameters like the number of motor poles and the rated speed.
Solutions:
Check the speed regulation system: Check whether the speed regulation potentiometer can adjust the resistance value normally, and if there is any abnormality, replace it; check the electronic components in the speed regulation circuit, such as transistors and diodes, and replace them if they are damaged.
Adjust the load: Try to ensure the uniformity of the load during the winding process, select an appropriate wire diameter and material, and avoid affecting the winding speed due to sudden changes in the load.
Reset the motor parameters: According to the actual parameters of the motor, make correct settings in the controller to ensure that the motor operates under appropriate parameters.
3. The counter is inaccurate.
Reasons for the fault:
Sensor fault: The counting sensor is damaged, the installation position of the sensor is inappropriate, or the sensitivity setting of the sensor is unreasonable, resulting in inaccurate counting.
Counter circuit fault: There is a fault in the internal circuit of the counter, such as a chip fault or capacitor leakage, affecting the accuracy of counting.
Interference problem: Electromagnetic interference in the electrical system or power supply ripple interference causes the counter to miscount.
Solutions:
Check the sensor: Check whether the sensor can work normally. You can block the sensor to detect whether it can output a signal normally. If it is damaged, replace it; adjust the installation position of the sensor to ensure that it can accurately detect the winding action; adjust the sensitivity of the sensor so that it can stably detect the winding signal.
Check the counter circuit: Check whether there are signs of component damage in the counter circuit, and use professional tools to detect the working status of the counter chip. If there is a fault, repair or replace the chip.
Eliminate interference: Shield the electrical system to reduce electromagnetic interference; add a filter capacitor to the power supply circuit to reduce the power supply ripple and eliminate the influence of interference on the counter.
4. The control button fails.
Reasons for the fault:
Button itself fault: The contacts inside the button are oxidized, worn, or the spring fails, causing the button to fail to conduct or reset normally.
Button connecting wire fault: The connecting wire between the button and the controller is loose, open-circuited, or short-circuited, preventing the control signal from being transmitted normally.
Controller input interface fault: The input interface of the controller is damaged and cannot receive the control signal of the button.
Solutions:
Check the button: Disassemble the button, clean the oxidation layer on the surface of the contacts, check the status of the contacts and the spring. If there is any wear or failure, replace the button.
Check the connecting wire: Check the connecting wire between the button and the controller to ensure good connection and no looseness, open-circuit, or short-circuit. If there is a problem, repair or replace it in a timely manner.
Check the controller input interface: Use professional tools to detect the working status of the controller input interface. If it is damaged, repair the controller or replace the input interface circuit.
※ If the equipment failure still cannot be solved through the above methods, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for help.
