What are the common mechanical failures and solutions for brushless motor motor manual duplex external winding machine?
Brushless motor motor manual duplex external winding machine common mechanical failures and solutions:
First, the transmission components failure
1, belt drive failure
Failure phenomenon:
Belt slippage: the winding machine in the working process, the belt slippage phenomenon, resulting in unstable winding speed, affecting the quality of winding.
Belt wear or fracture: belt surface wear is serious, cracks or even fracture, so that the motor power can not be effectively transmitted, the winding machine stops working.
Cause analysis:
Insufficient belt tension: Improper adjustment of belt tension during long time use or initial installation leads to reduced friction between the belt and the pulley, which makes it easy to slip.
Pulley wear: the surface of the pulley is worn, making poor contact between the belt and the pulley, which also causes slippage.
Overload operation: The winding machine works under more than the designed load, such as winding wire diameter is too thick or winding tension is too large, which will accelerate the belt wear or even lead to breakage.
Belt quality problem: the belt used is of poor quality, the material does not meet the requirements or aging, so that its strength and wear resistance is reduced.
Solution:
For belt slippage, first check and adjust the belt tension. The tension can be increased by adjusting the position of the pulley or the tensioning device so that there is enough friction between the belt and the pulley. If the pulley is worn, the pulley should be replaced.
When the belt is found to be worn or broken, replace the belt in time. When replacing the belt, select the belt with qualified quality and appropriate specifications, and install it in accordance with the correct installation method to ensure that the tension and alignment of the belt are good.
2, gear drive failure
Failure phenomenon:
Gear wear: gear teeth wear, resulting in a decline in transmission accuracy, the winding process will produce vibration and noise, affecting the accuracy of the winding position.
Broken teeth: the teeth of the gear partially broken, so that the transmission is interrupted, the winding machine can not work properly.
Poor gear meshing: the meshing clearance between gears is too large or too small, resulting in unstable transmission and jamming.
Cause analysis:
Long-term use and friction: after a long time of operation, the friction between the gear teeth will lead to wear.
Overload or impact: during the starting and stopping process of the winding machine, if there is a large impact force, or a sudden increase in the load of the winding machine, it may lead to tooth breakage.
Poor lubrication: Lack of adequate lubrication or deterioration of grease will increase friction between gears, accelerating wear and possibly leading to failure.
Problems with installation accuracy: Gears installed with inaccurate center distance, non-parallel axes, and other problems can lead to poor meshing.
Solution:
For slightly worn gears, the transmission can be improved by adjusting the mesh clearance. If the wear is severe or the teeth are broken, the gears must be replaced. After replacing the gears, check and adjust the installation accuracy of the gears to ensure good meshing.
Ensure that the gears are well lubricated, check and add grease regularly according to equipment requirements. If the grease deteriorates, clean and replace it with new grease in time.
Second, winding parts failure
1, bobbin failure
Failure phenomenon:
Bobbin jamming: the bobbin suddenly stops during the rotation process, which prevents it from releasing the wire normally and leads to interruption of the winding.
Spool jumping: the spool in the rotation of the obvious jumping, so that the release is not smooth, affecting the quality of winding.
Cause analysis:
Damaged bearings: The bearings at both ends of the bobbin are worn or damaged, causing the bobbin to rotate inflexibly and appear to be stuck or jumping.
Deformation of bobbin: The bobbin may be deformed due to external impact, overload or prolonged use, making it unable to rotate normally.
Problems with the fit between the bobbin and the bracket: the clearance between the bobbin and the bracket is too small or too large, or there are foreign objects entering, which will affect the normal rotation of the bobbin.
Solution:
Check the bearings at both ends of the bobbin and replace them in time if they are damaged. When replacing the bearings, pay attention to choosing the right model and make sure it is installed correctly.
For deformed spools, decide whether it can be repaired according to the degree of deformation. If the deformation is small, it can be restored to normal by straightening; if the deformation is serious, the bobbin needs to be replaced.
Clean up the foreign matter between the bobbin and the bracket, and adjust the fit gap between them so that they can rotate normally.
2, winding head failure
Fault phenomenon:
Inaccurate position of the winding head: during the winding process, the winding head can not accurately wind the wire on the motor stator or rotor, resulting in a shift in the winding position.
Damage to the winding head: the mechanical structure of the winding head, such as the guide pin and pressure device, is damaged, so that the wire can not be wound properly.
Cause analysis:
Failure of positioning device: the positioning mechanism of the winding head is loose, worn or improperly adjusted, which cannot accurately position the winding position.
Mechanical collision: During operation, the bobbin winding head may be subject to collision, resulting in deformation or damage to its mechanical structure.
Long-term use and wear: After a large number of winding operations, the winding head's guide pins, crimping device and other components will be worn out, affecting the winding function.
Solution:
Check the positioning device of the winding head, if it is loose, readjust and tighten it. If the positioning device is worn, replace the worn parts to ensure that the winding head can be accurately positioned.
For damaged winding head mechanical structure, repair or replace it in time. During operation, care should be taken to avoid collision of the winding head.
Third, fixture failure
1, workpiece fixture failure
Failure phenomenon:
Loose fixture: During the winding process, the fixture used to fix the motor stator or rotor becomes loose, resulting in changes in the position of the workpiece and affecting the winding accuracy.
Damage to the fixture: the clamping jaws, grooves and other parts of the fixture are damaged, and the workpiece cannot be fixed properly.
Cause analysis:
Loose fastening bolts: The fixture is fixed by bolts, and prolonged use or vibration may cause the bolts to loosen.
Material fatigue: After the fixture has been used for many times, its material may be fatigued, resulting in deformation of the clamping jaws, wear and tear of the card slot and other damage.
Impact: When mounting or dismounting the workpiece, the fixture may be damaged if it is not operated properly or if it is impacted by external forces.
Solution:
Regularly check the fastening bolts of the fixture and tighten them in time if they are found to be loose. You can use anti-loosening washers or thread locking agents to enhance the tightening effect of the bolts.
For damaged fixtures, repair or replace them according to the degree of damage. In the selection of fixtures, to consider the material and strength to meet the requirements of the winding work.
Fourth, the mechanical structure is loose or deformed
1, loose or deformed body frame
Failure phenomenon:
Fuselage loosening: the fuselage of the winding machine loosening, shaking in the working process, affecting the stability and precision of the winding.
Fuselage deformation: the fuselage frame is deformed due to external force or long-term uneven force, resulting in a decrease in precision between the two stations, such as the two stations of the winding shaft is not centered.
Cause analysis:
Loose connection bolts: the parts of the machine body are connected by bolts, and the bolts may be loose after long time use.
Cracking of welded parts: For the body of welded structure, poor welding quality or long-term vibration may lead to cracking of welded parts.
Overload or external impact: When the winding machine is subjected to loads exceeding the designed carrying capacity or accidental external impact, it may lead to deformation of the machine body.
Solution:
Check the connecting bolts of the machine body and tighten the loose bolts. For the case of cracked welded parts, the welds need to be repaired, such as re-welding or reinforcement.
If the fuselage is deformed, take appropriate measures according to the degree of deformation. For slight deformation, the accuracy of the fuselage can be restored by adjusting the shims or straightening devices; for severe deformation, it may be necessary to replace part of the fuselage frame.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for help.
