How to conduct fault analysis and troubleshooting for a brushless motor manual dual-station internal winding machine?
The common methods for fault analysis and troubleshooting of a brushless motor manual dual-station internal winding machine are as follows:
I. Mechanical Faults
1. Unsmooth Winding
Fault Analysis: It may be due to the wear of the winding wheel, foreign objects in the wire groove, or improper tension adjustment. Long-term use of the winding wheel will lead to surface wear, affecting the smoothness of winding; if there are foreign objects in the wire groove, it will hinder the normal passage of the wire; if the tension is too high or too low, the wire will get stuck or become loose during the winding process.
Troubleshooting Method: Check the wear condition of the winding wheel and replace it in time if there is wear; clean the foreign objects in the wire groove; readjust the tension device to make the tension appropriate.
2. Abnormal Station Switching
Fault Analysis: It may be that the transmission components of the switching mechanism are damaged, such as worn gears, loose chains, etc., or it may be that the positioning sensor is faulty and cannot accurately identify the position of the station.
Troubleshooting Method: Check the transmission components, replace the worn gears, and adjust the tightness of the chain; check the positioning sensor, clean the surface of the sensor, check whether the connection line is loose, and replace it if it is damaged.
II. Electrical Faults
1. Motor Not Rotating
Fault Analysis: It may be a power supply fault, such as a broken power cord, a loose plug, etc., or the motor itself may be damaged, such as a short circuit or open circuit in the winding, or the controller may be faulty and unable to output the correct control signal.
Troubleshooting Method: Check the power cord and plug to ensure they are properly connected; use a multimeter to check the resistance value of the motor winding to determine whether there is a short circuit or open circuit, and replace the motor if there is a problem; check the input and output signals of the controller, and repair or replace the controller if there is a fault.
2. Unstable Winding Speed
Fault Analysis: It may be due to improper parameter settings of the motor driver, or a fault in the motor encoder, resulting in inaccurate speed feedback, or the motor load may be too large, exceeding its rated load.
Troubleshooting Method: Readjust the parameters of the motor driver, such as acceleration time, deceleration time, speed loop gain, etc.; check the connection line and working status of the encoder, and replace it in time if it is damaged; check the load condition of the winding machine, reduce the load or replace the motor with a larger power.
III. Control System Faults
1. Operation Panel Not Responding
Fault Analysis: It may be that the buttons on the operation panel are damaged, or there is a fault in the communication line between the panel and the controller, or the controller may be frozen or the program may be wrong.
Troubleshooting Method: Check whether the buttons are elastic and whether they are stuck, and replace the buttons if they are damaged; check whether the communication line is loose, broken, or short-circuited, and repair or replace the line; perform a reset operation on the controller. If the problem still cannot be solved, re-download the program or replace the controller.
2. Parameter Settings Cannot Be Saved
Fault Analysis: It may be that the storage chip of the controller is faulty, or the power supply battery has insufficient power, resulting in the loss of stored data.
Troubleshooting Method: Check the working status of the storage chip and replace it if it is damaged; replace the power supply battery to ensure that the controller has a stable power supply to save the parameters.
※ If the equipment fault still cannot be solved through the above methods, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. for help through the chat tool on the page.
