Motor motor automatic screwing machine what are the common control unit faults and solutions?
1, program operation failure
l Fault phenomenon
Program error: the machine's screwing order is chaotic, may appear to skip some screws, repeat screwing or follow the wrong path to operate. This is usually due to errors in the program code, which may be caused by electromagnetic interference, program memory chip damage or software update failure.
Program crash: the machine suddenly stops working during operation, the operation interface is unresponsive, but the power supply and other parts are normal. This may be due to a dead loop, memory overflow, or an abnormal situation that cannot be handled during program operation.
l Solution
For the case of program error, first try to restart the device to see if it can resume normal operation. If the problem persists, check whether there are external electromagnetic interference sources, such as large motors, high-frequency communication equipment, etc., move the equipment away or take shielding measures. If you suspect that the program memory chip is damaged, you can try to rewrite the correct program code or replace the memory chip. Problems occurring after a software update may require reinstalling the previous stable software version or contacting the vendor for a fix patch.
When the program crashes, press and hold the power button to force a shutdown and then reboot. Check the system log or error report after startup to analyze the cause of the crash. If the dead loop or memory overflow is caused by a defect in the program itself, the program needs to be optimized or updated. At the same time, check the memory usage of the device to ensure that the memory resources required to run the program are sufficient.
2. Communication faults
l Failure phenomenon
Unable to communicate with the host computer: the automatic screwing machine can not receive the commands sent by the host computer (such as the production line control system), such as screw tightening parameters, product model information, etc., or can not work status (such as the amount of work completed, fault information, etc.) feedback to the host computer. This may be the communication interface is damaged, communication line failure or communication protocol mismatch.
Internal communication failure: different modules within the machine (such as between the control unit and motor driver, sensors) can not communicate properly with each other, resulting in information can not be transmitted, such as sensor data can not be transmitted to the control unit, affecting the judgment of the screw tightening status.
l Solution
For the case of failure to communicate with the host computer, first check whether the communication interface (such as serial port, USB port, Ethernet port, etc.) is physically damaged, check whether the pins of the interface are bent, whether there are debris inside the interface, etc. If the interface is normal, check whether the communication line is normal. If the interface is normal, check whether the communication line is firmly connected, whether there is any broken or short-circuit phenomenon, use a multimeter to carry out line through the test. At the same time, confirm whether the communication protocol settings of the two sides of the communication is consistent, including baud rate, data bits, stop bits, check bits and other parameters.
For internal communication failure, check the communication line connection between each module, similar to the method of checking the external communication line. If the line is normal, check whether the communication module (such as communication chips, signal converters, etc.) is damaged, you can replace the method of testing, that is, the suspected damage to the communication module is replaced with a new module to see whether the communication is back to normal.
3、Parameter setting failure
l Failure phenomenon
Parameters can not be saved: After setting the screw tightening torque, rotational speed, screw spacing and other parameters, the equipment restarted or after a period of time, the parameters returned to the default value or the old value before, can not save the newly set parameters. This may be due to parameter storage module failure or software permission problems.
Parameter setting errors lead to abnormal operation: set the parameters beyond the permissible range of the equipment, such as too much torque leads to screw damage, too high a rotational speed of the machine can not run normally, etc., or between the parameters are incompatible, such as tightening order settings do not meet the requirements of the mechanical structure.
l Solution
For the parameters can not be saved, check whether the parameter storage module (such as EEPROM chip) is damaged, you can read and write other simple data to test the function of the storage module. If the storage module is damaged, you need to replace it with a new one. At the same time, check the user rights settings of the software to ensure that there are enough rights to modify and save parameters.
When incorrect parameter settings result in abnormal operation, first stop the machine from running to prevent further damage to the equipment. Reset the correct parameters according to the technical specifications and operation manual of the equipment. When setting parameters, pay attention to the correlation and mutual constraints between different parameters to ensure that the combination of parameters meets the actual operating requirements of the equipment.
4、Control signal output failure
l Fault phenomenon
Abnormal motor control signal: the motor can not run in accordance with the set speed and direction, such as motor speed is not stable, the motor can only rotate in one direction or the motor rotates uncontrollably. This may be because the control signal output from the control unit (e.g. PWM signal, pulse signal, etc.) is incorrect, which may be caused by the failure of the control chip, the damage of the signal amplification circuit or the interference of the signal transmission line.
Failure of other actuator control signals: In addition to the motor, there are problems with the signals controlling the actuator such as the movement of the robotic arm and the clamping of the fixture, such as the robotic arm cannot reach the specified position accurately, and the fixture cannot be normally clamped or loosened. This may be the control signal timing error, insufficient signal strength or actuator driver failure.
l Solution
For abnormal motor control signals, use an oscilloscope or other equipment to check whether the waveform of the motor control signal output from the control unit is normal. If the waveform is abnormal, check the working status of the control chip to see if there is overheating, short-circuiting of the pins and so on. Check whether the components in the signal amplification circuit (such as transistors, field effect tubes, etc.) are damaged, and replace the damaged components. At the same time, pay attention to the shielding of the signal transmission line and anti-interference measures to reduce the impact of electromagnetic interference on the signal.
When the other actuator control signal failure, first check whether the timing of the control signal is correct, by viewing the program code or using tools such as logic analyzers to analyze the timing of the signal. If the timing is wrong, modify the program code to make adjustments. Check whether the signal strength is sufficient, it may be necessary to adjust the gain of the signal amplification circuit. For actuator driver failure, check the power supply, input signal and output status of the driver, and repair or replace the driver according to the driver's fault indicator or error code.
※ 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.
