How to fault analysis and troubleshooting for DC motor motor automatic carbon brush cover assembly machine?
First, the basic steps of fault analysis
1, collect information
Observe the failure phenomenon: carefully observe the specific performance of the assembling machine when the failure occurs, including whether the equipment is completely stopped or part of the function is abnormal, whether there is an abnormal sound (such as sharp friction sound, impact sound), smell (such as burnt smell) or smoke and so on. For example, if you hear an unusual humming sound in the motor area, it may suggest a problem with the motor or its nearby drive components.
Ask the operator: Talk to the operator who was present at the time to find out exactly how the fault occurred, such as whether the fault occurred when the equipment was started up, during operation, or at a specific assembly step, whether the equipment had previously behaved abnormally, and whether equipment adjustments or maintenance had recently been performed, among other information. This helps to narrow down the scope of the fault.
2, analyze the scope of possible causes of failure
According to the information collected, combined with the structure and working principle of the equipment, the cause of the failure is initially categorized. Failures may originate from factors such as mechanical systems, electrical systems, software systems, or the working environment. For example, if the equipment is running for a period of time and then suddenly stops, and the motor shows signs of overheating, it may be caused by electrical overload, poor heat dissipation, or excessive frictional resistance of mechanical parts.
3, step by step to investigate the possible causes
Starting from the very likely cause, gradually check the various components and systems. You can use the first easy to difficult, first external after the principle of internal. For example, first check whether the external connection of the equipment is loose, and then check the internal mechanical structure and electrical wiring in depth.
Second, the mechanical system failure analysis and elimination
1, transmission component failure
Belt and chain problems: If the belt or chain is found to be slack, it will lead to poor power transmission. Check whether the tensioning device of the belt or chain is working properly, and readjust the tension if necessary. If the belt or chain is worn or broken, it needs to be replaced promptly.
Gear Failure: Worn, missing or poorly meshed gears can produce abnormal noise and vibration. Check the tooth wear of the gears, replace the worn or damaged gears with new ones, and make sure that the installation accuracy and meshing clearance of the gears meet the requirements.
Bearing Failure: Worn bearings can cause rotating parts to rotate inflexibly, noisily, or with heat. Check the lubrication of the bearings, if the lubrication is insufficient, add the appropriate amount of grease. If the bearings are damaged, it is necessary to replace the bearings and pay attention to the operation specification during installation to avoid damaging the new bearings.
2、Fixture and robotic arm failure
Fixture problem: Wear and deformation of the fixture will affect the fixing effect of the carbon brush or cover. Check whether the clamping force of the fixture is appropriate, and adjust the clamping device of the fixture if necessary. For worn or deformed fixture parts, such as collets, positioning pins, etc., replace or repair them in time.
Mechanical arm failure: Inflexible movement or loss of precision of the mechanical arm may be caused by loose joints, worn or poorly lubricated moving parts. Check the joint parts of the mechanical arm, tighten the loose screws; clean and lubricate the moving parts of the mechanical arm; calibrate the precision of the mechanical arm to ensure that its movement precision meets the requirements.
Third, the electrical system failure analysis and troubleshooting
1、Motor failure
The motor does not rotate or the speed is abnormal may be due to power supply problems, motor winding failure, brush wear and other reasons. Firstly, check whether the power supply of the motor is normal, including whether the voltage is stable and whether the fuse is blown. Then, use a multimeter to check the resistance value of the motor winding to determine whether there is a short circuit or broken circuit. For DC motor, but also check the brush wear, such as brush wear serious, need to replace the brush.
2, sensor failure
Photoelectric sensor failure: If the photoelectric sensor can not detect the position of the parts normally, first check whether the sensor's optical path is blocked, clean the sensor's lens and the optical path in the dust, oil and so on. Check whether the installation position of the sensor is correct and whether it is aligned with the detected object. If the sensor output signal is abnormal, use a multimeter or oscilloscope to check the output signal of the sensor to determine whether the sensor is damaged, such as damage, it needs to be replaced.
Other sensor failures: for proximity sensors, pressure sensors, displacement sensors, etc., check the sensor's sensing surface for dirt or damage, clean or repair the sensing surface. Check whether the connection line of the sensor is normal, make sure the signal transmission is smooth. Calibrate the sensor to check whether its detection accuracy meets the requirements, such as not in line with the need to recalibrate or replace the sensor.
3, controller failure
Programmable Logic Controller (PLC) failure: If the PLC program runs abnormally, check whether there are logic errors in the program, monitoring and debugging through the programming software. Check whether the input / output (I / O) interface of the PLC is normal, use a multimeter to check the electrical status of the I / O point, for the damaged I / O module, should be replaced in time. If there are communication problems between PLC and other devices, check whether the communication line and communication parameters are set correctly.
Failure of other controllers: For motor controllers, touch panel controllers, etc., check their power supply, connection lines and parameter settings. If the controller fails, try to restart the device, such as the problem still exists, you may need to replace the controller or its internal fault components.
Fourth, the software system failure analysis and troubleshooting
l Program Failure: If the software crashes, crashes or runs incorrectly, first try to restart the software and the device. Check whether the software has an updated version, updated software may fix known program errors. If the problem persists, check the system log file of the software and analyze the error messages. It may be necessary to contact the software vendor for further troubleshooting, such as fixing bugs or errors in the program code.
l Parameter setting error: If the operating parameters of the equipment (e.g. assembly speed, pressure control parameters, etc.) are incorrect, check the parameter setting interface in the software. Make sure that the parameter setting meets the requirements of the equipment and the actual production situation. If there is any error, reset the correct parameters. At the same time, check whether the parameters have been accidentally modified, consider setting user rights to prevent unauthorized parameter modification.
l Communication failure: If there is a communication problem between the software and hardware (e.g., with motor controller, sensor) or with other systems (e.g., upper computer management system), first check whether the communication line is firmly connected and whether the communication interface is normal. Check whether the communication protocol and parameter settings are consistent, such as baud rate, data bits, stop bits, etc. Use debugging tools to check whether the data sent and received by the software is correct, if necessary, reconfigure the communication settings or repair the errors in the communication software module.
V. Failure analysis and troubleshooting caused by working environment factors
l Temperature and humidity problems: If the temperature of the equipment's working environment is too high or too low, it may affect the performance of the electrical components and the precision of the mechanical parts. Check whether the equipment has appropriate heat dissipation measures, such as whether the cooling fan is working properly and whether the heat sink is blocked. For too low a temperature, heating measures may be necessary. If the ambient humidity is too high, it may lead to electrical short-circuiting or rusting of mechanical parts. At this time, you can use dehumidification equipment to control the humidity, and at the same time, check whether the equipment's waterproof and moisture-proof measures are in place.
l Dust and impurity problems: a large amount of dust and impurities may enter the interior of the equipment, affecting the movement of mechanical parts and the heat dissipation of electrical components. Clean the equipment regularly, especially the dust around the motor, sensors, controllers and other key components. You can use compressed air to blow dust, wipe and other ways to clean.
l Electromagnetic interference problems: If there is a strong source of electromagnetic interference around the equipment (such as large motors, welding machines, etc.), it may affect the normal operation of the sensors and controllers. Take electromagnetic shielding measures, such as the use of shielded wires to connect electrical equipment, installation of electromagnetic shielding cover. At the same time, adjust the layout of the equipment as far away from the source of interference as possible.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. technical specialists through the page chat tool to seek help.
