How to fault analyze and troubleshoot the DC brushed motor motor automatic case tile assembly machine?
First, the basic steps of fault analysis
1、Collect information
Observe the fault phenomenon: carefully check the specific performance of the equipment when the fault occurs. For example, whether the equipment completely stops running, or part of the function is out of order; whether the magnetic tile assembly position deviation, assembly is not solid, etc.; whether the motor has an abnormal noise, heat, smoke and other phenomena; at the same time, observe whether there is an alarm light on the control panel or error code display. Record these details, including the time of the first occurrence of the fault, the frequency of occurrence and whether it occurs after a specific operation (such as starting, stopping, changing materials, etc.).
Ask the operator: Talk to the employee who was operating the equipment at the time to find out what the equipment was doing before the fault occurred. For example, information such as whether parameter adjustments were made, whether the equipment ever vibrated or sounded abnormally, and whether different size tiles or housings were replaced. Feedback from the operator may provide important clues about the cause of the failure.
Check equipment operation records and historical data: Check the equipment's own operation record system (if available) to see changes in equipment parameters, operation records, alarm messages, and past maintenance records before and after the failure. These data can help determine whether the failure occurred suddenly or caused by the long-term accumulation of problems.
2, preliminary judgment of the type of failure and the range of possible causes
According to the collected information, the preliminary classification of fault types, such as mechanical failure, electrical failure, software failure or a combination of faults. For example, if the equipment has obvious mechanical noise and loose parts, it may be a mechanical fault; if the motor does not rotate and does not have any electrical alarms, it may be a connection problem in the electrical system or a fault in the motor itself; if the equipment moves in a chaotic manner but the hardware part seems to be normal, it may be a software fault.
For different types of faults, list the range of possible causes. For mechanical failure, it may involve wear and tear of transmission parts, damage to fixtures, blockage of foreign objects, etc.; for electrical failure, it may include power supply problems, motor failure, sensor failure, damage to components in the electrical control cabinet, etc.; for software failure, it may be a program error, improper parameter settings, communication failures and so on.
3, step-by-step investigation of possible causes
From the simple to the complexity of the investigation: first check the parts that are easy to observe and deal with, such as the appearance of the equipment, connecting lines, external sensors and so on. For example, check whether the equipment is obviously blocked by foreign objects, whether the wires are loose or broken, and whether the sensor surface is contaminated. If no problem is found in the simple inspection, then go deeper into the interior of the equipment to check the wear and tear of mechanical parts, the performance of electrical components, etc.
Use isolation method or replacement method for troubleshooting: In the troubleshooting process, isolation method can be used to determine whether the fault is caused by a particular component or system. For example, for suspected faulty electrical components, you can temporarily disconnect them and observe the operation of other parts of the equipment. Replacement method is also an effective means of elimination, for easy to replace parts, such as sensors, fuses, etc., you can replace the suspected faulty parts with new parts to see if the fault disappears.
Second, the common faults and troubleshooting methods
1、Mechanical faults
l Transmission system failure
Failure phenomenon: transmission belt (chain) slipping or broken, resulting in interruption of power transmission; gear wear or damage, abnormal noise or transmission precision decline.
Cause analysis: improper tension of transmission belt (chain), excessive load, fatigue damage caused by long-term wear; gears under high load or poor lubrication, tooth surface wear, tooth root fracture.
Remedy: For transmission belt (chain) slipping, check and adjust the tension; if broken, replace the new transmission belt (chain). For gear wear, minor wear can be repaired (e.g., grinding the tooth surface), while severe wear or broken teeth require gear replacement. Meanwhile, check and make sure the transmission parts are well lubricated to avoid overload operation.
l Failure of fixture and positioning device
Failure phenomenon: the fixture can not be clamped or the clamping force is insufficient, resulting in the position of the magnetic tile or casing offset; positioning device precision drops, so that the magnetic tile assembly position is inaccurate.
Cause analysis: Wear of fixture parts (such as clamping jaws, seals), loose connections; positioning devices (such as positioning pins, positioning blocks) are worn or loose.
