How to fault analyze and troubleshoot the DC motor motor automatic front end dielectric assembly machine?
First, the basic steps of fault analysis and troubleshooting
1, observe and record the fault phenomenon
Observation of the operating state: When the equipment fails, first observe whether the assembly machine stops working completely or some of its functions are out of order. For example, note whether the motor is still running, whether the mechanical arm can move normally, and whether the movement of various components is coordinated. At the same time, observe whether there is any obvious change in the running speed of the equipment, such as a sudden decrease in the motor speed or the mechanical movements become sluggish.
Abnormal sound and odor detection: Listen carefully to the sound emitted by the equipment to determine whether there is abnormal noise, friction or vibration. For example, sharp metallic friction sounds may suggest poor contact or wear and tear between mechanical parts; rhythmic thumping sounds may be due to a loose part. At the same time, pay attention to whether there is a burning odor, which may be an electrical component overheating or wire short circuit signs.
Failure to occur location judgment: by observing the abnormal performance of the equipment during operation, the initial determination of the approximate location of the failure may occur. For example, if it is found that the meson assembly position is inaccurate, it may be the fixture, sensor or robot arm motion control system problems; if the motor is running normally but no power output, the problem may be in the transmission system.
Record detailed information: Record the observed fault phenomena, including the time of occurrence, the equipment operating state, the specifics of abnormal sounds and odors, as well as the possible location of the fault and other information in detail. This helps to follow up on the fault for more accurate analysis.
2, downtime inspection and protective measures
Shutdown: before the fault check to ensure that the equipment is shut down, cut off the power supply to prevent accidental start-up caused by personnel injury. For some equipment with energy storage devices, such as capacitors, to wait for its complete discharge before operation.
Appearance check: the initial appearance of the equipment to check whether there are obvious signs of damage, such as mechanical parts of the fracture, deformation, electrical wiring burnt, broken, and whether there is a foreign body into the interior of the equipment and so on.
3, analyze the possible causes of failure
Mechanical system: consider whether the transmission parts (such as belts, chains, gears, worm gears) are worn, loose or damaged; whether the fixture is inaccurately positioned, insufficient clamping force; whether there is any obstruction to the movement of the mechanical arm, joint wear and tear, etc.; whether the shafts and bearings are worn out, jammed or poorly lubricated.
Electrical system: doubt whether the motor is faulty, such as motor winding short circuit, broken circuit, brush wear, motor driver damage; check whether the sensor (photoelectric sensor, proximity sensor, encoder, etc.) is ineffective, including the optical path is blocked, the sensing surface is polluted, the component is damaged, etc.; whether the controller (e.g., PLC) is programmed wrongly, the input and output signals are abnormal, and the communication failure, etc.; the electrical wiring Whether there is a short circuit, broken circuit, poor contact and other problems.
Software system: Think about whether there are logic errors, improper parameter settings, incompatible versions of the software program. For example, the movement instruction error in the control program may lead to abnormal movement of the robotic arm; the parameter setting error may make the motor speed, assembly pressure, etc. does not meet the requirements.
4、Gradual troubleshooting
From simple to complex troubleshooting: in accordance with the principle of first easy then difficult troubleshooting. First check the parts that are easy to observe and test, such as whether the connection line is loose, whether the fuse is blown, whether the sensor is blocked and so on. Then check the complex parts and systems in depth, such as the internal structure of the motor, the controller program, and so on.
Use the appropriate tools for testing: use the multimeter, megohmmeter and other electrical testing tools to check the resistance, voltage, insulation resistance and other parameters of the electrical components; use calipers, micrometers and other measuring tools to check the dimensional accuracy of the mechanical components; for software problems, you can use the programming software, monitoring tools, etc., to carry out troubleshooting.
Second, the mechanical system failure analysis and troubleshooting
1、Transmission components failure
Belt and chain problems: If the belt or chain is found to be slack, it will lead to unstable 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. At the same time, check the pulleys and sprockets for wear and make sure they fit well together.
