How to analyze and troubleshoot the faults of DC brush motor motor fully automatic pressure bearing magnetizing integrated machine?
1, the basic steps of fault analysis
l 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; observe whether there are abnormal sounds, smoke, sparks, etc.; check the processing quality of the product, such as whether the press bearing is in place, whether the magnetizing strength meets the requirements, etc.; at the same time, pay attention to the status of the equipment's indicator light, whether there is an alarm light on.
Ask the operator: Communicate with the employee who was operating the equipment at that time to understand the operation of the equipment before the failure. For example, whether the parameter adjustment, replacement of raw materials, equipment, whether there has been abnormal vibration or sound. The operator may provide some valuable clues, such as some abnormal operation or feeling before the equipment failure.
Check the equipment operation records and historical data: check the equipment comes with the operation record system (if any), check the equipment before and after the failure of parameter changes, operation records, alarm information and previous maintenance records. These data can help determine whether the failure occurred suddenly or was caused by problems accumulated over a long period of time.
l Preliminary judgment of the type of failure and the range of possible causes
According to the collected information, the initial classification of fault types, such as mechanical faults, electrical faults, software faults or a combination of faults. For example, if the device has obvious mechanical noise and loose parts, it may be a mechanical fault; if the motor does not rotate and there is no electrical alarm, it may be a connection problem in the electrical system or a fault in the motor itself; if the device 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 setting, communication failure, etc.
l Step-by-step investigation of possible causes
Examine from simple to complex: 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 device is blocked by obvious 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.
2、Common faults and troubleshooting methods
l Mechanical faults
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, long-term wear and tear resulting in fatigue damage; 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. At the same time, check and make sure the transmission parts are well lubricated to avoid overloading operation.
Failure of pressure bearing mechanism
Failure phenomenon: insufficient or uneven pressure on the press bearing, resulting in the bearing press fitting not in place or quality is not qualified; the pressure head is damaged, can not carry out normal press fitting work.
Cause analysis: hydraulic (pneumatic) system problems (such as insufficient pressure, pipeline leakage); pressure head material fatigue, overload damage.
Remedy: Check the hydraulic (pneumatic) system, including the working status of the pump, the setting of the pressure regulating valve, whether the pipeline connection is tight, etc., and repair the problem of insufficient pressure or leakage. For damaged pressure head, replace the pressure head with a new one in time and calibrate it after replacement.
Failure of magnetizing mechanism
Failure phenomenon: Insufficient or uneven magnetizing strength, so that the magnetism of the motor fails to meet the requirements; the magnetizing head is damaged and cannot be magnetized normally.
Cause analysis: unstable output voltage of the magnetizing power supply, insufficient current or damaged components in the magnetizing circuit (e.g. capacitors, inductors, etc.); the magnetizing head may be worn out and overheated due to the contact with the magnetized object and electromagnetic induction during frequent magnetization, which may lead to damage.
Elimination method: 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. For worn or damaged magnetizing head, replace the head with a new one in time.
Positioning and clamping device failure
Failure phenomenon: inaccurate positioning, resulting in deviation in the installation position of bearings or motor parts, affecting the assembly accuracy of the equipment; insufficient or excessive clamping force, insufficient clamping force will make the parts move during the machining process, affecting the machining quality; excessive clamping force may damage the parts.
Cause analysis: positioning parts are worn or loose (such as positioning pins, positioning blocks); clamping mechanism failure (such as clamping claw wear, the piston seal of the clamping cylinder (or hydraulic cylinder) is damaged).
Remedy: 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. Check the wear of the clamping jaws and seals of the clamping mechanism. For worn clamping jaws, repair or replace them; for cylinders (or hydraulic cylinders) with damaged seals, replace them with new seals to restore normal clamping force.
l Electrical Failure
Power failure
Failure phenomenon: the equipment can not be started, the power indicator does not light; or equipment in the operation process suddenly power failure.
Cause analysis: loose power plug, socket failure, blown fuse, damaged power switch or power line breakage.
Remedy: Check whether the power plug is tightly inserted, try to replace the socket; check the fuse, if blown, then replace the fuse with the same specification; check the power switch on and off, if damaged, then replace it; use a multimeter to check the power supply line, repair or replace the disconnected part.
Motor failure
Failure phenomenon: motor does not turn, abnormal speed or abnormal noise.
Cause analysis: power supply problems (such as low voltage, lack of phase, loose or damaged power cord); motor internal damage (such as brush wear, armature winding short circuit or broken, commutator surface problems); motor drive failure (such as parameter setting error, 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 you suspect that the internal circuit of the driver is damaged, you need a professional to repair or replace it.
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 the equipment can not operate 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 fasten, reduce electromagnetic interference around the equipment (such as using shielding measures, away from the source of interference).
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; electrical component quality problems 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 operation errors lead to uncoordinated action of the equipment
Failure phenomenon: the action sequence of the equipment is chaotic, such as the wrong sequence of bearing pressure and magnetization, a certain action is repeated or cannot be started.
Cause analysis: program logic errors (such as programming errors, software update compatibility issues); software parameter setting errors (such as assembly speed, position parameters, etc. improper settings).
Troubleshooting: Check the program logic through software debugging tools, 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, specify the unit of the parameters in the software interface, set the parameter limitations and reminder messages to prevent parameter setting errors.
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 the device.
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.
