How to fault analysis and troubleshooting of DC motor motor automatic bearing press fitting machine?
I. Failure analysis steps
1, collect information
Observe the failure phenomenon: carefully observe the specific performance of the equipment at the time of failure, including whether the equipment completely stops running, whether there is an abnormal sound (such as sharp friction, buzzing, impact, etc.), whether there is an abnormal odor (such as burning smell), whether there is an alarm on the operating panel information display, and so on.
Ask the operator: to the personnel who were operating the equipment to understand the process of failure, such as equipment before the failure of special operations (such as changing parameters, replacement of workpieces, etc.), whether the failure is a sudden or gradual occurrence, whether the equipment has been repaired or maintained recently, and so on.
Preliminary judgment of the type of failure
According to the information collected, the initial judgment of the fault is a mechanical failure, electrical failure, software failure or sensor failure, etc.. For example, if the equipment has abnormal mechanical noise, it may be mechanical parts are worn, loose or jammed; if the equipment is completely unresponsive and the power indicator does not light up, it is likely that the power supply part of the electrical system has problems.
2、Check the vulnerable parts and key parts
Mechanical parts: Check whether there are obvious damages, such as abrasion, deformation, breakage and so on, such as press fitting head, mold, guide rail, slider, transmission parts (such as belts, chains, gears) and other perishable parts. At the same time, check the connecting parts of the equipment, such as whether the bolts are loose, whether the connecting parts are off, etc.
Electrical part: Check whether the power line is normal, including whether the plug is plugged in tightly, whether the socket is energized, whether the fuse is blown or not, whether the circuit breaker is tripped or not, and so on. Check whether the wiring of the motor is firm, and whether the motor itself shows signs of overheating and smoke. Check whether the contacts of the relays, contactors and other components in the electrical control box are normal, and whether there is any ablation, sticking and so on.
Sensor part: For pressure sensors, displacement sensors, photoelectric sensors, etc. in the equipment, check whether the connecting wires of the sensors are loose or damaged, whether the sensor probes are covered or damaged, and whether the sensor's working status is normal (e.g., whether there is signal output).
Software part (if applicable): If software failure is suspected, check whether there are error prompts in the control software of the device and whether the software can start and run normally. Check whether the parameter settings in the software are correct, whether there is a program conflict or stuck.
3, in-depth analysis of the cause of the failure
If the initial inspection did not find obvious problems, further in-depth analysis is required. For example, the use of professional testing tools (such as multimeter, megohmmeter, oscilloscope, etc.) on the testing of electrical components, check its resistance, voltage, current and other parameters are normal; precision measurement of mechanical components, such as checking the parallelism of the guide rail, the perpendicularity of the head of the press-fit, etc.; for software problems, you can check the system logs or software debugging tools to find the cause of the failure.
Second, common troubleshooting methods
1、Mechanical troubleshooting
Component wear or damage: If you find serious wear and tear of the press fitting head, mold and other parts, should be replaced in a timely manner with new parts. For damaged transmission parts (such as broken belts, worn chains), replace new parts with the same specifications, and install and debug according to the installation requirements of the equipment.
Loose or jammed connections: Tighten loose bolts and connections to ensure that all parts of the equipment are firmly connected. If the mechanical parts are jammed, such as the guide rail slider jammed, you need to clean up the debris between the guide rail and the slider, add lubricant, check whether there is any foreign matter entering to cause the jamming, and if necessary, repair or replace the jammed parts.
2, electrical troubleshooting
Power supply problems: if the fuse is blown, first check whether the circuit has a short circuit, after eliminating the short-circuit fault, replace the fuse with the same specifications. For power line damage, repair or replace the damaged wires. If the power switch is faulty, replace the power switch with a new one.
Motor failure: If the motor does not rotate, check whether the wiring of the motor is correct and whether the motor is overloaded. For overload conditions, reduce the motor load and restart. If motor brushes (for brushed motors) are badly worn, replace brushes. If the motor windings are shorted or disconnected, the motor needs to be repaired or replaced.
ELECTRICAL COMPONENT FAILURES: For burnt relay or contactor contacts, sandpaper can be used to gently sand the contacts to restore good contact. If the contacts are badly damaged, replace the relay or contactor with a new one. For faulty circuit boards, check whether the components on the board are damaged, such as capacitor bulging, burnt chips, etc. If necessary, replace the damaged components or the whole board.
3, sensor troubleshooting
Signal abnormality: If the sensor signal is unstable, check whether the sensor connection line is loose or disturbed. Re-plug the connecting wire to ensure a firm connection, and take shielding measures (such as the use of shielded wire) to reduce interference. If the sensor probe is contaminated, clean the probe surface.
No signal output: Check whether the power supply of the sensor is normal, use a multimeter to measure whether the power supply voltage of the sensor is within the specified range. If the power supply is normal but no signal output, may be the sensor itself is damaged, replace the new sensor, and calibrate according to equipment requirements.
4、Software Troubleshooting
Program error: If there is a program error in the software, try to restart the device to see if it can return to normal. If the problem still exists, repair it according to the software's error prompts, which may require reinstalling the software, updating the software version or modifying the wrong parameters in the program.
Wrong parameter setting: Double check the pressing parameters of the equipment, such as pressing force, displacement, speed and other parameters are set correctly. If the parameters are wrongly set, reset the parameters according to the process requirements and carry out trial loading verification.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Ltd. through the page chat tool to seek help.
