What are the common control unit failures and solutions for manual servo presses?
First, the common control unit failure
1, no response to the control instructions
Reason: the communication line between the control unit and external equipment (such as operating panels, sensors) is broken, short-circuited or poor contact. For example, in the parts of the equipment frequently moved and bent, the line is easy to be damaged; the input interface of the control unit is damaged, unable to receive the correct control instruction signals, which may be caused by instantaneous high-voltage shocks, etc.; the control program error or dead, such as logical loopholes in the program, in a particular order of operation into a dead loop, unable to deal with the new instructions.
Solution: carefully check the communication lines, use a multimeter to measure the line resistance, determine the location of the breaks, shorts and repair, re-insertion and removal of line connectors to ensure good contact; if the input interface is damaged, professional replacement of the same type of interface chip or module; try to restart the control unit, if the problem persists, re-download the correct control program, if necessary, contact the equipment manufacturer to obtain technical support for the program to debug and optimize. Debugging and optimization of the program.
2、Pressure control is not stable
Reason: The PID (Proportional-Integral-Differential) control parameters are not set properly, and the output cannot be adjusted accurately according to the actual pressure feedback. For example, the proportionality coefficient is too large, the system will overreact to the pressure deviation, resulting in sharp pressure fluctuations; sensor failures, such as zero drift of the pressure sensor, the measurement accuracy is reduced, the pressure signal fed back to the control unit is inaccurate, so that the control unit to make the wrong adjustments; the control unit of the power drive module performance degradation, unable to stabilize the output of sufficient drive current or voltage, affecting the implementation of components (such as servo motors. hydraulic valves) action stability, and then the stability of the control unit, the control unit is not stable, Hydraulic valve) action stability, which in turn leads to unstable pressure.
Solution: According to the working characteristics of the press and the actual operating conditions, re-adjust the PID parameters, and gradually adjust the proportional, integral and differential coefficients through the experimental method, so that the pressure control to achieve stable and accurate results; use the standard pressure source to calibrate the pressure sensors, and if the calibration is still unable to return to normal, replace with new pressure sensors; check the heat dissipation of the power drive module, clean up the surface of the module, dust, measure the output parameters of the module, and then replace with new pressure sensors. Check the heat dissipation of the power drive module, clean the surface of the module, measure the output parameters of the module, if the performance is not up to standard, replace the power drive module.
3、Equipment operation chaos
Reason: the logic of the control unit internal control circuit failure, such as integrated circuit chip damage, solder joints, etc., leading to logical judgment errors, sending the wrong action control signal; control program in the action sequence of logical errors, may be in the equipment upgraded, the program has not been updated accordingly to improve the trigger conditions between different actions and the order of confusion; external interference affects the normal operation of the control unit, such as strong electromagnetic interference, so that the control module output parameters, if the performance of the replacement of the power drive module. Such as strong electromagnetic interference, so that the control unit receives the wrong signal or data transmission errors, resulting in abnormal operation of the equipment.
Solution: Check all the logic control circuits of the control unit, use professional testing equipment (such as logic analyzers) to detect the working state of the chip, re-weld the solder joints, and replace the damaged chip; carefully check the logic of the action in the control program, compare with the actual demand for equipment action, and correct the wrong logic in the program; add shielding measures for the control unit, such as the use of shielded wires to connect external equipment, install the electromagnetic shielding cover, and connect the control unit with external equipment. Electromagnetic shielding cover, the control unit and strong electromagnetic interference source isolation, while adding anti-interference algorithms in the program to improve system stability.
※ If the above ways and means still can not solve the fault of the equipment, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
