What are the common sensor failures and their solutions for motor motor rotor automatic duplex fine-turning machine?
Motor motor rotor automatic duplex fine-turning machine common sensor failures and solutions:
First, the displacement sensor failure
l Failure phenomenon
Measurement accuracy decline: the display of displacement data and the actual displacement deviation, resulting in processing accuracy can not be guaranteed, such as the diameter of the rotor, length and other dimensions of the processing error.
Signal instability: the fluctuation and jumping of the output signal of the displacement sensor makes it difficult for the control system of the precision turning machine to accurately judge the positional relationship between the tool and the workpiece, which may lead to deterioration in the quality of the machined surface, and the appearance of ripples or tool marks.
No signal output from the sensor: There is no displacement signal at all, and the equipment cannot obtain the position information of the workpiece normally, resulting in interruption of the machining process or serious errors.
l Possible reasons
Improper installation position: the mounting bracket of the displacement sensor is loose, or the relative position between the sensor and the object to be measured (e.g., tool, workpiece) changes, affecting the measurement accuracy.
Sensor probe contamination: the probe surface is covered with impurities such as oil, iron filings, dust, etc., which obstructs the normal transmission of signals, thus leading to measurement errors or unstable signals.
Signal line damage: the signal line connecting the sensor and the controller is broken, short-circuited or in poor contact, making the signal can not be transmitted normally.
Damage to internal components of the sensor: due to long-term use, environmental factors (such as temperature changes, humidity, electromagnetic interference) or accidental collision, resulting in damage to the sensor's internal optical, electromagnetic or capacitive components, affecting the signal generation and output.
l Solution
Check and adjust the installation position: tighten the mounting bracket to ensure that the sensor position is stable. Use special tools to recalibrate the distance and angle between the sensor and the object to be measured, so that it meets the equipment requirements.
Clean the probe: Use a clean soft cloth or special cleaner to gently wipe the probe surface to remove impurities such as oil, iron filings and dust. Be careful to avoid damaging the probe during the cleaning process.
Check the signal line: Carefully check whether the signal line is broken, fractured or loose. If the signal wire is found to be damaged, it should be replaced in time; for poor contact, re-insert or solder the connection point.
Detecting and repairing internal components: If you suspect that the internal components of the sensor are damaged, you can use professional testing equipment (e.g., oscilloscope, multimeter, etc.) for testing. For damaged components, repair or replace them according to the model and structure of the sensor. If it is impossible to repair by yourself, contact the sensor manufacturer or professional maintenance personnel.
Second, the speed sensor failure
l Fault phenomenon
Inaccurate speed measurement: the displayed spindle speed or tool feed speed does not match the actual speed, resulting in incorrect setting of machining parameters (such as cutting speed and feed), which affects the machining quality and efficiency.
Abnormal fluctuation of speed signal: the output signal of the speed sensor is unstable, appearing high and low, making it difficult for the control system of the precision turning machine to accurately control the speed, which may lead to vibration, noise increase and other problems in the machining process.
Sensor intermittent work: the speed sensor can sometimes output signals normally, and sometimes there is no signal output, resulting in unstable speed control function of the equipment, and the machining process has a pause or a sudden change in speed.
l Possible reasons
Coupling problem between the sensor and the rotating parts: the connection method between the speed sensor and the spindle or feed mechanism (such as contact friction wheel connection, non-contact electromagnetic induction coupling) is faulty. For example, worn or loose friction wheels or changes in the electromagnetic induction gap can affect the signal transmission.
Damage to internal components: Failure of the speed sensor's speed measuring components (e.g., Hall components, photoelectric components, etc.) or signal processing circuits results in abnormal signals.
External interference: the surrounding electromagnetic interference, mechanical vibration and other external factors may affect the normal operation of the speed sensor, resulting in signal fluctuations or interruptions.
l Solution
Check the coupling situation: for the contact speed sensor, check the wear degree of the friction wheel and whether the connection is tight, if there is wear, it should be replaced in time to ensure that the friction wheel is in close contact with the rotating parts. For non-contact sensors, adjust the electromagnetic induction gap to a suitable range and check whether the fixing device is firm.
Detect internal components: Use professional equipment (such as oscilloscopes, signal generators, etc.) to check the output signals of the speed measuring components and the working status of the signal processing circuit. After determining the failure point, replace the damaged components or repair the signal processing circuit.
Reduce external interference: Carry out reasonable electromagnetic shielding for the fine-turning machine, avoiding the proximity of 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 Fault phenomenon
Pressure detection error: the displayed cutting force, clamping force and other pressure values do not match the actual pressure, which may lead to damage to the cutting tool during machining, the workpiece clamping is not secure and other issues.
Pressure signal abnormality: the signal output from the pressure sensor jumps, interrupts or remains unchanged, so that the precision turning machine can not correctly determine the pressure changes, and can not adjust the processing parameters or take corresponding measures in time.
Sensor failure alarm: the equipment control system displays the 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 the sensor's impending serious failure.
Possible Causes
Problems with the probe: the probe of the pressure sensor is contaminated, such as stained with oil, impurities, etc., affecting the accurate transmission and detection of pressure. Improper installation 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 and adjust the probe: 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 connection wiring: Look for broken, shorted, or poorly contacted signal wires. For wiring problems, repair or replace damaged parts to ensure good wiring connections. At the same time, check the power supply of the power cord to ensure that the sensor is normally powered.
Testing and Repairing the Sensor: For pressure sensors with degraded performance, try to recalibrate them. 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 calibration parameters: Look in the device control system to see if any calibration parameters are incorrect. If the parameters are missing, re-calibrate according to the requirements of 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.
