How to Troubleshoot and Troubleshoot Brushless Motor Motor Manual Six Station External Winding Machine?
The following are the general steps and methods of fault analysis and troubleshooting for brushless motor motor automatic rotor loading machine:
First, the basic steps of fault analysis
1, observation and collection of information:
First of all, observe the overall operating status of the equipment, and pay attention to whether there is any abnormal sound during the operation of the equipment, such as the abnormal noise of the motor, the friction sound of the transmission parts, and the impact sound.
Check the operation panel of the equipment, check whether there are alarm messages or fault indicator lights on, these messages can usually suggest the general scope of possible failure.
Observe whether the feeding action of the feeding machine is normal, including the feeding speed and position of the rotor, whether the feeding process is smooth, whether there is material jamming, material leakage and other phenomena.
2, to determine the failure phenomenon and scope:
According to the observed situation, determine the specific failure phenomenon. For example, if the feeding machine can not start, this may be an electrical failure, control unit failure or mechanical failure, etc.. If the loading position is inaccurate, this may be a mechanical transmission component problem, position sensor failure or control program error, etc.
Classify the fault phenomenon, the initial judgment is a mechanical failure (such as transmission components, feeding mechanism, silo, etc.), electrical failure (such as motors, sensors, control circuits, etc.), software failure (such as program errors, communication problems) or other types of failures, to narrow down the scope of the fault.
Second, mechanical failure analysis and troubleshooting
1, transmission component failure:
Conveyor belt or chain failure:
If the conveyor belt is found to be slipping, it may be due to insufficient conveyor belt tension or severe surface wear. Check the conveyor belt tensioning device, properly adjust the tension, if the wear and tear is serious, you need to replace the conveyor belt.
For chain drive, if the chain is loose or jumping teeth, check the chain tensioner, adjust the tension; if the chain is worn or damaged links, need to repair or replace the chain.
2、Feeding mechanism failure:
Feeding claw or suction cup can't grab the rotor normally, check whether the feeding claw is worn, deformed or damaged, if so, replace the feeding claw; for the suction cup, check whether its suction is enough, if there is leakage or damage should be repaired or replaced in time.
When the moving parts of the feeding mechanism are stuck, clean up the foreign matter around the moving parts, add lubricant, check whether the parts fit with the gap is appropriate, if the gap is too large due to wear and tear, the corresponding parts need to be replaced.
3、Bin failure:
When the silo is clogged, stop the equipment first, manually clean up the clogged rotor, can optimize the silo structure (such as adjusting the silo tilt angle, increase the channeling device) to prevent clogging again.
If the silo vibrator does not work, check the power connection of the vibrator, whether the motor is damaged, repair or replace the vibrator motor, and ensure that the vibrator is firmly installed, the vibration frequency and amplitude to meet the requirements.
Third, electrical failure analysis and troubleshooting
1, motor failure:
Check whether the brushless motor starts and runs normally. Use a multimeter to measure whether the power supply voltage of the motor is normal, if the voltage is abnormal, check the power line, switch and fuse.
If the motor does not rotate, check whether the motor winding is normal or not, use insulation resistance meter to test the insulation resistance and determine whether there is a short circuit or broken circuit; for abnormal motor operation (e.g., unstable rotation speed, abnormal noise), check the motor bearings, and replace the bearings if they are worn out seriously, and also check the heat dissipation of the motor and whether the motor driver is working properly.
2、Sensor failure:
For position sensors, counting sensors and proximity sensors, first check whether their connection lines are loose or damaged, use a multimeter to check the line conductivity, repair or replace the problematic lines.
Clean the sensor head and detection surface of the sensor to remove dust, oil and other impurities; calibrate the sensor to ensure that it is accurately detected, and if the sensor is damaged beyond repair, replace it with the same type of sensor.
For counting sensors, check whether its settings and parameters are matched with the rotor characteristics, according to the rotor characteristics to adjust the sensitivity and counting method; check whether the sensor's power supply is normal, for optical sensors to clean the lens, mechanical sensors to check the trigger mechanism.
3, control circuit failure:
Check whether the contacts of the relays and contactors are ablated, sticking or spring failure, use sandpaper to polish the ablated contacts or replace the damaged relays and contactors.
For PLC or other controllers, check whether the input and output signals are normal, use the programming software or monitoring equipment to check the program operation, if the program is wrong, re-download the program or modify the program logic; check whether the control line is broken or short-circuited, use a multimeter to check the line segment by segment, to rule out the failure point.
Fourth, software failure analysis and troubleshooting
1, software compatibility and operation problems:
If the software can not be opened or run in the crash, check the compatibility of the software with the operating system and hardware, try to update the software or operating system, update the hardware driver.
For software with error prompts, check the error log, troubleshoot and modify the code according to the prompted information, optimize the software code for memory overflow and other problems, and check whether there is a situation where resources are not released.
If the software is running lag or response delay, check the use of hardware resources in the software operating environment, use performance analysis tools to locate performance bottlenecks, optimize algorithms or upgrade hardware.
2、Communication failure:
Check whether the communication line is damaged, whether the plug is loose, for shielded cable check whether the shield is well grounded, repair or replace the communication line.
Ensure that the communication protocol settings of both sides of the communication are consistent, including baud rate, data bits, stop bits, parity bits and other parameters, check and modify the communication protocol settings.
Exclude electromagnetic interference, use electromagnetic shielding cover, filter, etc. to reduce the impact of electromagnetic interference on communication.
V. Comprehensive inspection and testing
After eliminating the failure of a component or system, carry out a comprehensive test of the equipment and observe whether the overall operation of the feeding machine is back to normal.
Carry out a number of feeding operations to check whether there are other hidden faults or anomalies appear.
Through the above systematic failure analysis and troubleshooting methods, you can gradually find out the failure points of the brushless motor motor automatic rotor loading machine, and take corresponding measures to repair, so that the equipment to return to normal operation. In practice, the maintenance personnel need to have a certain mechanical, electrical and software knowledge and skills, and at the same time to make good use of a variety of detection tools, such as multimeter, insulation resistance meter, oscilloscope, etc., in order to accurately diagnose the fault.
※ 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.
