How to troubleshoot and analyze a brushless motor motor automatic rotor into magnet steel machine?
The following are the detailed steps of fault analysis and troubleshooting for brushless motor motor automatic rotor into magnet steel machine:
First, fault analysis steps
1, observe the equipment running status:
l The overall operation of the equipment:
Observe whether the equipment starts normally. If the equipment can not start, it may involve power supply, control circuit, motor and other aspects of the problem.
Check the sound when the equipment is running, for example, abnormal mechanical friction sound may imply the failure of the transmission parts, into the magnetic steel mechanism or bin; abnormal electrical noise may suggest the failure of electrical components.
Observe the running speed and consistency of the equipment. If the equipment runs at an unstable speed or has inconsistent movements, there may be problems with the transmission, control or motor drive.
l Into the magnet operation:
Check whether the magnet installation process is normal or not, whether there are problems such as the magnet can not be adsorbed, the magnet installation position is not accurate, or the magnet is stuck when entering the magnet, etc. These problems may be related to the failure of the magnet entry mechanism, the magnet adsorption device, the positioning system or the control software.
l Check the fault alarm message:
Check the operation panel, human-machine interface or control unit of the equipment to see if there are fault alarm codes or prompt messages. Different alarm codes usually correspond to different types of failure, according to the equipment manual to find the code corresponding to the cause of the failure.
2、Check the equipment components and connections:
l Mechanical parts inspection:
Check the transmission parts, such as whether the conveyor belt runs off, slips or breaks; whether the chain is loose or jumps teeth; whether the gears are worn or poorly meshed.
Check the parts of the magnet entry mechanism, such as whether the magnet entry tool is damaged or worn, and whether the moving parts are stuck.
Check whether the material bin is blocked and whether the discharging mechanism works normally.
l Electrical parts check:
Check whether the electrical wiring is broken or burnt, whether the plug is loose, and whether the terminals are firmly connected.
Check the connection and status of the sensor to ensure that it is firmly installed and the sensor head is not damaged or covered with foreign matter.
Second, troubleshooting methods
1、Mechanical troubleshooting:
l Failure of transmission parts:
Conveyor belt problem:
For conveyor belt slipping, adjust the tensioning device of the conveyor belt to increase the tensioning force; for deflection, adjust the guiding device of the conveyor belt, such as adjusting the position of the rollers and the parallelism of the guide rail.
If the conveyor belt breaks, replace the conveyor belt in time and check whether the conveyor belt drive system is working properly.
Chain problem:
When the chain is loose, adjust the tension through the tensioner; when jumping teeth, check the wear of the chain and sprocket, and replace the chain or sprocket if necessary.
Gear problems:
If the gears are worn, it is necessary to replace the gears and readjust the center distance and meshing status to ensure the transmission ratio is accurate.
l Into the magnet steel mechanism failure:
Failure of the magnet entry tool:
If the entry magnet steel tool is worn or damaged, replace the entry magnet steel tool with a new one to ensure that its size and performance meet the requirements.
Check the connecting parts of the magnetizing steel tool and tighten the loose bolts.
Moving parts are jammed:
Clean the dust, oil and foreign matter on the surface of moving parts (such as guide rails, slides, cylinders or hydraulic cylinders), and add appropriate amount of lubricating oil or grease.
Replace the moving parts that are badly worn, such as worn guide rails or sliders with too large a fit gap.
l Silo failure:
Silo clogging:
Clear the blockage in the silo, check the structure of the silo, such as adjusting the inclination angle of the silo, increase the vibration or mixing device to prevent clogging again.
For silo discharging mechanism failure, check the working status of the driving parts (such as cylinders, electric actuators), ensure that the power supply and air source is normal, repair or replace the damaged parts.
2、Electrical troubleshooting:
l Power supply failure:
Use a multimeter to check whether the power supply voltage is normal, check whether the power switch, fuse, circuit breaker, etc. are working properly, repair or replace the damaged power supply components.
If the voltage of the equipment is not stable, install a voltage regulator or check whether the power line has poor contact or overload.
l Motor failure:
Check whether the three-phase power supply of the motor is normal, use a multimeter to measure the voltage, current and resistance. If the motor does not rotate, check the control signals of the motor, such as drive signal, start signal, etc., through the oscilloscope or PLC program.
If the motor runs abnormally, check the load of the motor to exclude overload condition; check whether there is short circuit or open circuit in the winding of the motor, check the heat dissipation system of the motor, clean up the heat sink and replace the damaged motor bearing.
l Sensor failure:
For position sensors, proximity sensors, counting sensors, etc., check whether their connecting lines are loose or disconnected, use a multimeter to check the conductivity of the lines, repair or replace the damaged lines.
Clean the sensor sensor head to ensure that no dust, oil and other impact on sensing; if the sensor performance decline or failure, recalibration or replacement.
3, control and software troubleshooting:
l PLC and controller failure:
If the PLC program runs abnormally, use the PLC programming software to check the program logic, find out the error and modify it; check whether the input and output modules of the PLC work properly and replace the damaged modules.
For controller crash or failure, try to restart, check its working environment (such as temperature, humidity, electromagnetic interference), update or repair the software; if the controller parameters are lost, re-enter the correct parameters.
l Man-machine interface failure:
For display abnormality, check the power supply and connection line of HMI, update the software or driver; for touch function failure, clean the touch panel or replace the touch panel.
l Communication failure:
Check whether the communication line is damaged, whether the plug is loose, for shielded cable check the grounding of the shield; repair or replace the communication line.
Check the communication protocol settings between the two sides to ensure that the baud rate, data bits, stop bits, check bits and other parameters are the same; to rule out electromagnetic interference, electromagnetic shielding or filtering measures can be used.
Third, comprehensive testing and verification:
After eliminating one or more faults, conduct a comprehensive test of the equipment, run the equipment and observe its operation to ensure the accuracy, speed and stability of the operation into the magnet.
Conduct several tests to observe whether there are other potential faults in the equipment to ensure that the equipment returns to normal operation.
Through the above systematic fault analysis and troubleshooting steps, the common faults of the brushless motor motor automatic rotor into the magnet steel machine can be effectively solved to ensure the stable operation of the equipment. In the process of troubleshooting, the maintenance personnel need to have a variety of knowledge and skills, while using the appropriate detection tools, such as multimeters, oscilloscopes, tool kits and so on.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
