What are the common electrical faults and solutions for brushless motor motor fully automatic rotor into shaft machine?
The following are common electrical faults and corresponding solutions for brushless motor motor automatic rotor shafting machine:
First, the power supply failure
Fault phenomenon:
The equipment can not start: it may be due to the power supply is not connected, the power switch is damaged, or the power line is broken or short-circuited, resulting in the entire rotor into the shaft machine can not be turned on normally.
Unstable power supply voltage: it will cause unstable operation of the equipment, such as motor speed fluctuation, control circuit working abnormally, etc., affecting the accuracy and efficiency of the rotor into the shaft.
Solution:
First check the power switch, use a multimeter to measure the voltage at both ends of the switch, if the switch is normal but there is no voltage output, it may be a power line problem. Check along the power line to find out whether there is a break or short circuit point, for the break point, you can reconnect the wire; for the short circuit, you need to find out the location of the short circuit and repair the insulation.
For unstable power supply voltage, use a voltmeter to monitor the power supply voltage, and check the power supply line for poor contact or excessive load. If the power supply line is normal, it may be the problem of the power supply itself, consider using a voltage regulator to stabilize the voltage, or check whether the power supply internal capacitors, transformers and other components are damaged, such as damage, you need to replace the corresponding parts.
Second, motor failure
Failure phenomenon:
Motor does not rotate: it may be that the motor winding is damaged, the motor driver is faulty, the power supply of the motor is abnormal or the control signal of the motor is lost resulting in the motor can not start.
Motor running abnormality: manifested as motor speed is too high or too low, motor rotation with abnormal sound, motor running overheat, etc. These may be due to the motor drive parameters set incorrectly, the motor load is too large, the motor winding part of the short-circuit or open-circuit, the motor bearings are damaged and other reasons.
Solution:
When the motor does not rotate, first check the power supply of the motor to ensure that the three-phase voltage of the motor is normal. If the power supply is normal, check the input and output signals of the motor driver to confirm whether the driver is working properly, either by checking the status indicator of the driver or using an oscilloscope to view the control signals. If the drive is damaged, the drive will need to be replaced or repaired. For the motor winding, use an insulation resistance meter to measure the insulation resistance of the motor winding, if the insulation resistance is too low, the winding may be short-circuited or damp, and the motor needs to be dried or rewound.
For abnormal motor operation, first check the load of the motor to exclude overloading. Adjust the driving parameters of the motor to ensure that it meets the operating requirements of the equipment. If the motor speed is too high or too low, check the speed setting and feedback signal of the driver and adjust accordingly. For motor rotation abnormal noise, check the motor bearings, if the bearings are badly worn, the bearings should be replaced; for motor overheating, check the cooling system of the motor, clean up the heat sink to ensure good heat dissipation, and at the same time, check whether the motor winding has a local short-circuit or open-circuit, and repair or replace the motor in a timely manner.
Third, sensor failure
Failure phenomenon:
Position sensor failure: it will cause the rotor into the shaft position is not accurate, there may be shaft body insertion position offset, can not detect the rotor position and other issues, affecting the accuracy of the shaft.
Counting sensor failure: it will cause inaccurate counting of the number of rotors into the shaft, and may overcount or omit to count the number of rotors into the shaft, which will affect the accuracy of production data statistics and production process.
Solution:
For position sensor failure, first check whether the connection lines of the sensor are normal, including the power line and signal line, use a multimeter to check the conductivity of the line, and repair or replace the damaged line. Clean the sensor head of the sensor to prevent dust or oil from affecting the sensing accuracy. If the sensor itself is damaged, replace it with a sensor of the same model and recalibrate it to ensure that it can accurately detect the rotor position.
For counting sensor failure, check whether its counting parameters are set correctly, and adjust the sensitivity and counting mode of the sensor according to the characteristics of the rotor into the shaft. At the same time, check the power supply of the sensor to ensure its normal operation. If the sensor is damaged, replace the new counting sensor, and test its counting accuracy.
Fourth, the control circuit failure
Fault phenomenon:
Failure of the relay and contactor in the control circuit: contact ablation and sticking may occur, resulting in the circuit can not be normal on and off, affecting the sequence of action of the equipment, such as not being able to start the action into the shaft, the action into the shaft can not be stopped, and so on.
Failure of the controller: it is manifested in the chaotic action sequence of the equipment, which may be due to the error of the program of the controller, the abnormal input and output signals of the controller, or the controller is dead.
Solution:
For relay and contactor failure, check the status of their contacts, use sandpaper to polish the abraded contacts, if the contacts are badly adhered or the spring fails, the relay or contactor should be replaced. Also check whether its coil is working properly, if the coil is damaged, it also needs to be replaced.
For controller failure, if the controller program is wrong, use programming software to check and modify the controller program to ensure that the logic of the program is correct. Check the input and output signals of the controller to make sure whether the signal transmission is normal or not, for abnormal signals, check the corresponding wiring and external devices. If the controller is dead, try to restart the controller, if it is often dead, consider updating the controller's software or check whether its hardware is faulty, and replace the controller if necessary.
V. Communication failure
Fault phenomenon:
Communication between different parts of the device is interrupted: for example, PLC and drive, HMI and controller can not communicate properly, resulting in the device can not be coordinated, the HMI can not display the status of the device or can not be controlled remotely.
Communication data error: In the communication process, the transmitted data is garbled, lost or wrong, so that the equipment receives wrong commands, which triggers abnormal action or shutdown of the equipment.
Solution:
Check whether the communication line is damaged, whether the plug is loose or has poor contact, and for the shielded line, make sure that the shield is well grounded. For damaged communication lines, repair or replace them.
Check the communication protocol settings of both sides of the communication, including baud rate, data bits, stop bits, parity bits and other parameters are consistent, inconsistent with the modification and adjustment. Exclude electromagnetic interference around the equipment, can use shielding, filtering and other measures, the use of anti-interference ability of the communication cable, to ensure stable and reliable communication.
Through the analysis of these common electrical failures and the implementation of the corresponding solutions, you can effectively maintain the normal operation of the brushless motor motor automatic rotor into the shaft machine, improve the reliability of the equipment and production 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.
