What are the common mechanical failures and solutions for DC brushed motor motor automatic pressure bearing magnetizing machine?
1, transmission system failure
l Failure phenomenon
Transmission belt (chain) problems: transmission belt (chain) slippage, so that the equipment power transmission is unstable, affecting the work efficiency; transmission belt (chain) fracture, resulting in sudden stopping of the equipment.
Gear failure: gear wear will produce abnormal noise, and may lead to transmission precision decline; gear broken teeth will interrupt the transmission, the equipment can not work normally.
l Cause analysis
Tension problem: For transmission belt (chain), insufficient tension is a common cause of slippage, which may be due to natural relaxation after long time use or failure of tension adjusting device. Excessive tension may lead to overstretching or even breakage of the drive belt (chain).
Excessive load: If the equipment encounters excessive resistance during operation, such as jammed mechanical parts, poorly installed bearings, etc., it will make the drive belt (chain) or gears bear loads exceeding their limits, thus leading to failure.
Wear and fatigue: transmission belt (chain) and gear in the long-term operation process, due to friction and periodic stress, will produce wear and fatigue. For example, rubber aging of drive belt, pin wear of chain, and tooth fatigue wear of gears.
l Solution
Adjust or replace the transmission belt (chain): For the case of transmission belt slipping, first check the tension adjusting device, increase the tension of the transmission belt by adjusting the tensioning wheel, etc., so as to restore the normal friction. If the drive belt has been aging or badly worn, it should be replaced with a new one in time. For the transmission chain, check whether its tension is appropriate. After the chain breaks, you need to replace the chain with the same specification and make sure that it is installed correctly and the number of links and connection of the chain meet the requirements.
Checking and repairing the gears: When the gears show abnormal rattling, stop the machine to check the wear of the gears. For mildly worn gears, they can be repaired by adjusting the gear's meshing gap and grinding the tooth surface. If the gear has broken teeth, it must be replaced with a new one, and it is necessary to ensure that the new gear is consistent with the original gear in terms of modulus, number of teeth, precision and other parameters.
Reduce the load and optimize the operation: Check the mechanical parts of the equipment and exclude the factors that may lead to jamming, such as cleaning foreign objects and lubricating bearings, etc., in order to reduce the load of the transmission system. In the process of equipment design and operation, rationalize the workflow to avoid overloading.
2、Pressure bearing mechanism failure
l Failure phenomenon
Insufficient or uneven pressure: resulting in bearing press-fitting is not in place or the quality is not qualified, affecting the performance of the motor.
Damage of press fitting tool: such as deformation and rupture of press head, which can not carry out press fitting work normally.
l Cause analysis
Problems of hydraulic (pneumatic) system: If the press bearing mechanism is driven by hydraulic (pneumatic), insufficient system pressure, faulty pressure regulating valve, leakage of pipeline, etc. may lead to pressure problems.
Tool material fatigue and overload: Press fitting tools may cause material fatigue, deformation or rupture due to frequent pressure during long-term operation. If greater resistance is encountered during press fitting, such as bearings fitting too tightly with the shaft, the press fitting tool may be subjected to overload pressure, accelerating its damage.
l Solution
Check and repair the hydraulic (pneumatic) system: Check the working condition of the hydraulic (pneumatic) pump, including whether the pressure output of the pump is normal, whether there is abnormal noise, etc.. Check whether the setting of the pressure regulating valve is correct, if necessary, readjust the pressure. Check piping connections for tightness and leakage. For leaking piping, seals need to be replaced or piping repaired.
Replace and calibrate press fit tools: For damaged press fit tools, such as deformed nipples or cracked fixtures, replace the tool with a new one in a timely manner. After replacement, calibrate the new tool, e.g., check the flatness and perpendicularity of the press head to ensure that it can meet the press fitting requirements. Regular inspection and maintenance of the press fitting tools, the use of appropriate materials and processes for the production of press fitting tools to improve their durability.
3、Failure of magnetizing mechanism
l Failure phenomenon
Insufficient or uneven magnetizing strength: the magnetism of the motor fails to meet the requirements, affecting the performance of the motor.
Damaged magnetizing head: such as worn out or short-circuited magnetizing head, it can not be magnetized normally.
l Cause analysis
Power supply and circuit problems: unstable output voltage of the magnetizing power supply, insufficient current or damaged components in the magnetizing circuit (e.g. capacitors, inductors, etc.) may lead to insufficient or uneven magnetizing intensity.
Frequent use and wear of the magnetizing head: During frequent magnetization, the magnetizing head may be worn and overheated due to contact with the magnetized object and electromagnetic induction, which may lead to damage.
l Solution
Check the magnetizing power supply and circuit: Use a voltmeter and ammeter to check whether the output voltage and current of the magnetizing power supply are stable and meet the requirements. Check the components in the magnetizing circuit, use multimeter and other tools to detect whether the components are damaged, and replace the damaged components in time. At the same time, check whether the connection of the circuit is good to ensure that the signal transmission is normal.
Replace and maintain the magnetizing head: for worn or damaged magnetizing head, replace the head with a new one in time. In daily use, pay attention to the working environment of the magnetizing head to avoid excessive heat and moisture. You can set up a suitable buffer material between the magnetizing head and the magnetized object to reduce wear and tear.
4. Positioning and clamping device failure
l Failure phenomenon
Inaccurate positioning: causing deviation in the installation position of bearings or motor parts and affecting the assembly precision of the equipment.
Insufficient or excessive clamping force: Insufficient clamping force will cause the parts to move during the machining process and affect the machining quality; excessive clamping force may damage the parts.
l Cause analysis
Wear or loosening of positioning parts: positioning parts such as positioning pins and blocks may wear out during frequent operation, resulting in a decrease in positioning accuracy. Loose fixing screws of the positioning device may also affect the positioning effect.
Failure of the clamping mechanism: Wear of the clamping jaws of the clamping mechanism, damage to the piston seals of the clamping cylinder (or hydraulic cylinder), etc., may lead to problems in the clamping force.
l Solution
Adjust and repair the positioning device: check whether the fixing screws of the positioning device are loose, if loose, retighten them. For worn positioning pins and blocks, repair or replace them according to the degree of wear. For example, for worn positioning pins, repair their diameters by means of chrome plating, etc., or directly replace them with new ones. In the course of equipment maintenance, calibrate the positioning device regularly and check the positioning accuracy using gauges (e.g. calipers, micrometers, etc.).
Repair or replace the clamping mechanism components: check the wear of the clamping jaws and seals. For worn clamping jaws, they can be repaired or replaced; for cylinders (or hydraulic cylinders) with damaged seals, replace the seals with new ones to restore normal clamping force. At the same time, check the mechanical structure of the clamping mechanism, tighten the loose screws and connecting pins to ensure the stability of the clamping mechanism.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Ltd. through the page chat tool to seek help.
