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

I. Bearing Failure

• Abnormal temperature rise. When the bearings of the DC brushed motor malfunction, excessive heat will be generated due to increased friction, which will lead to a rise in the motor's temperature.

• Increased noise. Faulty bearings may produce abnormal noises, affecting the normal operation of the equipment.

• Intensified vibration. Bearing failures will cause an increase in the amplitude of the motor's vibration, which may have an impact on the structural stability of the entire material collecting machine.

• Regularly check the condition of the bearings and use means such as temperature monitoring and vibration analysis to detect potential failures in a timely manner.

• Select bearings with reliable quality to ensure that they can withstand the working load of the equipment.

• Replace the faulty bearings in a timely manner to avoid further expansion of the failure.

II. Brush Failure

• Decline in motor performance. Wear or damage to the brushes will lead to a reduction in the motor's output power, affecting the working efficiency of the material collecting machine.

• Spark generation. Poor contact between the brushes and the commutator may generate sparks, which will not only damage the motor components but also may cause potential risks.

• Increased noise. Brush failures may also cause the motor to produce abnormal noises during operation.

• Regularly check the wear condition of the brushes and replace the severely worn brushes in a timely manner.

• Optimize the hardness matching of the materials between the brushes and the commutator to ensure good contact performance.

• Increase the thickness of the copper plating layer on the commutator to reduce the wear of the commutator by the brushes.

III. Commutator Failure

• Unstable motor operation. Commutator failures may lead to unstable motor speed, affecting the working accuracy of the material collecting machine.

• Spark generation. Similar to brush failures, a defective commutator will also generate sparks.

• Accelerated wear. The wear of the commutator will affect the performance and service life of the motor.

• Regularly check the surface condition of the commutator and repair the worn or damaged parts in a timely manner.

• Ensure good contact between the commutator and the brushes to avoid spark generation.

• Use high-quality commutator materials to improve its wear resistance and corrosion resistance.

IV. Motor Overheating Failure

• Excessive temperature. When the motor operates for a long time or under high load, overheating may occur, affecting the performance and service life of the motor.

• Insulation damage. Excessive temperature may cause damage to the motor's insulation materials, triggering faults such as short circuits.

• Strengthen the heat dissipation measures of the motor, such as adding heat sinks and improving ventilation conditions.

• Reasonably arrange the working load of the material collecting machine to avoid the motor operating under high load for a long time.

• Install temperature sensors to monitor the motor temperature in real time and take measures in a timely manner when the temperature is too high.

V. Transmission System Failure

• Wear of transmission components. Components such as gears and belts in the transmission system of the material collecting machine may experience wear during long-term operation, resulting in a reduction in transmission efficiency.

• Loosening or breakage. The loosening or breakage of transmission components will affect the normal operation of the equipment.

• Regularly check the condition of the components in the transmission system and replace the severely worn components in a timely manner.

• Ensure that the transmission components are firmly installed to avoid loosening.

• Perform lubrication and maintenance on the transmission system to reduce wear.