What are the common electrical faults and solutions for DC motor motor automatic worm gear assembly machine?
1、Power failure
Fault phenomenon:
The machine can not start at all, the power indicator does not light up. This may be caused by a loose power plug, socket failure, blown fuse or damaged power cord.
The machine suddenly loses power during operation, which may be caused by unstable power lines, faulty power switch or interruption of external power supply.
Solution:
First check if the power plug is firmly inserted into the socket, try to replace the socket to see if the power supply can be restored.
Check if the fuse is blown, if so, replace it with one of the same size. At the same time, check whether the power cord is broken, if so, the power cord should be replaced in time.
For the case of sudden power failure during operation, check whether the power switch is working properly and use a voltmeter to detect whether the external power supply is stable. If it is an external power supply problem, you need to contact the relevant power supply department to solve the problem.
2、Motor failure
Fault phenomenon:
The motor does not rotate. It may be caused by short circuit or broken motor winding, severe wear of brushes, motor bearing jamming or motor driver failure.
Motor speed abnormality. It may be caused by the wrong setting of the motor driver parameters, excessive motor load, motor performance degradation or unstable power supply voltage and other factors.
Solution:
For the case that the motor does not rotate, use a multimeter to check the resistance value of the motor winding to determine whether there is a short circuit or broken circuit. If the brushes are badly worn, the brushes need to be replaced; if the motor bearings are seized, the bearings should be cleaned, lubricated or replaced. Check the working status of the motor drive to see if there is a fault alarm signal, if so, follow the troubleshooting manual of the drive.
When the motor speed is abnormal, first check the parameter settings of the motor drive to ensure that the speed parameters are correct. If the motor load is too large, you need to check whether there is any stagnation phenomenon in the worm assembly process, such as parts stuck, excessive friction of mechanical parts, etc., and make adjustments accordingly. At the same time, monitor the power supply voltage, if the voltage is not stable, you can install a voltage regulator to solve the problem.
3、Sensor failure
Fault phenomenon:
The photoelectric sensor cannot accurately detect the position of the worm or other parts, resulting in assembly position deviation. This may be caused by the sensor optical path is blocked, the sensor is damaged or the sensor installation position is offset.
The proximity sensor does not sense objects properly, causing errors in the machine's automation process. This may be caused by dirt on the sensor sensing surface, improper distance between the sensor and the object to be measured, or damage to the internal components of the sensor.
Solution:
For photoelectric sensor failure, check whether the optical path is smooth, clean the lens of the sensor and the optical path of dust and oil. Check the installation position of the sensor, use the adjustment tool to re-align the sensor so that it can accurately detect the position of the part. If the sensor is damaged, replace it with a new one in time.
When there is a problem with the proximity sensor, first clean the sensing surface to remove dirt. Adjust the distance between the sensor and the object being measured so that it is within the proper sensing range. If you suspect that the internal components are damaged, use a multimeter and other tools to detect, if necessary, replace the sensor.
4, controller failure
Failure phenomenon:
Programmable Logic Controller (PLC) program runs wrong, resulting in chaotic worm assembly sequence or uncoordinated machine movements. This may be due to program logic errors, PLC electromagnetic interference, PLC internal component damage or program storage problems and other reasons.
Communication failures between the controller and other devices (e.g., motor drives, sensors) cause data transmission to be interrupted or incorrect, affecting the normal operation of the machine. It may be caused by damaged communication lines, loose communication interface, wrong setting of communication parameters and other factors.
Solution:
When the PLC program runs wrong, use programming software to monitor and debug the program to check whether the program logic is correct. If there is electromagnetic interference, take shielding measures, such as using shielded wires to connect equipment, installing electromagnetic shielding cover. Check the internal components of the PLC for signs of damage such as overheating and scorching, and replace them promptly if damaged. At the same time, ensure the reliability of program storage, and regularly back up program data.
For communication failures between the controller and other devices, first check whether the communication line is intact and whether the connection is firm. Confirm whether the communication parameters (such as baud rate, data bits, stop bits, etc.) are set correctly, and if there is any error, reset the communication parameters. If the communication interface is damaged, replace the communication interface or the relevant communication module.
5、Electrical connection failure
Fault phenomenon:
Intermittent faults occur during the operation of the machine, such as some parts work normally from time to time, and stop working from time to time. This may be due to loose electrical connections, terminal oxidation or wire inside the false connection and other circumstances.
Some electrical components work abnormally, which may be caused by a broken or short circuit in the line connecting the component.
Solution:
Check all electrical connection points, including terminals, plugs, sockets, etc., to ensure that the connections are firm. For oxidized terminals, use tools such as sandpaper to clean them and then reconnect them. If you suspect that the wires are internally falsely connected, use a tool such as an insulation resistance meter to test and replace the wires if necessary.
For some electrical components working abnormally, according to the electrical schematic diagram, step by step check the wiring connected to the component, find the break or short circuit point, and repair.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Company Limited through the page chat tool to seek help.
