What are the common sensor failures and their solutions for motor motor rotor duplex testers?
Motor motor rotor duplex tester common sensor failures and solutions:
First, the displacement sensor failure
l Failure phenomenon
Inaccurate displacement measurement: the displayed motor rotor displacement does not match the actual displacement, resulting in test data error, affecting the motor rotor size, position accuracy and other parameters of the judgment.
Loss or abnormal fluctuation of displacement signal: the sensor cannot output normal displacement signal, or the signal appears to jump, sudden change, etc., which makes the tester unable to accurately obtain the displacement information of the rotor, thus affecting the testing process and results.
Sensor non-response: the displacement sensor does not work at all, without any signal output, and the relevant test functions of the equipment (such as rotor concentricity test and other items that rely on displacement measurement) cannot be carried out.
l Possible reasons
Mechanical installation problems: the displacement sensor is improperly installed, such as not maintaining the correct parallelism or perpendicularity with the object to be measured, or the mounting bracket is loose, resulting in changes in the relative position of the sensor and the object to be measured, affecting the measurement accuracy.
Sensor component damage: the internal optical, electromagnetic or capacitive and other sensitive components are damaged, for example, the optical sensor's light path is blocked, electromagnetic sensor coil breaks, capacitive sensor pole plate is damaged, etc., which will lead to signal abnormality or no signal output.
Signal line failure: the signal line connecting the sensor and the controller is broken, short-circuited, poor contact, etc., or the signal line is subject to electromagnetic interference, affecting the signal transmission.
Working environment impact: in high temperature, humidity, dusty or corrosive gas environment, the performance of the sensor may decline, such as component aging, short-circuit and other problems.
l Solution
Check the installation of the sensor to ensure that its installation position is correct and firmly fixed. Use professional tools to adjust the position of the sensor so that it maintains a suitable relative position to the object to be measured, and recalibrate the sensor.
For sensors with damaged internal components, repair or replace them according to the damage. For optical sensors, check the optical path and clean or replace the optical components; for electromagnetic or capacitive sensors, use tools such as a multimeter to test the components and replace the damaged parts.
Check whether the connection of the signal wire is firm and look for signs of breakage or short circuit. If the signal line is damaged, replace it with a new one; if there is electromagnetic interference, use shielded wires or add filters to reduce the interference.
Improve the working environment, such as increasing ventilation equipment, installing dehumidification devices, and strengthening dustproof measures. For the bad environment and performance decline in the sensor, consider replacing it with a better protection performance of the sensor.
Second, the speed sensor failure
l Failure phenomenon
Speed measurement deviation: the motor rotor speed displayed by the tester is inconsistent with the actual speed, which may lead to an incorrect assessment of the motor performance, such as calculating the motor power, efficiency and other parameters in error.
Speed signal instability: frequent fluctuations in the speed signal output from the sensor make it difficult for the tester to accurately determine the stable running speed of the motor rotor, affecting the repeatability and reliability of the test.
Sensor intermittent work: the speed sensor can sometimes output signals normally, and sometimes no signal output, resulting in discontinuous and unreliable test data.
l Possible reasons
Problems in the coupling between the sensor and the rotor: Problems in the connection between the speed sensor and the motor rotor (e.g., contact friction wheel connection, non-contact electromagnetic induction coupling, etc.), such as wear and tear of the friction wheel, loosening, or changes in the electromagnetic induction gap, leading to unstable signal transmission.
Internal failure of the sensor: the speed sensor's speed measuring element (such as Hall element, photoelectric element, etc.) is damaged, or the signal processing circuit is faulty, which affects the generation and output of the speed signal.
External interference: the surrounding electromagnetic interference, mechanical vibration and other external factors may affect the normal operation of the speed sensor, resulting in abnormal signals.
l Solution
Check the connection between the sensor and the motor rotor. For contact sensors, check the wear of the friction wheel and replace it in time if it is worn; make sure that the friction wheel is in close contact with the rotor without loosening. For non-contact sensors, adjust the sensing gap to the appropriate range, and check whether the fixing device is firm.
Test the internal components and circuitry of the sensor. Use professional equipment (such as oscilloscopes, signal generators, etc.) to check the output signals of the speed measurement components and the working status of the signal processing circuit, and repair or replace them after determining the failure points.
