How to analyze and troubleshoot Brushless Motor Motor Automatic Stator Inserter?
To analyze and troubleshoot the brushless motor motor automatic stator into the machine shell machine, you can follow the following steps from mechanical, electrical, pneumatic (if any), software and other aspects of the systematic investigation and solution:
First, fault information collection
On-site observation: After arriving at the scene of the faulty equipment, first observe the current state of the equipment, such as whether there is damage to the components, deformation, whether there is an abnormal sound, odor, the operating position of the equipment and whether the action stays in a particular stage. For example, if you smell the burning odor, there may be electrical components overheating or short-circuit problems; if you hear abnormal friction sound, it may be a mechanical transmission components failure.
View records: Check the equipment's operating records, maintenance records and failure history. Understand the equipment before the failure of the operating parameters, production tasks, as well as whether there has been a similar failure and treatment methods. For example, if you find that the same part of the recent frequent failures, there may be potential design or installation problems in that part.
Ask the operator: Communicate with the equipment operator to understand the specifics of the failure, including the operating steps of the equipment, whether there are any abnormal alert messages, and the suddenness of the failure. For example, the operator may feedback in the press of a button equipment immediately after the failure, which helps to quickly locate the source of the fault.
Second, the mechanical system failure analysis and troubleshooting
1, transmission component failure
Failure performance: equipment running noise, vibration increases, transmission is not smooth, or stator into the shell action can not be completed normally.
Troubleshooting methods: check the belt, chain tension, to see whether there is loose, slippage or wear and tear; check the gear mesh, whether there is wear and tear, broken teeth and other issues; check whether the coupling is loose, damaged.
Solution: adjust the tension of the belt, chain, if necessary, replacement; repair or replacement of damaged gears; tighten or replace the coupling.
2, positioning and clamping mechanism failure
Failure performance: inaccurate positioning of the stator or shell, resulting in deviation from the shell position; clamping force is insufficient or unstable, so that the stator in the shell in the process of displacement.
Troubleshooting method: Check whether the position of the positioning sensor is offset or damaged; check whether the pressure of the clamping cylinder or hydraulic cylinder is normal and whether the clamping element is worn out.
Solution: recalibrate the position of the positioning sensor, replace the damaged sensor; adjust the pressure of the cylinder or hydraulic cylinder, replace the worn clamping elements.
3, guide rail and slide failure
Failure performance: equipment moving parts in the guide rail sliding is not smooth, there is a jamming phenomenon, affecting the stator into the shell precision and speed.
Troubleshooting: check the guide rail surface for debris, wear and tear or scratches; check the lubrication of the slider and the degree of fastening.
Solution: clean up the debris on the surface of the guide rail, repair the worn or scratched parts; lubricate the slider and tighten the loose slider.
Third, the electrical system failure analysis and elimination
1, power failure
Failure performance: the equipment can not be turned on, the indicator does not light up, or in the process of running suddenly cut off the power.
Troubleshooting: Check whether the power switch is normally closed, whether the fuse is blown, whether the power plug and socket are in good contact, and measure whether the power supply voltage is within the range required by the equipment.
Solution: Repair or replace the damaged power switch, replace the blown fuse, make sure the power plug and socket are in good contact, if the power supply voltage is abnormal, you need to check the power supply line or use a voltage regulator.
2、Motor failure
Failure performance: the motor does not rotate, abnormal speed, serious heat or abnormal noise.
Troubleshooting methods: use a multimeter to check whether the resistance value of the motor winding is normal, check whether the connecting wires of the motor are loose, short-circuited or disconnected; check whether the parameters of the motor drive are set correctly, and whether there is an alarm message on the drive.
Solution: Repair or replace the damaged motor winding, tighten the loose connection line; adjust the parameters of the drive, eliminate drive failure.
3、Sensor failure
Failure performance: inaccurate positioning of the device, abnormal action, or false alarm information.
Troubleshooting methods: check whether the sensor is installed in the correct position, whether the probe is blocked, contaminated; the use of oscilloscopes and other tools to detect the sensor's output signal is normal.
Solution: Reinstall the sensor to ensure that its position is accurate; clean the sensor probe, if the sensor is damaged, replace it.
4, controller failure
Failure to perform: the logic of the device running chaos, can not perform actions in accordance with the preset program, or program loss, error.
Troubleshooting: Check whether the controller's power supply is normal, check the controller's display or indicator whether there is an error message; use the programming software to check whether the controller's program is normal.
Solution: Repair or replace the controller's power supply module, according to the error message to investigate the cause of the failure, re-download or modify the controller program.
Fourth, the pneumatic system failure analysis and troubleshooting (if any pneumatic system)
1、Insufficient air pressure
Failure performance: the cylinder action is weak, the clamping force is not enough, or the equipment moves slowly.
Troubleshooting: Check the working status of the air compressor to see if it is a normal air supply; check whether there is air leakage in the air pressure pipeline, whether the air pressure regulator valve is set correctly.
Measures: Repair or replace the faulty air compressor, find and repair leaks, adjust the pressure of the air pressure regulator valve.
2、Pneumatic component failure
Failure to perform: the cylinder does not move, the action is not in place or the phenomenon of jamming; solenoid valve can not be normal direction.
Investigation methods: check whether the cylinder seals are damaged, whether the piston rod is bent; check whether the solenoid valve coil is energized, whether the spool is jammed.
Solution: Replace the damaged seals and piston rod, repair or replace the solenoid valve.
V. Software system failure analysis and troubleshooting
1, program error
Failure performance: equipment running abnormal action, such as repeated execution of a step, skip some steps, etc..
Troubleshooting: Use programming software to check the syntax of the equipment program to see if the logic in the program is correct; check whether the parameter settings in the program with the actual production requirements.
Solution: Modify the error code in the program, adjust the program parameters to ensure that the program logic is correct.
2、Data transmission failure
Failure performance: unstable data transmission between the various parts of the device, resulting in information loss or error, affecting the cooperative work of the device.
Troubleshooting methods: Check whether the communication line is well connected, loose or damaged; check whether the communication interface and protocol are set correctly.
Solution: Tighten the connection of communication lines, repair or replace the damaged lines; reset the communication interface and protocol.
3、Verify and summarize
Verification after troubleshooting: After completing the troubleshooting measures, carry out all the test runs on the equipment to check whether the equipment is back to normal operation and whether the performance indexes meet the requirements. For example, carry out several stator shelling operations to check whether the shelling accuracy, speed and stability meet the standards.
Failure summary and record: Summarize the reasons for the failure, the troubleshooting process and the solution method, and record it in the failure file of the equipment. This will help accumulate experience and provide reference for the rapid elimination of similar faults in the future, as well as provide a basis for the maintenance and improvement of the equipment.
※ If you still can't solve the equipment fault 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.
