What are the common mechanical failures and solutions for DC motor motor automatic tester?
1, transmission components failure
l Belt slippage or breakage
Failure phenomenon: when the motor and the test equipment are transmitted through the belt, the belt may slip, resulting in unstable speed of the tester, or the belt is completely broken, so that the motor can not effectively transfer power to the test components.
Reason analysis: the belt is worn after long-term use, resulting in insufficient friction and slippage; improper adjustment of the belt tension, too loose and easy to slip; the belt is of poor quality or the load exceeds its limit, which may lead to breakage.
Solution: For belt slippage, first check the tension of the belt, increase the tension by adjusting the position of the pulley, so that there is enough friction between the belt and the pulley. If the belt is badly worn, replace it with a new one and choose a belt of suitable specification and quality, as well as make sure that the alignment of the belt is good when installing it.
l Gear wear or damage
Failure phenomenon: in gear-driven testers, gear wear will lead to transmission precision degradation, vibration and noise, severe wear or individual teeth will be damaged when the phenomenon of stalling, affecting the normal operation of the tester.
Cause analysis: Long-term friction, overload operation, poor lubrication or poor quality of gear material may lead to gear wear or damage.
Solution: Regularly check the wear of the gears, for slight wear of the gears, you can adjust the gear mesh clearance to reduce the impact of wear. If the gears are badly worn or have damaged teeth, new gears need to be replaced, and attention should be paid to the installation accuracy of the gears to ensure good meshing condition. At the same time, to ensure that the gears are well lubricated, in accordance with the requirements of the equipment to add or replace the grease on a regular basis.
2、Bearing failure
l Bearing wear
Failure phenomenon: the rotating parts of the motor or tester in the process of running vibration increases, noise increases, and even the feeling of stagnation.
Reason analysis: bearings are subject to radial and axial loads for a long time, after a long time of operation, there will be wear and tear between the rolling body and the inner and outer rings; insufficient lubrication or deterioration of the grease will accelerate the wear and tear; improper mounting, such as the bearing mounting by excessive impact or improper fit between the shaft and the bearing housing, will also lead to bearing wear.
Solution: When bearing wear is found, first check the lubrication situation and add or replace the grease in time. If the wear is light, the working condition of the bearing can be improved by adjusting the position of the shaft or adding shims. For bearings with serious wear, it is necessary to replace them with new bearings and pay attention to the installation method of the bearings when replacing them to make sure they are installed correctly and avoid causing secondary damage to the bearings.
l Bearing overheating
Failure phenomenon: The temperature of the bearing part is too high, which may trigger the temperature protection device of the tester and make the equipment stop running.
Cause analysis: In addition to poor lubrication and wear and tear caused by increased friction, the bearing preload is too large, the ambient temperature is too high and the motor or tester load is too heavy and other factors may cause bearing overheating.
Solution: Check the lubrication and wear of the bearings and treat them as described above. Adjust the preload on the bearings to the proper range and improve the ventilation of the equipment to reduce the effect of ambient temperature on the bearings. If it is caused by excessive load, you need to check the operating conditions of the tester and reduce unnecessary load.
3、Fixture failure
l Loose fixture
Failure phenomenon: During the testing process, the fixture used to fix the motor or test samples becomes loose, resulting in unstable connection between the motor and the test equipment, affecting the accuracy of the test data.
Cause analysis: The fastening bolts of the fixture are loose, which may be due to vibration of the equipment, frequent mounting and dismounting, or the failure of the bolt's own anti-loosening measures.
Solution: Regularly check the fastening bolts of the fixture and tighten them with appropriate tools. For bolts that are easily loosened, use lock washers and thread locking agents to enhance the anti-loosening effect.
l Fixture damage
Failure phenomenon: the mechanical structure of the fixture part, such as clamping jaws, grooves and other deformation, fracture and other damage, can not properly fix the motor or test samples.
Reason analysis: the fixture material strength is not enough, in the clamping process to withstand excessive force; long-term use leads to fatigue damage; or by accidental impact and damage.
Solution: Repair or replace the damaged fixture according to the specific structure of the fixture and the degree of damage. In the selection of fixtures, to consider whether the material and strength to meet the test requirements, and in the process of use to avoid overloading operations and accidental collision.
4, mechanical structure loose or deformation
l Loose fuselage or bracket
Failure phenomenon: The body or support of the tester is loose, causing the whole equipment to shake during operation, affecting the testing accuracy and stability of the equipment.
Cause analysis: The connection bolts of the equipment are loose, probably due to long-term vibration or not tightened during installation; cracks appear in the welded parts of the bracket, resulting in a decline in connection strength.
Solution: Check the connection bolts of the body and bracket and tighten them. For cases where there are cracks in the welding parts, the welds need to be repaired, such as re-welding or reinforcement. Meanwhile, measures such as adding shock absorbing pads at the bottom of the equipment can be taken to reduce the impact of vibration on the equipment.
l Mechanical deformation
Failure phenomenon: the mechanical structure of the tester, such as the test platform, transmission bracket, etc. deformation, resulting in concentricity, parallelism and other deviations between the motor and the test equipment, affecting the normal conduct of the test.
Cause analysis: the equipment is subject to excessive external impact, such as collision, heavy objects extrusion; long-term uneven load, resulting in local deformation of the structure.
Solution: For mechanical structures with small deformation, their normal geometry and positional accuracy can be restored by adjusting shims and calibrating devices. If the deformation is serious, it may be necessary to replace the deformed parts, and to analyze the cause of deformation and take measures to avoid recurrence of similar situations, such as strengthening the protection of the equipment, reasonable distribution of loads, and so on.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
