What are the common control unit failures and solutions for motor motor automatic rotor spot welding test all-in-one machine?
Motor automatic rotor spot welding test machine control unit as the equipment operation of the “brain”, its failure will lead to the overall performance of the equipment or even can not work. The following from the common failure phenomena, cause analysis and solutions to start the elaboration:
First, PLC (programmable logic controller) failure
l Failure phenomenon
Equipment can not start normally, no response after the operation of the start button, PLC on the indicator light does not light or flashing abnormally.
During operation, the equipment suddenly stops running, PLC error display specific fault code, and can not be restored to operation through conventional operations.
The control logic is confused, for example, the rotor does not carry out spot welding and testing in a predetermined sequence, or performs certain actions when the conditions are not met.
l Cause Analysis
Failure of the PLC power supply module, resulting in unstable or interrupted power supply, such as abnormal power input voltage, damage to internal components of the power supply module (e.g., aging of filter capacitors, blown fuses).
Input and output (I/O) module failure, signal transmission problems between external sensors, actuators and PLC, may be loose module interface, internal circuit short circuit or disconnection.
Errors in the PLC program, such as program logic loopholes, program loss or tampering, resulting in abnormal equipment control.
Environmental factors, such as the working environment is too high temperature, humidity, dust, resulting in PLC internal component performance degradation or damage.
l Solution
Check the PLC power supply module, use a multimeter to measure the input and output voltage is normal. If the power supply module is damaged, replace the power supply module with the same model; if the voltage is abnormal due to external power supply problem, check the power supply line and repair it.
Examine the I/O modules one by one, check whether the interface connection is firm, and determine whether the module is damaged by the replacement method. If it is determined that the I/O module is faulty, replace it with a new one and reconfigure the input/output signals.
Backup PLC program, if the program is lost or damaged, re-download the backup program to PLC; if there are logic errors, contact professional programmers to modify and debug the program.
Improve the working environment of the PLC, install cooling devices to control the temperature, use the dust cover to prevent the intrusion of dust, and ensure that the ambient humidity is within the allowable working range of the PLC.
Second, industrial computer failure
l Failure phenomenon
Industrial computer can not be turned on, press the power button, the screen does not display, the host fan does not turn or continue to run at high speed.
During operation, the industrial computer frequently crashes, blue screen, or software operation lags, seriously affecting equipment operation and data processing.
Communication with PLC, sensors and other equipment is interrupted, resulting in the equipment not being able to normally receive and send control instructions and data.
l Cause analysis
Hardware failure, such as motherboard damage, CPU overheating, memory failure, hard disk damage. The aging or short-circuiting of capacitors, resistors and other components on the motherboard will affect the normal operation of the motherboard; the failure of the CPU cooler leads to poor heat dissipation, causing the CPU temperature to be too high and the automatic protection shutdown.
Software system problems, operating system loopholes, virus infection, or device control software is not compatible with the system, resulting in system instability.
Communication interface failure, such as serial port, network port and other interfaces loose, damaged, or communication driver installation error, version mismatch, resulting in abnormal data transmission.
l Solution
Test the hardware of the industrial control machine one by one, use diagnostic tools to check the motherboard, CPU, memory, hard disk and other components. If the motherboard is faulty, repair or replace the motherboard; clean the CPU heatsink dust and replace the damaged heatsink; test the memory and hard disk and replace the faulty parts.
Reinstall the operating system and device control software; format the hard disk before installation to ensure a clean system. After installation, update the system patch and software version in time, and install antivirus software for virus checking and killing.
Check whether the communication interface is firmly connected, and use the replacement method to determine whether the interface is damaged. If the interface is damaged, repair or replace the interface; reinstall or update the communication driver to ensure that the driver is compatible with the hardware and system.
Third, the touch screen failure
l Failure phenomenon
Touch screen no display, the screen black screen or display abnormal screen, can not be operated.
Touch operation is unresponsive, click the button or icon on the touch screen, the device does not respond, or there is a touch position offset, inaccurate operation.
Cracks and scratches appear on the surface of the touch screen, affecting the display effect and operating experience.
l Cause analysis
Touch screen power failure, power supply line breakage, short circuit, or power module damage, resulting in the touch screen can not be normal power supply.
Touch screen control card failure, internal circuit components are damaged, or connection problems with the motherboard, can not transmit the touch signal to the motherboard.
Touch screen surface touch layer damage, long-term use or external impact, resulting in damage to the conductive material of the touch layer, affecting the touch sensor.
Software driver problems, the touch screen driver installation error, lost or incompatible with the system, resulting in the touch screen can not work properly.
l Solution
Check the touch screen power line, use a multimeter to measure the power supply voltage is normal. If the power module is damaged, replace the power module with a new one; repair or replace the faulty power supply line.
Check the connection between the touch screen control card and the motherboard, re-plug the connection line to ensure a firm connection. If the control card is damaged, replace the control card of the same type, and install the appropriate driver.
If the touch screen surface touch layer is damaged, according to the degree of damage choose to repair or replace the touch screen. Minor scratches can be repaired using a special touch screen repair agent; serious damage requires replacement with a new touch screen.
Uninstall the original touch screen driver, download the new version of the driver from the device manufacturer's website, reinstall and debug to ensure that the driver is compatible with the system and hardware.
Relay failure
l Failure phenomenon
Some functions in the equipment cannot be executed normally, such as the spot welding electrode does not move, the rotor transfer motor does not run, while the corresponding control signal has been issued.
The relay emits abnormal sound during operation, such as “buzzing” sound, or the phenomenon of contact sticking or burning, resulting in equipment control failure.
Frequent malfunctioning of relays, where the equipment does not need to perform certain actions, but the related relays are accidentally activated or released.
l Cause analysis
Oxidization and wear of relay contacts. After long-term use, an oxidized layer is formed on the surface of the contacts, and the contact resistance increases, resulting in the contacts not being able to conduct or disconnect normally.
Relay coil failure, coil burnt, short-circuited or disconnected, so that the relay can not be properly absorbed. It may be caused by the coil overheating after long time of energization, or the voltage is too high and the current is too large.
Abnormal control signals, such as unstable control voltage or current input to the relay, causing the relay to operate incorrectly; improper selection of the relay, its rated voltage, current and other parameters do not meet the working requirements of the equipment.
l Solution
For relays with oxidized and worn contacts, use fine sandpaper to gently polish the contact surface to remove the oxidized layer; if the contacts are seriously worn, replace the relay with a new one.
Check the relay coil, use a multimeter to measure the coil resistance to determine whether the coil is damaged. If the coil is burnt, short-circuited or disconnected, replace the relay with the same model. At the same time, check the coil power supply circuit to ensure that the voltage and current are stabilized within the rated range of the relay.
Examine the cause of abnormal control signals, check the signal generating device and related lines, and repair the fault. According to the actual working requirements of the equipment, select the appropriate specifications of the relay to ensure that it can work reliably.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
