What are some common sensor failures and their solutions for motor motor rotor (single station) spot welder?
Motor motor rotor (single station) spot welding machine in the operation process may encounter some common sensor failures and their solutions are as follows:
1, motor speed sensor failure:
Failure phenomenon: the sensor does not work, the signal is unstable or no signal.
Solution: Ensure that the sensor's power supply is normal, check the power supply connection, interface and voltage are in line with the specifications. Use an oscilloscope or multimeter to measure the output signal and check whether there is a pulse signal output. If there is no signal, the sensor may be damaged or poorly connected.
2、Sensor signal output problem:
Fault phenomenon: signal loss or interference.
Solution: Check whether the connecting wire from the sensor to the controller is firm, broken or short-circuited. Replace the connection line if necessary.
3、Improper sensor position:
Failure phenomenon: unstable or inaccurate signal.
Solution: Confirm whether the installation position is correct, and the distance between the rotor or magnet in the specified range, to avoid contact with the rotor shaft.
4、Signal interference problems:
Fault phenomenon: signal waveform distortion.
Solution: Check whether there is electromagnetic interference (EMI), ensure and signal line away from high-voltage cables and other possible sources of interference.
5, rotor and magnet problems:
Failure phenomenon: inaccurate speed.
Solution: Confirm whether there is a mark on the rotor or the magnet is working properly, make sure there is no wear or fall off.
6、Servo motor temperature sensor failure:
Fault phenomenon: temperature sensor signal abnormality, disconnection, short circuit, aging, high ambient temperature, pollution or damage.
Solution: Check the temperature sensor connection line to ensure that there is no broken or short circuit; for aging sensors, need to be replaced; for high ambient temperatures, need to improve the working conditions of the sensor; for contaminated or damaged sensors, need to be cleaned or replaced.
7, Hall sensor failure:
Failure phenomenon: Once the Hall position sensor failure, the position signal it contains is then lost, which may lead to motor speed disorders, and even cause greater damage to the electric drive system.
Solution: Acquire the rotor position information fed back by the Hall sensor in real time and select the appropriate drive voltage vector to be applied to the drive bridge arm. If the fault is not detected, troubleshooting of the control system is required to ensure that the motor can maintain its original steering and speed.
These are some of the common sensor faults and their solutions that may be encountered during the operation of a motor rotor spot welder (a machine that welds commutator hooks). For different fault phenomena, corresponding inspection and maintenance measures should be taken to ensure the normal operation and productivity of the equipment.
※ If you still can not solve the equipment failure by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for help.
Case:
When using the spot welder for motor rotor welding operations, encountered a sensor failure problem, specifically manifested in the welding process sensor signal abnormality, resulting in unstable welding quality.
Fault phenomenon:
During the welding process, the sensor signal is unstable or lost, resulting in welding parameters can not be accurately controlled, affecting the welding quality.
Failure cause analysis:
l Sensor electromagnetic interference: the strong magnetic field generated by the industrial spot welding machine will cause the unprotected sensors to malfunction or fail.
l Sensor aging or damage: the sensor may be aging or damaged after a long time of use, resulting in abnormal signal output.
l Sensor connection line problem: the sensor connection line may have a broken or short circuit, resulting in signal transmission interruption.
Solution:
l Use anti-magnetic and anti-welding sensors: Select anti-magnetic and anti-welding inductive sensors, which are not subject to electromagnetic interference and are equally effective in sensing steel and aluminum targets, providing a cost-effective solution.
l Checking and replacing sensors: Check the working status of the sensors regularly, and replace the aging or damaged sensors in time to ensure the stability and accuracy of the signal.
l Checking and repairing the connecting lines: Check all the connecting lines of the sensors, repair or replace the damaged lines to ensure the continuity of signal transmission.
Through the above solutions, the sensor failure problems encountered in the welding process of spot welder for manufacturing motors can be effectively solved to ensure the welding quality and production efficiency.
