DC motor motor automatic tester how to carry out maintenance?
DC motor motor automatic tester maintenance:
I. Daily maintenance
1、Cleaning
External cleaning:
At the end of each day's use, wipe the shell of the tester with a clean soft cloth to clear away dust, oil and other debris on the surface. This not only keeps the equipment neat and tidy, but also prevents dust from entering the interior of the equipment and affecting the electrical performance and normal operation of mechanical components.
For hard-to-clean nooks and crannies, a small cleaning brush or can of compressed air can be used. Note that when using compressed air, keep the proper distance and angle to avoid damaging the sensitive components inside the equipment.
Internal cleaning (performed periodically):
Depending on the environment and frequency of use of the equipment, open the case of the tester at regular intervals (e.g., one month or one quarter) and use a vacuum cleaner or soft-bristle brush to clean the dust on the internal circuit boards, motors, sensors, and transmission parts.
For circuit boards, special care should be taken to avoid static electricity damage to electronic components. You can use anti-static cleaning tools such as anti-static brushes and cleaners. After cleaning, make sure the circuit board is completely dry before reinstalling and energizing.
2、Check mechanical components
Transmission parts check:
Before turning on the machine every day, check the tension and wear of transmission parts such as belts, chains and gears. For belt transmission, proper tension can ensure the effective transmission of power. If the belt is found to be slack, adjust it according to the requirements of the equipment manual; if the belt is worn seriously, it should be replaced in time.
Check the meshing of the gears and chains to see if there is any wear of the tooth surface, chain looseness or jumping teeth. If necessary, add an appropriate amount of lubricant, such as grease or lubricant, to reduce friction and wear.
Fixture Inspection:
Before each test, check that the fixture used to hold the motor is secure and that the jaws of the fixture are not deformed, worn, or loose. Ensure that the fixture can accurately hold the motor so that the connection between the motor and the test equipment is stable and reliable.
For worn fixture parts, such as rubber pads or metal contact surfaces of the clamping jaws, they should be replaced in time to ensure good clamping effect.
Mechanical connection check:
Check whether the connection bolts and nuts between the various mechanical parts of the test machine are loose. Regularly use wrenches and other tools to tighten the key parts of the connection parts to prevent vibration, displacement and equipment damage caused by loosening.
Check whether there are signs of deformation or damage to the mechanical structure of the equipment, such as whether the test platform is flat and whether the bracket is stable. If deformation is found, adjust or replace the damaged parts in time.
Second, regular maintenance
1、Electrical system maintenance
Electrical connection check:
Every month or so, check whether the wire connections inside the tester are firm, including the power line of the motor, the signal line of the sensor, and the connection line between the controller and each component. Check whether the wire connectors are oxidized, loose or detached.
For loose connectors, use appropriate tools to re-tighten them; for oxidized connectors, you can use professional electrical cleaners to clean them and apply the appropriate amount of conductive paste to reconnect them.
Electrical component inspection:
Periodically (quarterly or half-yearly) use tools such as multimeters to conduct simple performance tests on major electrical components, such as the motor's windings, capacitors, resistors, relays and so on. Check whether the insulation resistance of the motor windings is within the normal range, whether the capacity of the capacitors is normal, and whether the resistance value of the resistors is in accordance with the nominal value, etc.
Replace electrical components that have deteriorated in performance or are damaged. When replacing electrical components, make sure that components of the same specifications and models are used and that they are installed in accordance with the correct installation methods.
Software system update and maintenance:
Pay attention to the software update information released by the tester's software developer, and update the software system on a regular basis (according to the frequency of software updates). Software updates may include fixing software vulnerabilities, adding new features, improving system stability, and other aspects.
Before updating the software, back up important test data and parameter settings to prevent data loss due to unforeseen circumstances during the update process. After the update is completed, test the main functions of the software to ensure that the software can operate normally.
