How to fault analyze and troubleshoot the motor motor rotor automatic spring clamping machine?
1, the basic steps of fault analysis
l Observation of fault phenomenon
Observation of the overall running status of the machine: When the machine fails, the first thing to do is to observe the overall running status of the machine. For example, to see whether the machine completely stopped running, or part of the function is out of order; whether there are abnormal sounds, such as sharp friction sound, dull impact sound or irregular vibration sound; whether there is smoke, odor and so on. These phenomena can help to initially determine whether the failure occurs in the electrical system, mechanical transmission part or other components.
Key components status check: carefully check the motor, sensors, clamps and card spring mounting mechanism and other key components. Observe whether the motor is running normally and there is no sign of overheating; check whether the indicator light of the sensor is on normally and whether its mounting position is loosened or shifted; check whether the fixture is able to clamp and loosen the rotor of the motor normally, and whether the action of the clamp spring mounting mechanism is smooth and accurate.
l Collect relevant information
Failure time and environment: to understand whether the failure occurred when the machine was first started, after running for a period of time, or after a specific operation (such as the installation of a specific specification of the card spring). At the same time, pay attention to the environmental conditions at the time of the failure, including temperature, humidity, the presence of external sources of interference (such as large electrical equipment in the vicinity) and so on. For example, if the machine fails frequently in a high-temperature environment, it may be the result of a heat dissipation problem or a decrease in the performance of certain electronic components affected by temperature.
The machine's operation records and maintenance history: Check the machine's operation log to see if there are any abnormal operation records, parameter adjustments or alarm messages recently. Check the machine's maintenance records, to understand the close to the maintenance time, maintenance content and the replacement of components and other circumstances. This information can help determine whether the failure is related to recent maintenance operations or parts replacement.
l fault classification and initial judgment
Judgment of electrical faults: If the machine does not light up the power indicator, the motor does not rotate, no signal output from the sensor, etc., it may be an electrical fault. Electrical failure may involve power supply, motor failure, sensor failure, controller failure or electrical wiring connection problems. For example, use a multimeter to check whether the power supply voltage is normal, check whether the resistance of the motor winding meets the requirements, and see whether the output signal of the sensor is within the normal range.
Mechanical failure judgment: when you hear abnormal mechanical sound, found that the moving parts jammed or card spring installation position is inaccurate, etc., the probability is mechanical failure. Mechanical failure may include transmission parts wear, fixture damage, guide screw failure or loose mechanical structure. For example, check whether the drive belt is loose or broken, check whether the fixture jaws are worn, to see whether the guide rail is a foreign body to impede the movement of the slider and so on.
2、Common troubleshooting methods
l Electrical troubleshooting
Power problem: If it is a power failure, first check whether the external power supply is normal, including whether the plug is plugged in, whether the socket is energized, whether the power switch is open, etc. Then check the power line inside the machine. Then check the power line inside the machine to see whether the fuse is blown and whether the power transformer is working normally. If the fuse is blown, after replacing the fuse with the same specification, further check whether there is a short circuit phenomenon causing the fuse to blow.
Motor failure: for the motor does not rotate, check whether the wiring of the motor is correct and firm, and use a multimeter to measure whether the resistance value of the motor winding is normal. If the motor windings are shorted or disconnected, the motor may need to be replaced. If the motor is able to rotate but overheats, check if the load on the motor is too large, see if the motor's cooling system (e.g. fan) is working properly, and also check if the motor's bearings are well lubricated.
Sensor failure: When the sensor has no signal output or the signal is abnormal, first check whether the connection line of the sensor is loose or damaged. If the line is normal, clean the sensing surface of the sensor to remove dust, oil and other impurities that may affect signal transmission. Then use professional testing equipment (e.g. signal generator, oscilloscope) to check whether the output signal of the sensor meets the standard. If the sensor is damaged, replace the sensor with the same model.
Controller failure: If the controller appears to be dead, program confusion, etc., try to restart the controller to see if the fault disappears. If the problem still exists, check whether the power supply of the controller is stable, and whether there are signs of damage to the internal electronic components (e.g., capacitor bulging, chip overheating, etc.). For software problems, try reinstalling or updating the controller's software program to ensure the correctness and stability of the program.
l Mechanical Troubleshooting
Transmission component failure: If the transmission belt is loose or worn, adjust the tension of the belt or replace it with a new one. For chain drive, check the tension of the chain and the wear of the chain links, and tension or replace the chain if necessary. When gears are worn, decide whether to repair or replace the gears based on the degree of wear. Also, check the lubrication of the drive components to ensure that good lubrication will reduce wear.
Failure of fixture and circlip mounting mechanism: If the fixture jaws are worn and prevent clamping of the motor rotor, replace the jaws or repair the jaws (e.g., welding, grinding, etc.). For the circlip mounting mechanism, check whether the mounting tool is damaged or not. If the jaws of the circlip clamp are deformed, the mounting tool needs to be replaced or repaired. At the same time, check the movement accuracy of the mechanism, by adjusting the guide rail, silk rod and other components to ensure the accuracy of the card spring installation position.
Mechanical structure loosening fault: Check whether the various mechanical connection parts of the machine, such as bolts, nuts, couplings, etc. are loose. Use wrenches and other tools to retighten the loose parts to ensure the stability of the mechanical structure. In the process of fastening, be careful to operate according to the specified torque to avoid over-tightening or over-loosening.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
