What are the common electrical faults and solutions for DC brushed motor motor fully automatic case tile assembly machine?
First, motor failure
(A) Failure phenomenon
Motor does not turn
The motor is completely unresponsive, after the start signal is issued, the motor does not have any action, and the equipment can not run normally.
The motor has a slight buzzing sound, but the shaft does not rotate, which may be that the motor is in a blocked state.
Abnormal motor speed
The motor speed is faster or slower than the set speed, resulting in the speed of the magnetic tile assembly not meeting the requirements, affecting the assembly quality and efficiency.
The motor speed is unstable and appears to be fast or slow, so that the magnetic tile may not be accurately assembled to the specified position of the housing.
(ii) Cause analysis
Power supply problem
The power supply line is disconnected or has poor contact, resulting in the motor failing to obtain sufficient power. Examples include loose plugs, broken wires inside the cord, etc.
Power supply voltage is unstable or does not meet the rated voltage requirements of the motor, such as grid voltage fluctuations, power supply equipment failure, etc.
Damage inside the motor
Brushes are so worn that they cannot contact the commutator properly, resulting in poor current transmission. Brushes of brushed motors are wearable parts and will gradually wear out after long-term use.
The armature winding is short-circuited or disconnected, affecting the electromagnetic torque generation of the motor, which may be caused by overheating, moisture or mechanical damage.
Wear, oxidation or dirt on the surface of the commutator, resulting in increased contact resistance between the brushes and the commutator, which affects current commutation and thus the normal operation of the motor.
Drive Failure
The parameters of the motor driver are set incorrectly, such as speed control parameters, current limit parameters and other improper settings, resulting in abnormal motor speed.
The electronic components inside the driver are damaged, such as power transistors, integrated circuits and other faults, which can not properly output the signal to drive the motor.
(iii) Solution
Power supply inspection and repair
Check the power supply line to see whether the plug is tightly inserted and whether the wire is broken or fractured. For loose plugs, reinsert them tightly; for damaged wires, replace them with new ones.
Use a voltmeter to measure the power supply voltage to ensure that it is within the allowable range of the motor's rated voltage. If the voltage is unstable, install a voltage regulator to stabilize the supply voltage.
Motor Repair and Replacement Parts
Regularly check the wear of the brushes, and when the brushes are worn to a certain extent (generally the remaining length is less than the specified value), replace the brushes in time. When replacing brushes, pay attention to selecting brushes that match the motor model and ensure good contact between brushes and commutator.
Check the resistance of the armature winding with a multimeter to determine whether there is a short circuit or broken circuit. If the windings are damaged, the motor needs to be rewound or replaced. For commutator problems, clean the commutator surface of dirt and gently polish the oxide layer with fine sandpaper to make the surface smooth.
Drive Adjustment and Repair
Check the user's manual of the drive to recheck and adjust the parameters of the drive. For example, according to the rated speed of the motor and the requirements of the equipment, adjust the gain, integration time and other parameters of the speed control loop so that the motor speed reaches the normal range.
If damage to the internal components of the drive is suspected, professional technicians are required to use specialized tools for testing and repair. For damaged components, use the same type of components for replacement, and performance testing to ensure that the drive can normally drive the motor.
Second, the sensor failure
(A) fault phenomenon
Magnet tile position detection error
The equipment is unable to accurately detect the position of the magnetic tile, resulting in the magnetic tile can not be correctly assembled to the predetermined position of the housing, there may be magnetic tile assembly offset, overlap and so on.
The sensor misjudges the position of the magnetic tile, resulting in redundant movements or skipping of certain assembly steps during the assembly process, affecting the accuracy and completeness of the assembly.
Failure of casing positioning detection
Failure to correctly locate the position of the housing, resulting in positional deviation of the housing during the assembly process, which in turn leads to problems in the assembly of the tiles, such as poor fit between the tiles and the housing.
The unstable signal of the casing positioning sensor causes the equipment to adjust the casing position frequently, which reduces the assembly efficiency.
(ii) Cause analysis
Sensor surface pollution or damage
Dust, oil, iron filings and other pollutants in the working environment are attached to the sensor's sensing surface, affecting the sensor's detection accuracy of the magnetic tile or housing position.
The sensor is affected by mechanical collision, long-term vibration or electrical overload and other factors, resulting in damage to internal components, such as photoelectric sensor light-emitting diode or photosensitive element damage, proximity sensor sensor induction coil damage.
Improper or loose sensor installation position
The installation position of the sensor is offset, resulting in changes in its detection range and accuracy. For example, a change in the mounting angle of the tile position sensor may prevent accurate detection of the edge position of the tile.
