What are the common sensor failures and their solutions for DC motor motor automatic carbon brush cover assembly machine?
The following are common sensor failures and their solutions for DC motor motor automatic carbon brush cover assembly machine:
1, photoelectric sensor failure
Failure phenomenon:
Unable to accurately detect the position of carbon brushes or cover plates, resulting in assembly position deviation, affecting the assembly quality;
Reduced or unstable sensitivity to the sensing of objects, resulting in misjudgment, such as mistakenly judging the parts that are not in place as being in place, or vice versa;
Abnormal output signals of the sensor, such as no signal output or the signal is continuously unchanged.
Solution:
Check whether the optical path of the sensor is blocked or polluted, such as dust, oil, etc., clean the optical path in time;
Adjust the installation position and angle of the sensor to ensure that it can be accurately aligned with the detected object;
Check whether the power supply of the sensor is normal and the voltage is stable;
For aging or damaged photoelectric sensors, timely replacement of new sensors.
2, proximity sensor failure
Failure phenomenon:
The proximity sensor cannot normally sense the proximity of the target object, resulting in the automation process of the assembly machine interrupted or error;
Inaccurate sensing distance, may be farther or closer than the normal distance, affecting the judgment of the location of parts;
Sensor malfunction, sending out sensing signals when there is no target object approaching.
Solution:
Check the sensing surface of the sensor for dirt or damage, if so, clean or replace;
Adjust the sensitivity parameters of the sensor to adapt it to the actual working environment;
Check whether the installation of the sensor is firm, whether there is electromagnetic interference around, etc. If there is a source of interference, take shielding or isolation measures;
If the sensor itself fails, replace with a new proximity sensor.
3, pressure sensor failure
Fault phenomenon:
Unable to accurately measure the pressure when the carbon brush or cover is installed, resulting in too much or too little pressure, affecting the firmness of the assembly;
The reading of the pressure sensor is unstable and fluctuates greatly, making the operator unable to accurately determine the assembly;
Zero drift of the sensor, i.e., readings were taken without applying pressure, or inaccurate readings were taken after pressure was applied.
Solution:
Check the connecting lines to the pressure sensor for clogging, leaks, or air bubbles; if so, clean, repair, or vent;
Calibrate the pressure transducer and readjust the zero point and range in accordance with the prescribed calibration methods and standards;
Checking the elastic element of the transducer for deformation or damage, if so, replacing the elastic element or the whole pressure transducer;
Ensure that the sensor is installed in a suitable location to avoid the impact of vibration, shock and other factors.
4, displacement sensor failure
Fault phenomenon:
Unable to accurately measure the displacement of carbon brushes or cover plates, resulting in inaccurate assembly position, affecting product quality;
The output signal of the displacement sensor does not match the actual displacement, and there is deviation or bad linearity;
The sensor jumps and jams during the working process, affecting the continuity and accuracy of the measurement.
Solution:
Check whether the connecting parts of the displacement sensor are loose, if so, tighten them in time;
Clean the measuring rod and guide rail of the sensor, remove oil, impurities, etc., to ensure smooth movement of the measuring parts;
Calibrate and scale the displacement sensor to adjust its measurement accuracy and linearity;
If the electronic components inside the sensor are damaged, replace the corresponding components or the entire displacement sensor.
5、Temperature sensor failure
Fault phenomenon:
Unable to accurately measure the temperature of the motor or other key components, resulting in the temperature is too high when the alarm or measures can not be taken in time, may damage the equipment;
Temperature sensor readings are inaccurate, and there is a large deviation from the actual temperature;
Sensor intermittent failure, sometimes good and sometimes bad, affecting the monitoring of the temperature state of the equipment.
Solution:
Check whether the probe of the temperature sensor is in good contact with the object to be measured, and if it is loose, re-fix it;
Clean the dirt on the surface of the sensor probe to ensure good heat transfer;
Calibrate the temperature sensor, a standard thermometer can be used for comparison calibration;
Checking the wiring of the sensor for breaks, shorts or poor contact, if so, repairing or replacing the wiring;
If the temperature sensor itself is damaged, replace it with a new one in time.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
