What are the common control unit failures and solutions for DC motor motor automatic front-end meson assembly machine?
1, controller hardware failure
Failure phenomenon
The controller can not start normally, may be caused by damage to the power supply module, circuit board components burned and so on.
Dead phenomenon, in the process of running suddenly stop working, the screen does not respond, the key operation is invalid. This may be caused by hardware overheating, internal chip failure, or memory error.
No output or abnormal output of control signals, resulting in the assembly machine's motor, robotic arm and other components can not be in accordance with the predetermined program action, such as the motor does not rotate, robotic arm movement out of control, and so on.
Solution
Check the power supply and see if the power indicator light of the controller is on. If the power indicator does not light up, use a multimeter to check whether the power input voltage is normal and whether the fuse is blown. If the fuse is blown, replace the fuse with the same specification; if the power module is damaged, the power module needs to be replaced.
For the crash situation, first try to force restart the controller. If it crashes frequently, check the heat dissipation of the controller and clean the dust from the cooling fan and vents to ensure a good cooling environment. At the same time, check for loose hardware and re-insert internal components such as memory sticks. If chip failure is suspected, professional maintenance personnel may be required to use specialized equipment for testing and repair.
When the control signal output is abnormal, use an oscilloscope or other tool to check the signal waveform of the control signal output port and compare it with the normal signal waveform. If abnormal signals are found, check whether the relevant chips, relays, amplifiers and other components on the circuit board are damaged. For damaged components, replace them according to the component specifications.
2、Controller software failure
Failure phenomenon
Program operation errors, such as error codes, program crash or fall into a dead loop, resulting in the assembly machine can not work properly.
Software version is not compatible, after updating the software or replacing some hardware, there are compatibility problems between the controller software and hardware, such as some functions can not be used normally or error prompts.
Control logic confusion, may be due to the software program in the logic error or parameter setting error, so that the action sequence of the assembly machine is wrong, such as the meson assembly steps reversed or repeated execution of an unnecessary step.
Solution
For the case of program running error, check the error log file of the controller and find out the problem according to the error code and prompt message. Try reinstalling the software program to ensure that the installation process was done correctly. If the problem occurs with a custom-written program, you need to debug the program code to check for syntax errors, variable definition errors, and other problems.
When there is a software version incompatibility, first check the software update instructions or the compatibility list of the hardware device. If it is a software problem, try to roll back to a previous stable version or wait for the software developer to release a compatibility patch. If the incompatibility is caused by a hardware replacement, you may need to update the controller's driver or firmware to match the new hardware.
For control logic confusion, check the control logic code and parameter settings in the software. Reorganize the workflow of the assembler, compare the actual running situation with the expected workflow, and find out the logic error points. You can verify and modify the control logic through simulated operation, single-step debugging and other ways to ensure that the assembly machine's action sequence is correct.
3、Communication fault (if the control unit of the assembly machine involves communication with other equipment)
Fault phenomenon
Communication with the upper computer or other external devices is interrupted, and data cannot be received or sent, such as when the remote monitoring system cannot obtain the operating status of the assembler, or cannot send new control instructions to the assembler.
Communication data error, the data received or sent is lost, incorrect, or garbled, causing the assembler to receive incorrect commands and perform abnormal actions.
Solution
Check whether the communication lines are connected properly, including whether the network cable and data cable are loose or damaged. For wireless communication, check whether the signal strength and frequency band settings are correct. If there is a problem with the communication line, replace the line or reconnect the line to ensure that the connection is firm.
Check whether the communication protocol and parameter settings are consistent, such as baud rate, data bits, stop bits, check bits, etc. Check whether the device address settings of both communication parties are correct. If the parameter settings are inconsistent, modify them to the same communication parameters.
Using a communication test tool or software, check whether the communication port is working properly. If the communication port is malfunctioning, it may be necessary to replace the communication interface module or repair the related circuitry. For the case of communication data errors, you can also increase the data verification and error correction mechanisms, such as the use of CRC checksums, etc., to improve the accuracy of communication data.
4、Driver failure (for driving the motor and other executive parts)
Failure phenomenon
The motor cannot start, and even if the controller sends out a start signal, the motor remains stationary. It may be a problem with the power input of the driver, a faulty drive circuit or a connection problem with the motor.
Motor speed is unstable, the motor speed goes up and down during operation, which may be due to problems with the speed control circuit of the driver, fluctuations in the power supply voltage, or excessive changes in the load.
Insufficient motor torque, in the assembly process, the motor can not provide enough force to complete the assembly action of the meson, such as the inability to drive the robotic arm to grasp or place the meson.
Solution
Check the power input of the driver to ensure that the power supply voltage is normal and stable. Check to see if the connecting wiring between the drive and the motor is loose, broken, or shorted. If it is a power problem, repair the power supply line or replace the power supply; if it is a connection problem, reconnect the line and make sure the connection is firm.
For unstable motor speed, check whether the speed control parameters of the driver are set correctly, such as whether the speed feedback link works normally. Use a voltmeter to monitor the power supply voltage; if the voltage fluctuates greatly, increase the voltage stabilizing equipment. If the problem is caused by load changes, you can optimize the mechanical structure of the assembly machine to reduce unnecessary load fluctuations, or adjust the control parameters of the drive to enhance its adaptability to load changes.
When the motor torque is insufficient, first check whether the motor selection meets the working requirements of the assembly machine. If the motor selection is correct, check whether the current limit setting of the drive is too low, and increase the current limit appropriately. At the same time, check the heat dissipation of the motor and drive; overheating may cause the motor performance to degrade. If the motor or driver is faulty, such as short circuit of motor winding, damage of driver power module, etc., it is necessary to replace the corresponding parts.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. technical specialists through the page chat tool for help.
