What are the common control unit failures and solutions for motor motor rotor automatic duplex fine-turning machine?
Motor motor rotor automatic duplex fine turning machine common control unit failure and solutions:
First, the programmable logic controller (PLC) failure
l Failure phenomenon
Equipment can not start: press the start button, fine turning machine does not have any response, PLC running indicator does not light.
Confused program operation: During the operation of the equipment, there are cases in which the actions are not executed according to the predetermined program, such as the machining steps are disorderly, and the movement sequence of the tool and the working table is wrong.
Abnormal input/output signals: PLC cannot receive sensor signals (such as displacement, speed, pressure sensors) correctly, or cannot control the action of the execution elements (such as motors, solenoid valves) properly, resulting in reduced machining accuracy or equipment failure.
l Possible causes
Power supply problem: Failure of the PLC's power supply module, loose power cord or voltage fluctuation may cause the PLC to fail to work normally.
Program Error: The program is lost or damaged due to errors in uploading or downloading, or due to electromagnetic interference or memory chip failure.
Input/output interface failure: After a long time of use, the input/output interface of PLC may have poor contact, chip damage, etc., which affects the reception and transmission of signal.
l Solution
Check the power supply: Make sure the power cable of PLC is firmly connected, and use a multimeter to measure whether the input voltage is in the normal range (generally ±10% of the rated voltage). If the power module is faulty, it is necessary to replace the power module with the same model.
Handling program problems: Perform a reset operation on the PLC to restore the factory settings (pay attention to backup important parameters). If the problem still exists, check the program backup and re-upload the correct program. If memory chip failure is suspected, it may be necessary to replace the memory chip or the entire PLC module.
Service Interface: Check the input and output interfaces of the PLC, clean the interface pins, and re-plug the connecting cables. Use a multimeter to check whether the input and output signals of the interface are normal or not. For the damaged interface chip, it needs to be repaired or replaced by professional personnel.
Second, industrial computer failure
l Failure phenomenon
Can not start: industrial control machine power indicator does not light up, the screen does not display, the device can not start.
Abnormal operation of software: the control software of precision turning machine runs slowly, crashes or dies on the industrial control machine, affecting the processing operation.
Communication failure: the communication between the industrial control machine and PLC, sensors or other devices is interrupted, unable to acquire or send data, resulting in the equipment not working normally.
l Possible causes
Hardware problems: power supply failure, hard disk damage, insufficient or damaged memory, motherboard failure, etc. may lead to the industrial computer can not work properly.
Software problems: operating system damage, control software conflict, virus infection or software update failure may cause software failure.
Communication problems: communication interface (such as Ethernet port, serial port, etc.) is damaged, communication line failure or communication parameter setting error may lead to communication interruption.
l Solution
Check the hardware: first check whether the power supply is normal, try to replace the power supply. Check whether the hard disk has bad sectors, if necessary, repair or replace the hard disk. Add memory or replace damaged memory modules. For motherboard failure, professional maintenance personnel are required to overhaul.
Solve software problems: Try using the repair tool that comes with the system or reinstall the operating system. Uninstall potentially conflicting software and install antivirus software for virus checking. If the problem is caused by software update failure, try to re-update or rollback to the previous version.
Repair communication problems: Check whether the communication interface is damaged, use a substitute interface for testing. Check whether the communication line is loose or broken, reconnect or replace the communication line. Check the communication parameter settings to ensure consistency with other devices.
III. Drive Failure
l Fault phenomenon
The motor can not be driven normally: the spindle motor or feed motor can not run according to the set speed and torque, or even can not start.
Motor operation is unstable: motor speed fluctuation, jitter or out of step phenomenon during operation, affecting the machining accuracy.
Drive alarm: the drive displays fault codes, prompting error messages such as over-current, over-voltage, under-voltage, overheat and so on.
l Possible reasons
Wrong parameter setting: the speed, torque, current limit and other parameters of the drive are not set in accordance with the actual requirements of the motor, resulting in the motor can not operate normally.
Internal circuit failure: the power module, control circuit, power supply circuit and other internal components of the drive are damaged, causing abnormal motor drive.
External interference: the surrounding electromagnetic interference, power supply fluctuations or sudden changes in motor load and other external factors may affect the normal operation of the drive.
l Solution
Check the parameters: double-check the parameter settings of the drive, adjust the speed, torque, current limit and other parameters according to the rated parameters of the motor and processing requirements.
Repair the internal circuit: Use professional equipment (such as oscilloscope, multimeter) to check the internal circuit of the drive, determine the damaged components and repair or replace them. If you cannot repair it by yourself, contact the drive manufacturer or a professional repairer.
Reduce external interference: electromagnetic shielding of the drive, the use of isolation transformers to stabilize the power supply, optimize the load characteristics of the motor to reduce the impact of external factors on the drive.
IV. Relay and contactor failure
l Failure phenomenon
Abnormal circuit on-off: the relay or contactor can not be normally absorbed or released, resulting in the motor, solenoid valve and other execution elements of the circuit can not be normally on-off, affecting the action of the equipment.
Abnormal noise: During the working process, the relay or contactor emits abnormal humming or clicking sound, which may be caused by poor core suction or poor contact contact.
Contact burnout: The contacts of the relay or contactor may burn out after frequent operation, resulting in a short circuit or broken circuit, which affects the normal operation of the equipment.
l Possible causes
Overload operation: The load current controlled by the relay or contactor exceeds its rated capacity, and long-term overload causes the contacts to heat up and burn out, or the coil is damaged by overheating.
Frequent action: In high-frequency machining operation, the relay or contactor is frequently absorbed and released, resulting in contact wear, fatigue, and damage behind.
Environmental factors: Harsh working environment, such as high temperature, humidity, dust, etc., may affect the performance of relays or contactors, resulting in contact oxidation, insulation degradation and other problems.
l Solution
Check the load current: Make sure the load current controlled by the relay or contactor does not exceed its rated capacity. If the load current is too high, it is necessary to replace the relay or contactor with one of higher capacity, or to shunt the load.
Optimize operation: For frequent operation, consider using relays or contactors with a higher service life, or optimize processing procedures to reduce the number of unnecessary operations.
Improve the environment: Improve the working environment, ventilate the equipment to dissipate heat, and install dust and moisture-proof devices. Regularly clean the dust and debris on the surface of relays and contactors, check the oxidation of contacts, for oxidized contacts, you can use fine sandpaper to gently sand to restore its good conductivity.
※ 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.