Gear Failure: Gears that are worn, missing teeth, or mesh poorly will 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. When checking the worm and worm gear transmission, pay special attention to the helix wear of the worm and the tooth surface wear of the worm gear, because their accuracy has a great influence on the meson assembly.
2, fixture and robot arm failure
Fixture problem: fixture wear, deformation will affect the meson fixing effect. Check whether the clamping force of the fixture is appropriate, and if necessary, adjust the clamping device of the fixture. For worn or deformed fixture parts, such as collets, positioning pins, etc., should be replaced or repaired in a timely manner. At the same time, check the positioning accuracy of the fixture to ensure that it can accurately position the meson in the correct position for assembly.
Mechanical arm failure: The inflexible movement or decreased accuracy of the mechanical arm may be caused by loose joints, worn or poorly lubricated moving parts. Check the joint parts of the robotic arm and tighten loose screws; clean and lubricate the moving parts of the robotic arm; calibrate the accuracy of the robotic arm to ensure that its movement accuracy meets the requirements. If there is a problem with the motor or driver of the robotic arm, it needs to be checked according to the troubleshooting method of the electrical system.
3、Shaft and bearing failure
Shaft problems: The surface wear of the shaft 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 installation accuracy of the parts and transmission stability. Check the wear of the shaft. For slightly worn shafts, 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 severe, it is necessary to replace the shaft with a new one and ensure the accuracy of the fit with other parts. Bending and deformation of the shaft may be caused by excessive axial or radial force, vibration of the machine or improper installation, which makes the shaft vibrate and make noise during operation, and in serious cases, the machine will not work normally. For bent and deformed shafts, different repair measures need to be taken according to the degree of bending, such as straightening or replacing the shaft with a new one.
Bearing failure: bearing wear, rolling body and the gap between the inner and outer rings increased, will produce abnormal vibration and noise, and in the process of operation will appear heat phenomenon. 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 cleanliness of the installation and the correct installation method to avoid damage to the new bearings.
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 motors, also check the wear and tear of the brushes, if the brushes are badly worn, the brushes need to be replaced. If the motor drive failure, may also lead to the motor can not work properly, need to check the drive input and output signals, parameter settings and so on.
2、Sensor failure
Photoelectric sensor failure: If the photoelectric sensor can not detect the normal position of the meson, 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 needs to be replaced.
3, other sensor failures: for proximity sensors, pressure sensors, displacement sensors, etc., check the sensor's sensing surface whether there is dirt or damage, clean or repair the sensing surface. Check whether the sensor's connection line is normal, to ensure smooth signal transmission. 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.
4, 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, if the problem still exists, it may be necessary to replace the controller or its internal faulty components.
Electrical Wiring Failure: Check the electrical wiring for short circuits, broken circuits, or poor contact. Look for signs of broken or burnt wiring, and check to see if the wire connectors are secure, oxidized and corroded. Use the resistance file of the multimeter can check the line through the line, for suspicious line segments, you can check in segments to find out the point of failure and repair.
Fourth, the software system failure analysis and troubleshooting
1, program failure: If the software crashes, crashes or runs incorrectly, first try to restart the software and equipment. Check whether the software has an updated version, updated software may fix known program errors. If the problem still exists, check the system log file of the software, analyze the error message, you may need to contact the software vendor for further troubleshooting, such as fixing the vulnerabilities or errors in the program code.
2, parameter setting errors: If the operating parameters of the device (such as assembly speed, pressure control parameters, etc.) is not correct, 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, and if there is any error, reset the correct parameters. At the same time, check whether the parameters have been accidentally modified, and consider setting user rights to prevent unauthorized parameter modification.
3, communication failure: If there is a communication problem between the software and hardware (such as with motor controller, sensor) or with other industries (such as the 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 are correct, and if necessary, reconfigure the communication settings or repair errors in the communication software module.
※ 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.