Reduce external interference. Reasonable electromagnetic shielding of the test machine, avoiding proximity to large motors, high-frequency equipment and other sources of interference. For mechanical vibration interference, shock absorption measures can be taken, such as the installation of shock absorbing pads, adjust the installation position of the equipment.
Third, the pressure sensor failure
l Failure phenomenon
Pressure detection error: the displayed test pressure value does not match the actual pressure, which may lead to inaccurate pressure test results on the motor rotor, affecting the motor shaft bearing force and other conditions of judgment.
Pressure signal abnormality: the signal output from the pressure sensor jumps, interrupts or remains unchanged, which makes the tester unable to correctly judge the pressure change and adjust the test parameters or record accurate data in time.
Pressure sensor failure alarm: the equipment control system displays a pressure sensor failure alarm message, but the actual pressure test process seems to be normal, which may be a false alarm of the sensor itself or a precursor of an impending serious failure of the sensor.
l Possible causes
Sensor probe problem: the pressure sensor probe is contaminated, such as stained oil, impurities, etc., affecting the accurate transmission and detection of pressure. Improper installation position of the probe, such as not perpendicular to the force surface, can also lead to measurement errors.
Connection line failure: the sensor's signal line is short-circuited, broken or poor contact, or the power supply line power supply is not normal, resulting in the pressure signal can not be transmitted normally or the sensor can not work properly.
Sensor's own performance degradation: long-term in the high-pressure, high-frequency working environment, the pressure sensor internal strain gauges, capacitors and other sensitive components may be aging or damaged, resulting in performance degradation.
Loss or error of calibration parameters: The calibration parameters of the sensor may be lost or incorrect due to equipment failure, software problems or misuse, making the detected pressure inconsistent with the actual pressure.
l Solution
Clean the probe of the pressure sensor, remove oil and impurities to ensure that the probe surface is clean. Check the installation position of the probe, adjust it to be perpendicular to the force surface, and recalibrate the sensor.
Check the connecting wiring for breaks, shorts, or poor contact. For wiring problems, repair or replace damaged sections to ensure good wiring connections. Also, check the power supply to the power cord to ensure that the sensor is properly powered.
For pressure sensors with degraded performance, try recalibration. If the pressure still cannot be detected accurately after calibration, or if the internal components of the sensor are obviously damaged, such as broken strain gauges, shorted capacitors, etc., the pressure sensor should be replaced.
Check the calibration parameters of the sensor and look in the device control system to see if any calibration parameters are incorrect. If the parameters are missing, re-calibrate in accordance with the requirements of the equipment manual.
Fourth, the temperature sensor failure
l Fault phenomenon
Inaccurate temperature detection: the difference between the displayed motor rotor temperature and the actual temperature is large, which may lead to an incorrect assessment of the motor heating condition, affecting the accuracy of the motor performance test.
Temperature signal abnormality: the signal output from the temperature sensor jumps, interrupts or remains unchanged, which makes the tester unable to correctly determine the temperature change and take timely cooling measures or record accurate data.
Temperature Sensor Fault Alarm: The equipment control system displays a temperature sensor fault alarm message, but the actual temperature testing process seems normal, which may be a false alarm of the sensor itself or a precursor of an impending serious failure of the sensor.
l Possible causes
Probe contamination or damage: The probe of the temperature sensor is covered with dust, oil, etc., or damaged by collision or high temperature, affecting the accurate measurement of temperature.
Connection line problem: The signal line is short-circuited, broken or has poor contact, resulting in the temperature signal can not be transmitted normally.
Sensor performance degradation: working in a high temperature environment for a long time, the internal thermal element may be aging or damaged, resulting in inaccurate temperature detection.
Calibration problem: the calibration parameters of the sensor are wrong or lost, making the detected temperature not match with the actual temperature.
l Solution
Clean the probe of the temperature sensor to remove dust and oil. If the probe is damaged, replace the probe and recalibrate the sensor.
Check the connecting wiring, repair or replace the damaged part, and make sure the wiring is well connected.
For temperature sensors with degraded performance, try recalibration. If the temperature is still not accurately detected after calibration, or if the internal components of the sensor are visibly damaged, such as an open or shorted thermistor, the temperature sensor should be replaced.
Check the calibration parameters of the sensor and re-calibrate it according to the equipment manual.
※ 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.
