What are the common control unit faults and solutions for DC motor motor automatic carbon brush cover assembly machine?
The following are the common control unit faults and solutions for DC motor motor automatic carbon brush cover assembly machine:
1, programmable logic controller (PLC) failure
l Failure phenomenon
Abnormal operation of the program: PLC program dead loop, jump error and other situations, resulting in the assembly of the machine's action sequence is chaotic, such as carbon brushes and cover assembly steps reversed, repeated action, and so on.
Input/Output (I/O) Signal Failure: The I/O points of the PLC do not respond or respond incorrectly. For example, the input signal cannot correctly receive the signal from the sensor, resulting in failure to trigger the next action; the output signal cannot correctly control the actuator, such as motors, cylinders, etc. do not work according to the instructions.
Communication failure: When the PLC needs to communicate with other devices (e.g., host computer, touch screen, etc.), there may be communication interruption, data transmission error, etc., which affects the remote monitoring and operation of the assembling machine.
l Solution
Program checking and updating: Use programming software to monitor and debug the PLC program to check whether the program logic is correct. If program errors are found, modify and update them according to the correct assembly process and control requirements. At the same time, backup the normal program so that it can be quickly restored in case of problems.
I/O Point Inspection and Repair: First, check whether the I/O point wiring of the PLC is firm, and whether there is any looseness, detachment or short circuit. Use a multimeter or other tools to check the electrical status of the I/O points, and replace the damaged I/O modules in time. After replacing the module, it is necessary to reconfigure the related parameters and programs.
Communication fault troubleshooting: Check whether the communication line is intact, including whether the communication cable is connected correctly and whether it is broken. Confirm whether the communication parameters are set correctly, such as baud rate, data bits, stop bits, etc. If it is a network communication problem, check whether the network equipment (such as switches, routers, etc.) is working properly, try to reconfigure the network connection or replace the network equipment.
2、Touch screen failure
l Failure phenomenon
Touch unresponsive: when touching the screen, there is no response, unable to operate and parameter settings.
Abnormal display: the screen appears splash screen, black screen, flashing or display content errors, etc., affecting the operator's observation and control of the state of the assembly machine.
Inaccurate calibration: The touch position of the touch screen does not match the display position, resulting in operational errors.
l Solution
Hardware check: Check whether the power supply of the touch screen is normal and whether the voltage is stable. Check whether the connection between the touch panel and PLC or other control equipment is loose or damaged. For failures caused by connection problems, reconnect the lines; if it is a power problem, check the power module and repair or replace it.
Software problems: If the abnormal screen display is caused by a software failure, try to restart the device to see if it can return to normal. If the problem persists, it may be necessary to update or reinstall the driver for the touch screen. For inaccurate calibration, you can use the calibration tool that comes with the touch screen to recalibrate.
Cleaning and Maintenance: The surface of the touch screen may be affected by dust, oil and other contaminants. Use a clean, soft cloth to gently wipe the screen surface to remove dirt.
3, industrial computer failure
l Failure phenomenon
System crash or blue screen: industrial control machine in the operation of the process of sudden crash or blue screen, resulting in the entire assembly machine control software can not run.
Software operation error: the software to control the assembly machine flashback, can not open a specific function module or run too slow and so on.
Hardware failure: such as hard disk damage caused by data loss, insufficient memory to make the system lag, CPU overheating automatically shut down.
l Solution
System maintenance and repair: For system crash or blue screen, first try to do a hard reboot. If the problem occurs frequently, it may be caused by system file corruption or software conflicts. Use the repair tool that comes with the system or reinstall the operating system to solve the problem. After reinstalling the system, install new drivers and control software in time.
Troubleshooting software problems: Check if there is an updated version of the control software, and if so, update it in time to fix possible loopholes and errors. If the software is running too slowly, consider optimizing the system settings of the industrial control machine, such as closing unnecessary background programs and increasing virtual memory. For problems such as software flashback, check the system log file to analyze the cause of the error, and you may need to reinstall the software or adjust the configuration parameters of the software.
Hardware testing and upgrading: Use hardware testing tools to check the health of the hard disk, memory, CPU and other hardware. For the data loss problem of hard disk damage, you can try to use data recovery software to recover and replace the damaged hard disk in time. If the memory is insufficient, you can increase the memory capacity according to the specifications of the industrial control machine. For CPU overheating, check whether the cooling fan is working properly, clean the dust on the radiator, or replace the cooling device with a better one.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
