How to analyze and troubleshoot the motor automatic rotor test visual integrated machine?
Failure analysis and troubleshooting of motor automatic rotor test vision machine, need to follow the scientific steps, combined with the principle of the equipment and the actual performance, and gradually locate and solve the problem. The following general process of fault analysis and specific types of fault handling methods are described:
First, the general process of fault analysis
Collection of information
Failure phenomenon description: Detailed records of equipment failure performance, such as motor does not rotate, no image of the visual system, test data abnormalities, equipment issued by the noise or vibration, etc.. If the fault is intermittent, need to record the frequency of failure, time period, operating conditions and other information.
Equipment operation records: Check the operation log and maintenance records of the equipment to understand the recent use of equipment, maintenance and whether similar failures have occurred before.
Operating conditions: ask the operator the operating steps before the failure, whether there is parameter adjustment, equipment movement, software updates and other behavior, this information may be directly related to the cause of the failure.
Preliminary judgment
Distinguish the type of failure: Based on the information collected, make a preliminary judgment as to whether the failure is a mechanical failure, an electrical failure, a software failure or a sensor failure. For example, an abnormal vibration in the equipment may be a mechanical transmission component problem; while an abnormal data transmission may be related to the electrical system or software.
Determine the scope of the fault: further narrow down the scope of the fault to determine which part or subsystem of the equipment is the problem. For example, if there is no image of the vision system, it can be determined whether the camera, lens, light source, image processing software or the relevant connecting wires are faulty.
In-depth troubleshooting
Check the hardware connection: For the hardware parts that may have problems in the preliminary judgment, check whether the connection is firm, and whether there is any looseness, detachment, breakage and other situations. For example, check the connection line between the motor and the drive, the signal line of the sensor, and the data line between the camera and the computer.
Test electrical parameters: Use multimeter, oscilloscope and other tools to measure the voltage, current, resistance and other parameters of the electrical components to determine whether the electrical components are working properly. For example, measure whether the output voltage of the power supply module is stable and whether the resistance of the motor winding is within the normal range.
Analyze the software data: check the running status and data records of the software, and check whether there are error codes, parameter setting errors and other problems. For the vision system, analyze the data during image acquisition and processing to determine whether the algorithm is operating normally.
Replacement of suspicious parts: When it is impossible to determine the specific faulty parts, the replacement method can be used to replace the suspicious parts with known normal parts and observe whether the equipment is back to normal. For example, replace the original camera with a spare camera to see if the vision system can work normally.
Locate the fault: Through the above troubleshooting steps, gradually determine the specific cause and location of the fault, clear which component is damaged, parameter error or other problems lead to equipment failure.
Second, different types of failure analysis and troubleshooting methods
Mechanical failure
Failure phenomenon: abnormal vibration, noise, moving parts stuck, unable to move, unstable rotor clamping, etc. when the equipment is running.
Analysis and elimination: Check the mechanical transmission parts, such as guide rail, screw, belt, chain, gears, etc., to see whether there is wear and tear, loose, broken and so on. For worn parts, repair or replace according to the degree of wear; for loose parts, re-tighten; if the belt, chain breakage, timely replacement of new drive belt or chain. At the same time, check whether the rotor clamp is damaged, adjust the position and clamping force of the clamp to ensure that the rotor is firmly clamped.
Electrical failure
Failure phenomenon: the equipment can not start, the motor does not run, the indicator does not light up, the electrical components heat abnormally, the loss of control signals and so on.
Analysis and elimination: Check the power supply system to ensure that the input voltage is normal, the power cord is firmly connected and the fuse is not blown. If the power module failure, use a multimeter to detect its output voltage, replace the damaged power module. For motor driver failure, check whether the parameters of the driver are set correctly, observe whether the drive signal is normal through the oscilloscope, and replace the damaged power device or control board. In addition, check the connection of electrical lines, repair short-circuited and broken lines, and ensure the normal power supply and signal transmission of the electrical system.
Software failure
Failure phenomenon: the software can not start, run during the crash, flashback, test data error, no response to the operating interface.
Analysis and elimination: Check whether the installation and configuration of the software is correct, and confirm that the software version is compatible with the equipment hardware and operating system. If the software crashes, flashes back and other problems, check the error log of the software, analyze the cause of the error, it may be that the software has loopholes or conflicts with other programs, try to update the software version or uninstall the conflicting programs. For the problem of test data error, check the algorithm settings and parameter configuration of the software, recalibrate the relevant parameters to ensure accurate data processing.
Sensor Failure
Failure phenomenon: the sensor can not detect the object, the detection data is inaccurate, the equipment due to sensor signal abnormalities and false alarms, etc..
Analysis and elimination: Check whether the installation position of the sensor is correct, whether there is loose or offset, readjust the installation position of the sensor and fix it firmly. Clean the sensing surface of the sensor, remove dust, oil and other impurities to ensure that the sensor works properly. Use a multimeter and other tools to detect the sensor's supply voltage and output signal is normal, if the sensor is damaged, timely replacement of the same type of sensor. At the same time, check whether the connection line between the sensor and the control unit is normal, repair or replace the damaged connection line.
Third, after the troubleshooting verification and summary
Fault verification: After troubleshooting, restart the device, test it according to the normal operating procedures, and observe whether the device returns to normal operation and whether the fault phenomenon disappears. Repeat the test several times to ensure that the fault is completely eliminated and the equipment can work stably and reliably.
Summarize the record: the process of fault analysis and troubleshooting recorded in detail, including fault phenomena, analysis steps, causes of failure, solutions, replacement of parts and other information. These records not only help the subsequent maintenance and management of the equipment, but also provide reference experience for other similar fault handling.
Through the above systematic fault analysis and troubleshooting methods, you can quickly and accurately solve all kinds of faults of the motor automatic rotor test vision integrated machine, to ensure the normal operation and productivity of the equipment.
※ 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 to seek help.