The fixing screws of the sensor are loose, causing the sensor to shake during the operation of the equipment, affecting the stability of the detection signal.
Electromagnetic interference
Other electrical equipment around the equipment, strong magnetic field sources or electromagnetic radiation may interfere with the normal operation of the sensor. For example, magnetic fields or electromagnetic waves generated by nearby large motors and high-frequency equipment may affect the signal of the magnetic tile position sensor.
(iii) Solution
Clean and replace the sensor
Clean the sensing surface of the sensor regularly, using a clean, soft cloth to wipe contaminants from the sensor surface. For oil or iron filings that are difficult to remove, clean with an appropriate cleaning agent (e.g., alcohol).
If the sensor is damaged, use a multimeter or other tools to detect the output signal of the sensor and determine whether it is working properly. For damaged sensors, replace the sensor with one of the same model, and install and debug it according to the equipment manual.
Adjust and fix the sensor position
Check whether the installation position of the sensor is correct, use a gauge (such as calipers, angle ruler, etc.) to readjust the position of the sensor to ensure that it can accurately detect the position of the magnetic tile and the housing.
Check whether the fixing screws of the sensor are loose, if loose, tighten the screws in time so that the sensor can be installed firmly to avoid shaking during operation.
Reduce electromagnetic interference
Carry out electromagnetic compatibility inspection of the equipment to find out the source of possible electromagnetic interference. Keep the equipment at a certain distance from other large electrical equipment and strong magnetic field sources.
Install electromagnetic shielding devices around the sensor, such as shielding covers and shielding cables, to reduce the impact of external electromagnetic interference on the sensor. At the same time, the electrical system of the equipment can be grounded to improve the anti-interference ability of the equipment.
Third, the electrical control cabinet failure
(A) fault phenomenon
Control system does not respond
After pressing the operation button or issuing control instructions, the electrical control cabinet does not have any response, the equipment can not start or stop, the indicator does not light.
Part of the control system fails, for example, only certain specific operations can be performed, while other operations cannot be executed, resulting in the equipment not being able to complete the tile assembly process normally.
Damaged electrical components cause fault alarms
Components such as relays and contactors in the control cabinet appear to be burnt and smoking, while the equipment sends out a fault alarm signal and stops operation.
The fuse is blown, resulting in partial circuit power failure and localized functional failure of the equipment.
(ii) Cause analysis
Power module failure
Abnormalities in the input voltage of the power supply module, such as overvoltage, undervoltage and other conditions, may damage the electronic components inside the power supply module.
Quality problems of the power supply module itself or long-term use leads to aging and damage of the components, which can not normally output stable DC power for use by other components in the control cabinet.
Control program error or loss
Due to electromagnetic interference, power fluctuation or illegal operation, etc., the control program may be incorrect or part of the program is lost, so that the control system can not operate normally.
In the process of updating and modifying the control program, program errors may also be introduced if it is not operated properly.
Quality problem of electrical components or overload operation
The quality of electrical components in the control cabinet (e.g., relays, contactors, capacitors, etc.) is poor and can be easily damaged during normal operation.
Prolonged overload operation or frequent starting and stopping of the equipment will cause the electrical components to be subjected to excessive current or voltage shocks, resulting in damage to the components.
(iii) Solution
Power module inspection and repair
Use a voltmeter to check the input and output voltages of the power supply module to determine whether there are abnormalities such as overvoltage and undervoltage. If the input voltage is abnormal, check the power supply line and the superior power supply equipment; if the output voltage is abnormal, the power supply module may need to be replaced.
For the case of damage to the internal components of the power supply module, professional technicians are required to repair or replace the power supply module with a new one. After replacing the power module, check whether the output voltage is stable and the compatibility with other electrical components.
Control program check and recovery
Use programming software to check whether there is any error in the control program, if there is any error, restore or modify according to the program backup or the original program of the equipment.
Take electromagnetic shielding measures, such as installing metal shielding mesh around the control cabinet, to reduce the impact of electromagnetic interference on the control program. At the same time, install a regulated power supply to avoid damage to the program from power fluctuations. In the process of program update and modification, operate in strict accordance with the operation manual to ensure the integrity and correctness of the program.
Replacement of electrical components and overload protection
Regularly check the working status of the electrical components in the control cabinet, and replace the components that show signs of damage such as burning and smoking with new components of the same type in a timely manner. After replacing the components, check whether they are connected correctly and whether their actions are normal.
Install overload protection devices, such as thermal relays, circuit breakers, etc., and reasonably set the protection parameters to prevent the equipment from overload operation. At the same time, optimize the operation process of the equipment, avoid frequent starting and stopping, and reduce the current and voltage impact on the electrical components.
※ 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.
