What are the common mechanical failures and solutions for DC motor motor automatic worm gear assembly machine?
First, transmission components failure
1, belt and chain problems
Failure phenomenon:
The belt or chain is slack, resulting in unstable power transmission and slippage, which makes the working speed of the worm assembly machine uneven, and may even cause the machine not to work properly.
Severe wear of the belt, surface cracks, tooth loss or breakage, and loose, worn or broken links of the chain will interrupt the transmission and stop the machine from running.
Solution:
For loose belts or chains, the proper tension can be restored by adjusting the tensioning device. In the case of an automatic tensioner failure, the mechanics need to be inspected and repaired or the relevant parts replaced.
When a belt or chain is worn or damaged, it must be promptly replaced with a new part of the same specifications. At the same time, check whether the pulley or sprocket is worn or damaged, and if necessary, replace it together to ensure a good transmission fit.
2, gear failure
Failure phenomenon:
Worn gears with wear marks, pits or spalling on the tooth surface will result in reduced transmission accuracy, vibration and noise, and affect the positional accuracy of the worm assembly.
Poor gear mesh, may be due to installation errors, shaft parallelism or center distance does not meet the requirements, resulting in gears in the process of stalling, jumping teeth phenomenon, serious damage to the gear.
Solution:
For gears with light wear, the transmission can be improved by adjusting the mesh clearance of the gears. If the wear is serious, replace the gear with a new one and ensure that the installation accuracy, including the axial positioning and radial runout of the gear, is within the allowable range.
For poor gear meshing, it is necessary to re-check and adjust the shaft parallelism, center distance and other installation parameters, and use special tools for precise installation to ensure the correct meshing of gears.
Second, fixture and arm failure
1、Fixture problem
Failure phenomenon:
The clamping force of the fixture is insufficient to firmly fix the worm or other parts, and the parts are easily shifted during the assembly process, resulting in a decline in assembly quality.
The positioning accuracy of the fixture decreases, probably due to the wear of the positioning pin of the fixture, the deformation of the fixture seat, etc., so that the positioning of the worm gear is inaccurate, affecting the subsequent assembly operation.
Solution:
Check the clamping mechanism of the fixture, such as cylinder, hydraulic cylinder or clamping spring, and repair or replace the damaged parts to restore sufficient clamping force. At the same time, according to the size and shape of the part, adjust the size of the clamping force to ensure that the part can be firmly clamped without causing damage to the part.
For fixtures with decreased positioning accuracy, check the wear of the positioning pins and replace them with new ones if they are worn. If the fixture seat is deformed, the fixture seat needs to be repaired or replaced to recalibrate the positioning accuracy of the fixture.
2、Mechanical arm failure
Fault phenomenon:
The inflexible movement of the mechanical arm may be due to poor lubrication at the joints, bearing wear, deformation of the mechanical arm linkage or stuck by foreign objects, resulting in the mechanical arm not being able to accurately grasp and place the worm gear.
The positioning accuracy of the mechanical arm deviates, which may be caused by mechanical wear due to long-term use, failure of the electrical control system or loss of the zero position of the mechanical arm.
Solution:
For a mechanical arm with inflexible movement, first check the lubrication at the joints and add the appropriate amount of lubricant. If the bearings are worn out, the bearings need to be replaced; for the case of deformation of the connecting rod or foreign objects stuck, repair the deformed parts or clear away the foreign objects.
When the positioning accuracy of the robotic arm deviates, use professional calibration tools and methods to recalibrate the zero position and movement trajectory of the robotic arm. If the accuracy problem is caused by the failure of the electrical control system, you need to check the motor driver, encoder and other electrical components, and debugging and repair accordingly.
Third, shaft and bearing failure
1, shaft problems
Failure phenomenon:
Shaft surface wear, may be due to long-term friction, poor lubrication or improper coordination with other components, resulting in a reduction in the diameter of the shaft, affecting the accuracy of the installation of parts and transmission stability.
Bending and deformation of the shaft may be due to excessive axial or radial force, vibration of the machine or improper installation, etc., so that the shaft vibration and noise in the process of operation, which may cause the machine to fail to work properly in serious cases.
Solution:
For light wear on the shaft surface, surface repair techniques such as chrome plating and spraying can be used to restore the size and accuracy of the shaft. If the wear is serious, it is necessary to replace the shaft with a new one and ensure the accuracy of the fit with other parts.
When the shaft is bent and deformed, different repair measures need to be taken according to the degree of bending. For slight bending, it can be repaired by straightening; if the bending is serious, the shaft should be replaced with a new one, and the reasons leading to the bending of the shaft should be checked and adjusted, such as improving the force of the machine and strengthening the support structure.
2、Bearing failure
Failure phenomenon:
Bearing wear, the gap between the rolling body and the inner and outer rings increases, it will produce abnormal vibration and noise, and it will be hot during operation.
Bearing stuck, may be due to insufficient lubrication, into the foreign body or bearing itself quality problems, resulting in the bearing can not rotate normally, so that the parts connected with it to stop working.
Solution:
For worn bearings, first check the lubrication and replenish or replace the grease. If the wear is serious, replace the bearing with a new one and pay attention to cleanliness and correct installation method to avoid damaging the bearing again.
When the bearings are stuck, it is necessary to stop the machine operation immediately, disassemble and clean the bearings, and check whether there is any foreign matter entering. If the bearing is damaged, replace it with a new one and make sure the lubrication system works properly to prevent similar problems from happening again.
Fourth, the machine body and working platform failure
1、Structural problems of the machine body
Failure phenomenon:
Deformation or vibration of the fuselage may be due to the fact that the machine has been subjected to a large load for a long time, the foundation is not solid or it has been subjected to external impacts, etc., which leads to a decrease in the geometric accuracy of the fuselage and affects the overall performance of the assembling machine.
Loose bolts in the connecting parts of the machine body will make the connection between the various parts of the machine not tight, generating vibration and noise, and may even lead to changes in the relative position of the parts, affecting the assembly precision.
Solution:
For the case of deformation of the machine body, it is necessary to test and evaluate the machine body and take corresponding repair measures according to the degree of deformation, such as using mechanical correction or replacing the deformed parts. At the same time, check whether the foundation of the machine is firm, and if necessary, reinforce the foundation.
Regularly check the bolts of the connecting parts of the machine body, and tighten them promptly when loosening is found. During the operation of the machine, pay attention to avoid the impact of external impact on the machine, such as reasonable arrangement of the working environment, set up protective devices.
2、Working platform failure
Failure phenomenon:
Wear or scratches on the surface of the working platform will affect the placement accuracy of the worm and other parts, resulting in inaccurate assembly position.
The flatness of the working platform decreases, which may be due to long-term placement of heavy objects, uneven force or material aging, etc., making the working platform tilted or uneven, affecting the assembly operation.
Solution:
For light wear or scratches on the surface of the working platform, it can be repaired by grinding and polishing. If the wear is serious, it is necessary to replace the working platform or cover the surface with a new layer of wear-resistant material.
When the flatness of the working platform decreases, use the level meter and other tools to detect and restore the flatness of the platform by adjusting the supporting feet or adding shims at the bottom of the platform.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Mechanical and Electrical Equipment Co., Ltd. technical specialists through the page chat tool to seek help.
