How to troubleshoot and troubleshoot a brushless motor motor manual six station external winding machine?
The following are the detailed steps for fault analysis and troubleshooting of a fully automatic rotor-in-axis machine for brushless motor motors:
First, the basic steps of fault analysis
1, collect information:
First of all, observe the overall operating status of the equipment, including whether the equipment starts normally, whether there is abnormal sound when running (such as abnormal noise of the motor, friction sound of transmission components, impact sound, etc.), and whether the operating speed of the equipment is normal.
Check the operation panel and display screen of the equipment to check whether there are fault alarm messages, error codes or indicator lights lit abnormally, which usually provide important clues for fault analysis.
Check the quality and efficiency of the shaft entry, observe whether the position of the rotor into the shaft is accurate, whether the shaft entry process is smooth, whether there is any jammed shaft, shaft leakage or incomplete shaft entry and other issues.
2、Classify the type of fault:
Based on the information collected, the faults are initially categorized into mechanical faults, electrical faults, software faults and sensor faults. For example, if the device does not start and there is no electrical alarm information, it may be a mechanical stall or transmission failure; if there is an error code, it may be an electrical or software problem; inaccurate position into the shaft may involve the sensor or control software problems.
Second, mechanical failure analysis and troubleshooting
1, transmission component failure:
Conveyor belt and chain failure:
Conveyor belt slipping or run off:
If the conveyor belt slipping, first check the conveyor belt tensioning device to see if the tension is sufficient, by adjusting the tension wheel or tension screw to increase the tension.
For conveyor belt deviation, check whether the guiding device of the conveyor belt, such as rollers and guide rails are installed correctly, and adjust the position of the rollers or the parallelism of the guide rails if necessary.
Loose chain or jumping teeth:
When the chain is loose, adjust the chain tensioner to ensure that the chain has the proper tension; for the problem of skipping teeth, check the wear of the sprocket and chain, if the wear is serious, you need to replace the sprocket or chain.
Failure of shaft entry mechanism:
The shaft entry tool is worn or damaged:
Check the wear of the shaft entry tools (e.g. press fitting head, fixture, etc.); for seriously worn shaft entry tools, replace them in time to ensure that they can accurately enter the shaft.
Check whether the connecting parts of the shaft entry tool are loose, if loose, use a wrench or other tools to tighten the connecting bolts.
Stuck moving parts:
Check the moving parts such as guide rails, sliders, cylinders or hydraulic cylinders of the shaft-entry mechanism, clean the dust, oil and foreign matter on their surfaces, add appropriate amount of lubricating oil or grease to ensure their smooth operation.
Check the fit gap of moving parts, if the gap is too large due to wear and tear, it will cause stalling and need to replace the corresponding parts.
2, silo failure:
Silo clogging:
Stop the equipment, manually clean up the clogged material in the silo, check whether the structure of the silo is reasonable, such as the silo's tilt angle is appropriate, you can adjust the silo angle appropriately, to avoid the accumulation of materials.
For the vibration device of the silo, check whether the vibration motor is working properly, whether the vibration frequency and amplitude to meet the requirements of the damaged vibration motor for repair or replacement.
Silo discharging mechanism failure:
Check the silo discharge gate or discharge device to see if it can be opened and closed properly, for electric or pneumatic discharge mechanism, check whether the driving elements (such as cylinders, electric actuators) is working properly, to ensure that the power supply and gas supply is normal.
Third, electrical failure analysis and troubleshooting
1, motor failure:
The motor does not start:
Check the power supply of the motor, use a multimeter to measure the three-phase voltage of the motor to ensure that the voltage is normal; if the voltage is abnormal, check the power cord, switch and fuse to eliminate power supply failure.
Check the control signal of the motor, see whether the input signal of the motor driver is normal, such as speed control signal, start signal, etc., you can use an oscilloscope or multimeter to measure.
The motor runs abnormally:
If the motor speed is abnormal, check the parameter settings of the motor driver to ensure that they are set correctly, including speed, torque and other parameters; at the same time, check the load of the motor, if the load is too large, it is necessary to rule out the problem of the load.
For abnormal motor heat, check the motor cooling system, clean the motor's heat sink and vents to ensure good heat dissipation; check whether the motor bearing is damaged, if damaged, the bearing should be replaced.
2、Sensor failure:
Position sensor failure:
Check whether the connection line of the position sensor is loose or broken, use a multimeter to check the conductivity of the line, repair or replace the damaged line.
Clean the sensor's sensing head and the detected surface to prevent dust, oil, etc. from affecting the sensor's sensing accuracy; if the sensor itself is damaged, replace the sensor with the same type and recalibrate.
Other sensor failures (e.g., proximity sensors, pressure sensors):
For proximity sensors, check whether its sensing distance is appropriate, you can optimize the sensing distance by adjusting the location of the sensor or parameter settings; for pressure sensors, check whether its pressure measurement is accurate, calibrate its pressure measurement range.
3, control circuit failure:
Relay and contactor failure:
Check whether the contacts of the relays and contactors are ablated and sticking, use sandpaper to polish the ablated contacts or replace the damaged relays and contactors; check whether their coils are working properly, and if the coils are damaged, they need to be replaced.
Check whether the wiring terminals of the control circuit are loose, make sure the circuit is firmly connected.
Controller failure:
For PLC or other controllers, use programming software or monitoring tools to check the operation of the program to see if there is any program error or logic error, make program modification and debugging.
Check the input and output signals of the controller to confirm whether it is normal to receive and send signals, for abnormal signals, check the relevant lines and external equipment.
Fourth, software failure analysis and troubleshooting
1、Software running error:
The software cannot start or crashes:
Check the running environment of the software, including whether the operating system and hardware requirements are met, update the software to a new version or update the operating system.
Check the error log of the software, debug the code according to the error information, find out the reasons leading to the crash, such as memory overflow, unprocessed exceptions, etc., and modify the errors in the code.
The software is running abnormally:
Check the parameter settings of the software to ensure that the parameters such as entry axis speed, pressure, position, etc. are set correctly; if the software response is slow, check the software's running resource consumption, optimize the algorithms or code, and reduce unnecessary resource consumption.
2、Communication failure:
Communication interruption:
Check whether the communication line is damaged, whether the plug is loose, for shielded cable, make sure that the shield is well grounded; repair or replace the damaged communication line.
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, to ensure the consistency of the communication protocol.
Exclude electromagnetic interference around the equipment, electromagnetic shielding measures can be used or adjust the location of the equipment to reduce the impact of interference sources on communication.
V. Comprehensive testing and verification:
After eliminating a certain fault, conduct a comprehensive test of the equipment, run the equipment and observe whether the overall performance of the shafting machine is back to normal, including the accuracy, speed and quality of shafting.
Conduct several tests to ensure that the equipment can operate stably under different working conditions, and check whether there are any other potential failure hazards.
Through the above systematic fault analysis and troubleshooting steps, the common faults of the fully automatic rotor shafting machine for brushless motor motors can be effectively solved to ensure the normal operation of the equipment. In the troubleshooting process, maintenance personnel are required to have a certain degree of mechanical, electrical and software knowledge, and at the same time good use of a variety of detection tools, such as multimeter, oscilloscope, multimeter, etc..
※ 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.