2、Lubrication Maintenance
Motor bearing lubrication:
According to the working load and usage time of the motor, lubricate the motor bearings regularly (generally every 3 - 6 months). Use special motor bearing grease and add it through the grease injection hole on the bearing seat. When adding grease, pay attention to the proper amount to avoid overheating of the bearings caused by too much grease.
Before lubrication, clean the old grease and impurities around the bearing housing and bearings to ensure that the new grease can give full play to its function.
Lubrication of other mechanical parts:
Regularly lubricate other mechanical moving parts of the tester, such as transmission gears, screws, guide rails, etc., in accordance with the requirements of the equipment manual. Select the appropriate lubricant, such as lubricating oil or grease, according to the movement speed of the components, load and other factors to determine the lubrication cycle.
During the lubrication process, make sure that the lubricant is evenly applied to the surface of the moving parts to avoid lubricant dripping onto the electrical components or test samples.
3、Calibration and accuracy check
Sensor calibration:
Regularly (every six months or a year) calibrate the various sensors on the tester, such as speed sensors, temperature sensors, torque sensors and so on. Use standard calibration equipment or reference sensors of known accuracy to calibrate the sensors in accordance with the calibration procedures of the equipment.
During the sensor calibration process, record the calibration data, including calibration date, calibration equipment information, and sensor parameters before and after calibration. If the measurement error of the sensor is out of the allowable range, adjust the calibration parameters of the sensor or replace the sensor.
Test accuracy check:
Periodically check the overall test accuracy of the tester using a standard motor or a sample motor of known performance. Mount a standard motor on the tester, run a standard test program, and compare the difference between the test results output by the tester and the known parameters of the standard motor.
If it is found that the test accuracy has decreased, the factors that may affect the test accuracy are examined one by one, such as sensor accuracy, mechanical transmission accuracy, software algorithms and so on. According to the results of the investigation, adjust, repair or replace the corresponding components.
Third, long-term maintenance
1、All inspection and maintenance
All mechanical components are checked:
Conduct a full inspection of the mechanical parts of the tester every year or every two years. Dismantle important mechanical parts, such as motors, transmission mechanisms, fixtures, etc., to check its internal wear and tear, the integrity of the parts and the rationality of the structure.
Replace the parts with serious wear and tear, such as gears, bearings, screws, etc. When reassembling the mechanical parts, operate in strict accordance with the assembly drawings and technical requirements of the equipment to ensure that the installation accuracy and fit gap of the parts are in accordance with the standards.
Electrical system all check:
Conduct a full inspection of the electrical system, including whether the solder joints of the circuit boards are firm, whether the wires are aging, and whether the electrical components have potential failure hazards. Use professional electronic testing equipment, such as oscilloscope, insulation resistance tester, etc., to test the key parameters of the electrical system.
Repair or replace any electrical system problems found, such as damaged circuit boards and broken wire insulation. After repairing the electrical system, conduct all the electrical performance tests to ensure that the system can work normally.
2、Equipment upgrading and remodeling
Hardware upgrade:
According to the changes in testing requirements and technological development, consider upgrading the hardware of the tester. For example, replace higher precision sensors, more powerful motors or more advanced controllers to improve the performance and testing capabilities of the tester.
When upgrading hardware, ensure the compatibility of the new hardware with the existing equipment, including the electrical interface, mechanical installation dimensions and software control system. At the same time, all the upgraded equipment is debugged and calibrated so that it can operate normally.
Software upgrade and function expansion:
With the updating of test standards and the diversification of test requirements, the tester software is upgraded and functionally expanded. Software upgrade may include adding new test items, improving test algorithms, optimizing the user interface and other aspects.
In the process of software upgrading and function expansion, users' operating habits and data compatibility should be fully considered. The upgraded software should be strictly tested to ensure the stability and accuracy of the software, and the operators should be trained accordingly so that they can skillfully use the new software functions.
If you still can't solve the problem by the above ways and means, please contact Xinhui electromechanical technical specialists through the page chat tool to seek help.