Remedy: Repair or replace worn fixture parts, and tighten the connection part of the fixture. For the positioning device, recalibrate its position and replace the worn out positioning pins or blocks.
l Failure of the assembly mechanism
Failure phenomenon: the magnet tile assembly tools (such as push plate, suction cup) is damaged, can not properly push or adsorption of the magnet tile; assembly action is not coordinated, resulting in low assembly efficiency or quality problems.
Cause analysis: the assembly tools are damaged by material fatigue and overload after long-term use; control system failure or mechanical parts wear affects the coordination of assembly action.
Troubleshooting methods: Replace damaged assembly tools and calibrate them. Check the program and signal transmission of the control system, repair or replace the worn mechanical parts, such as transfer track, transmission parts, etc., to restore the coordination of assembly action.
2、Electrical faults
l Motor failure
Failure phenomenon: motor does not rotate, abnormal speed or abnormal noise.
Cause analysis: power supply problems (such as low voltage, lack of phase, loose or damaged power cord); internal damage to the motor (such as worn brushes, armature winding short-circuit or disconnection, commutator surface problems); motor driver failure (such as parameter setting errors, internal circuit damage).
Elimination methods: use a voltmeter to check whether the power supply voltage is normal, check whether the power cord is intact and firmly connected. For internal motor problems, use a multimeter to measure the resistance of the motor winding to determine whether it is short-circuited or disconnected, check the wear and tear of the brushes, and repair or replace the damaged parts. Check the parameter settings of the motor driver and readjust the parameters if necessary; if the internal circuit of the driver is suspected to be damaged, it needs to be repaired or replaced by a professional.
l Sensor failure
Failure phenomenon: the sensor can not properly detect the position and status of the magnetic tile or housing, resulting in assembly errors or equipment can not run normally.
Cause analysis: the sensor surface is contaminated, damaged; improper installation position or loose; electromagnetic interference.
Elimination methods: clean the sensor surface, check whether the sensor is damaged, use a multimeter and other tools to detect whether the output signal is normal, for damaged sensors, replace the same type of sensor. Re-adjust the installation position of the sensor and tighten, reduce electromagnetic interference around the equipment (such as shielding measures, away from the source of interference).
l Electrical Control Cabinet Failure
Failure phenomenon: the control system does not respond, part of the function failure or fault alarm, such as relays, contactors and other components are damaged.
Cause analysis: power module failure (such as abnormal input voltage, component aging damage); control program error or loss; quality of electrical components or overload operation.
Troubleshooting methods: Check the input and output voltages of the power supply module, and repair or replace the damaged components. Use programming software to check the control program and restore or modify the wrong program part. Regularly check the working status of the electrical components, replace the damaged components, install overload protection devices, and reasonably set the protection parameters to prevent the equipment from overload operation.
l Software failure
Program running errors lead to uncoordinated action of the equipment
Failure phenomenon: the assembly sequence of magnetic tiles is confused, the action time is inaccurate, and the equipment cannot be assembled according to the set process.
Reason analysis: program logic errors (such as programming errors, software update compatibility problems); software parameter setting errors (such as assembly speed, position parameters, etc. improper settings).
Troubleshooting: Check the program logic through the software debugging tool, set breakpoints, observe the program execution path and variable values, and find out and correct the wrong code logic. For compatibility problems after software update, conduct compatibility test and adjust the software interface or data reading method. Verify the software parameter settings, correct the wrong parameters to the correct values, clarify the unit of parameters in the software interface, set parameter limits and prompt messages to prevent parameter setting errors.
l Software running stability problems (such as software crash, running speed slows down)
Failure phenomenon: the software suddenly crashes during operation, or the operation speed slows down significantly, affecting the normal use of equipment.
Cause analysis: memory leakage or excessive resource occupation; software conflict or virus infection.
Troubleshooting methods: Check the software code to find the part that may lead to memory leakage and optimize it using memory detection tools. Reasonably allocate software resources and lower the priority of non-critical tasks. Troubleshoot software conflicts, close other software one by one, and observe the operation of the control software. Install antivirus software on the device, and conduct regular virus checking to remove the virus and repair the software.
※ If you still can't solve the equipment failure through the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
