What are the common electrical failures and their solutions for the fully automatic material collecting machine with DC brushed motor?

What are the common electrical failures and their solutions for the fully automatic material collecting machine with DC brushed motor? 1. Power supply failure Failure phenomena: The motor doesn't run at all and the material collecting machine has no response. This may be due to the power plug not being plugged in properly, the socket being damaged or the fuse being blown. The motor runs intermittently. This may be caused by poor contact of the power supply lines, such as looseness, oxidation or damage, resulting in unstable power supply. Solutions: Firstly, check whether the power plug is firmly inserted into the socket and try replacing it with a new socket for testing. If the fuse is blown, first find out the reason for the blowout, for example, whether there is a short circuit, and then replace the fuse with the same specification. For the situation of poor contact of the lines, carefully check the lines from the socket to the motor to see if there are loose connectors. If so, reconnect and tighten them. For the oxidized parts, you can use sandpaper to gently polish them to remove the oxide layer. If the lines are damaged, the damaged parts of the lines need to be replaced.2. Brush failure Failure phenomena: When the motor is running, a large number of sparks are generated. This is a typical symptom of brush wear or poor contact between the brush and the commutator. As the brush wears, the contact area between it and the commutator decreases, resulting in unstable current transmission. The motor speed is unstable or the torque drops. This may be because the brush is severely worn and cannot effectively transmit current to the rotor, thus affecting the performance of the motor. Solutions: Regularly check the wear condition of the brushes. When the length of the brush is less than the specified value, the brush should be replaced in time. When replacing the brush, make sure that the model of the brush matches the motor and it is installed correctly to ensure good contact pressure between the brush and the commutator. If the contact between the brush and the commutator is poor, first clean the surfaces of the brush and the commutator. Use fine sandpaper to gently polish the surface of the commutator to remove the oxide layer and dirt, and then wipe it clean with a clean cloth. At the same time, check whether the spring pressure of the brush is normal. If necessary, adjust or replace the brush spring. 3. Winding failure Failure phenomena: The motor emits an abnormal smell. This may be caused by a short circuit in the motor winding or overloading, which leads to overheating of the winding. A short circuit in the winding will cause the current to increase abnormally and generate excessive heat. The motor cannot start or has a very low speed after starting. This may be due to an open circuit in the winding or damage to part of the winding, resulting in the motor's inability to establish a normal magnetic field or insufficient torque. Solutions: For the case of a short circuit in the winding, professional tools (such as an insulation resistance meter) are needed to detect the insulation resistance of the winding. If the insulation resistance is found to be too low, it indicates a short circuit failure. For a slight short circuit, you can try to repair it by methods such as recoating with varnish and drying. For a serious short circuit, it may be necessary to replace the motor winding. If it is an open circuit in the winding, use the resistance range of a multimeter to check the resistance value of the winding. If the resistance is infinite, it indicates an open circuit in the winding. After determining the position of the open circuit, you can try to repair it by welding. If it cannot be repaired, it is necessary to rewind the winding or replace the motor. 4. Controller failure Failure phenomena: The running speed of the material collecting machine cannot be adjusted. This may be due to a failure in the speed control circuit of the controller, resulting in the inability to change the supply voltage or current of the motor and thus unable to adjust the motor speed. The automatic operation program of the material collecting machine goes wrong. For example, it cannot work according to the preset material collecting mode. This may be due to an error in the controller's program or damage to the storage chip. Solutions: Check the speed control circuit of the controller to see if there are any damaged components (such as potentiometers, thyristors, etc.). For damaged components, replace them according to the specifications of the components. At the same time, check whether the connecting lines of the speed control circuit are normal. If there are loose or short-circuit situations, repair them in time. If there is an error in the controller's program, you can try to perform a reset operation on the controller to restore the factory settings. If the problem still exists, it may be necessary to rewrite the program or replace the storage chip. This requires professional equipment and technical knowledge, and it is recommended that professional personnel carry out the operation. 5. Sensor failure (if there are relevant sensors) Failure phenomena: A failure of the level sensor may cause the material collecting machine to be unable to accurately judge the material level. For example, it cannot stop collecting materials when the materials are full or cannot start collecting materials in time when the materials are insufficient. A failure of the speed sensor will make the speed feedback of the material collecting machine inaccurate, which may lead to unstable speed control or the inability to achieve constant speed material collection. Solutions: For the level sensor, first check whether the installation position of the sensor is correct, whether it is blocked or damaged by materials. Clean the surface of the sensor to remove dirt and impurities. Use a multimeter to check whether the output signal of the sensor is normal. If there is an abnormality, carry out targeted maintenance or replacement according to the type of the sensor (such as photoelectric sensor, capacitance sensor, etc.). For the speed sensor, check whether the connection between the sensor and the motor shaft is firm and whether the signal line of the sensor is normal. Use an oscilloscope or a multimeter to check whether the output pulse signal of the sensor meets the requirements. If the signal is abnormal, it may be necessary to replace the speed sensor. ※ If the failure of the equipment still cannot be solved through the above methods, please contact the technical specialists of XinHui Electromechanical Equipment Co., Ltd. through the page chat tool for help.