What are the common control unit faults and solutions for DC brushed motor motor fully automatic pressure bearing magnetizing integrated machine?
1. Program logic error fault
l Failure phenomenon
Confused sequence of equipment action: For example, in the process of bearing pressing and magnetizing, there may be a wrong sequence of magnetizing first and then pressing the bearing, or a certain step is skipped or repeated, resulting in product quality damage.
The equipment cannot be started or stopped normally: the control unit may not respond correctly to start or stop commands, leaving the equipment in an abnormal state.
l Cause Analysis
Programming errors: When writing the equipment control program, the actions performed by the equipment may not be in accordance with the expectation due to wrong logic judgment conditions, improper setting of loop structure, wrong program jumps, etc.
Compatibility problem after software update: When the control software is updated, the new program code may be incompatible with the old hardware or other related software modules, making the control unit unable to correctly interpret and execute instructions.
l Solution
Check and correct the program logic: Check through the debugging tool of the control software. You can set breakpoints and gradually observe the variable values and execution paths of the program at key steps to find the location of logical errors and correct the code. For example, check the code segment controlling the sequence of pressure bearing and magnetization to see if there is any conditional judgment error that causes disorder in the sequence.
Perform compatibility testing and tuning: Perform all compatibility tests before updating the software. Run the updated software and the original hardware equipment and other related software simultaneously in the test environment to check for incompatibility. If incompatibility problems are found, adjust the software, which may involve modifying the software interface, adjusting the data reading and processing, etc., to ensure that the software and hardware and other software can work in coordination with each other.
2. Parameter setting error fault
l Fault phenomenon
Abnormalities in the operating parameters of the equipment: such as the pressure parameters of the bearing, the magnetic field strength of magnetization and time parameters are set incorrectly, resulting in unqualified product quality. For example, excessive pressure may damage the bearings, and insufficient magnetizing strength will make the motor's magnetism fail to meet the requirements.
Abnormal operation speed of the equipment: Including improper setting of the speed of bearing pressure and magnetizing frequency, which affects the working efficiency and product quality.
l Cause analysis
Operator's error: During the debugging of the equipment or parameter adjustment, the operator may accidentally input the wrong value or fail to understand the unit and range of the parameter correctly.
Parameter unit mismatch: In the control unit, different parameters may have different unit settings. If the operator does not pay attention to the unit when setting the parameters, it may lead to the actual setting of the parameters does not match with the expected.
l Solution
Check and correct the parameter settings: Carefully check the parameter settings in the control unit that are related to pressure bearing, magnetization, and so on. You can refer to the operating manual of the equipment to determine the correct parameter ranges and default values. Based on the results of the check, correct the incorrect parameters to the correct values. After correcting the parameters, carry out equipment testing and observe whether the operating parameters return to normal.
Define the units of the parameters and set limits: In the software interface of the control unit, define the units of each parameter and provide a unit conversion function (if required). Limit the setting of important parameters, such as setting the upper and lower limits of the parameters, to prevent the operator from inputting values beyond the reasonable range. At the same time, provide the default parameter values as a reference to facilitate the operator to set the parameters correctly.
3. Communication Failure
l Failure phenomenon
Failure to communicate properly between the control unit and other equipment components: e.g., failure to receive sensor signals, resulting in failure to accurately control the press bearing and magnetizing process; or failure to send commands to actuators (e.g., motor drives, hydraulic/pneumatic controllers), preventing the equipment from working properly.
Communication breakdowns or data transmission errors: may cause the device to act incorrectly or stop operating. For example, an error in sending speed control commands to the motor driver results in abnormal motor speed.
l Cause Analysis
Damaged communication lines: Loose, broken, or aged connection lines can affect the quality and stability of signal transmission.
Incompatible communication protocol: When the control unit and other equipment components use different communication protocols or inconsistent protocol versions, communication failures may occur.
Electromagnetic interference: Other electrical equipment around the device, sources of electromagnetic radiation, etc. may interfere with the communication signal, resulting in communication errors.
l Solution
Check and repair the communication line: Check the communication line to ensure that the connection line is firmly connected and not broken or aged. For damaged lines, replace the lines with new ones in time. A professional cable tester can be used to check the connectivity and signal quality of the lines.
Check the communication protocol settings: Make sure that the communication protocol between the control unit and other equipment components is consistent. If the protocols are incompatible, it is necessary to configure the device to use the same communication protocol or perform protocol conversion.
Take anti-interference measures: For electromagnetic interference problems, take shielding measures for communication lines, such as using shielded cables, and ensure that the shielding layer is well grounded. At the same time, the equipment and may produce electromagnetic interference source to maintain a certain distance, or the source of interference to take shielding, filtering and other measures to reduce its electromagnetic interference to the outside world.
4, control unit hardware failure
l Failure phenomenon
Control unit is dead or unresponsive: the indicator lights on the panel of the device does not light up or the operation button fails, the device can not start or stop normally.
Some functional modules of the control unit are damaged: for example, the input and output interfaces are damaged, resulting in failure to receive or send signals. For example, the correct signals cannot be output to control the pressure of the pressure bearing and the intensity of magnetization.
l Cause Analysis
Hardware aging: After long-term use, the electronic components (such as chips, capacitors, resistors, etc.) in the control unit may be aging and have deteriorated performance.
Power supply problems: excessive high or low power supply voltage, excessive power supply fluctuations, power supply short circuit, etc., may damage the electronic components in the control unit.
Environmental factors: such as high temperature, excessive humidity, excessive dust, etc., may affect the normal operation of the control unit, resulting in hardware damage.
l Solution
Detecting and replacing aging hardware components: For aging hardware components, it is necessary for professional maintenance personnel to use professional tools to detect and replace them. According to the maintenance manual of the device, you can find the corresponding faulty components and replace them with components of the same type.
Check the power supply: Use a voltmeter to measure the power supply voltage to ensure that it is within the rated voltage range of the control unit. If there is a problem with the power supply, repair the power supply equipment or install a voltage regulator, UPS, etc. to provide a stable power supply.
Improve the working environment of the control unit: keep the ambient temperature and humidity within the appropriate range, and regularly clean the dust inside and outside the control unit to prevent the accumulation of dust from damaging the hardware.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Company Limited through the page chat tool to seek help.
