What are the common mechanical failures and solutions for motor motor rotor automatic three-station fine turning machine?
Motor motor rotor automatic three-station fine-turning machine common mechanical failures and solutions are as follows:
1, tool-related problems
l Tool wear: In the fine turning process, the tool will be worn out after a long time of use, resulting in a decrease in machining accuracy and an increase in surface roughness.
Solution: Regularly check the wear of the tool and replace the tool in time according to the degree of wear. At the same time, reasonably choose the material and model of the tool to adapt to different machining requirements.
l Tool chipping: It may be due to poor tool quality, unreasonable cutting parameters, uneven hardness of the workpiece material and other reasons that lead to tool chipping, affecting the machining quality and efficiency.
Solution: Choose reliable tools and optimize the cutting parameters according to the workpiece material and machining process. Before machining, carry out sufficient pretreatment of the workpiece to ensure uniform material hardness. If the tool chipping, need to replace the tool in time, and check the causes of chipping, take appropriate measures to solve.
2、Fixture problems
l Loose fixture: In the process of machining, the loosening of the fixture will cause the rotor position to shift, affecting the machining accuracy.
Solution: Regularly check the clamping force of the fixture to ensure that the fixture can firmly fix the rotor. If necessary, repair or replace the fixture.
l Fixture wear: Frequent use of the fixture will lead to wear of its contact parts with the rotor, affecting the accuracy and service life of the fixture.
Solution: Repair or replace the worn fixture parts, meanwhile, pay attention to the maintenance and lubrication of the fixture in order to reduce the wear.
3、Transmission system failure
l Belt slippage: The belt will be worn and aged after long-term use, resulting in reduced friction between the belt and the pulley, resulting in slippage, which affects the transmission efficiency and processing accuracy.
Solution: Regularly check the belt tension and wear, adjust the belt tension or replace the belt in time.
l Gear wear: gears in the transmission system will be worn after long-term use, resulting in a decline in gear meshing accuracy, transmission noise increases, and even affect the normal work of the transmission system.
Solution: Regularly check the gear wear, according to the degree of wear and tear in time to replace the gear. At the same time, pay attention to the lubrication and maintenance of gears to extend the service life of gears.
4, spindle system failure
l Spindle precision decline: spindle wear, deformation and other problems will occur after long-term use, resulting in a decline in the accuracy of the spindle, affecting the machining accuracy.
Solution: Regularly check the accuracy of the spindle, if necessary, the spindle can be repaired or replaced. At the same time, pay attention to the spindle lubrication and cooling to reduce the spindle wear and deformation.
l Spindle vibration: Spindle vibration may be caused by spindle imbalance, bearing damage, tool wear, etc., which will affect the machining quality and efficiency.
Solution: carry out dynamic balance test and adjustment on the spindle, check the damage of bearings and replace them in time, at the same time, check the wear and tear of the tool and replace the tool in time.
5、Lubrication system failure
l Insufficient lubrication: Lubrication system failure or insufficient lubricant will lead to increased friction between the various components of the machine tool, accelerating wear and tear of the components, affecting the service life of the machine tool and machining accuracy.
Solution: Regularly check the working condition of the lubrication system to ensure that the lubricant is sufficient and clean. If necessary, the lubrication system can be repaired or replaced.
l Lubricant contamination: The lubricant may be contaminated by impurities, dust, etc. in the process of using, which affects the lubrication effect.
Solution: Replace the lubricating oil regularly and clean the lubricating system to ensure the cleanliness of the lubricating oil.
※ If through the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
Case background:
A motor manufacturing factory has a motor motor rotor automatic three-station finish turning machine, mainly used for motor rotor commutator finish turning processing. In the daily production process, the equipment has a problem of reduced machining accuracy.
Fault phenomenon:
After inspection, it is found that the surface roughness of the processed rotor commutator has increased significantly, and the dimensional accuracy has exceeded the allowable tolerance range. Moreover, abnormal cutting sounds can be heard during the fine turning process.
Fault troubleshooting process:
1, tool inspection
The first suspicion is that the tool problem, the tool disassembled, found that the cutting edge of the tool has obvious traces of wear. Due to tool wear, the cutting edge becomes unsharp, and the material cannot be effectively removed during the cutting process, thus increasing the surface roughness and the dimensional accuracy cannot be guaranteed.
2、Check the fixture
Next, the fixture was inspected, and it was found that there was no problem with the clamping force of the fixture, but the positioning surface of the fixture in contact with the rotor had some small wear marks. This may lead to a slight decrease in the positioning accuracy of the rotor in the machining process, which has a certain impact on the machining accuracy.
3, transmission system inspection
Check the belt in the transmission system, and found that the tension of the belt has decreased, and there is a slight slippage phenomenon. This will make the cutting speed of the tool is not stable, which in turn affects the machining accuracy.
4、Spindle system check
Check the spindle system, through the micrometer to measure the radial runout of the spindle, and found that the radial runout of the spindle is within the allowable range, but the lubricant in the spindle box has some impurities. This may affect the rotational accuracy and smoothness of the spindle, which is unfavorable to machining accuracy to some extent.
Solution:
1. Tooling
A new tool was replaced and a more suitable tool material and cutting parameters were selected according to the rotor material and machining requirements. For example, the original carbide tool was replaced with a coated carbide tool to improve the wear resistance and cutting performance of the tool. At the same time, the cutting speed, feed and depth of cut were adjusted. The cutting speed was reduced from the original 1000r/min to 900r/min, the feed was adjusted from 0.15mm/r to 0.12mm/r, and the depth of cut was adjusted from 0.5mm to 0.4mm to ensure that the tool can work under good cutting conditions.
2、Fixture
The positioning surface of the fixture was repaired, and the traces of wear were removed by grinding, so that the positioning accuracy of the fixture was restored to the normal level. And a thin layer of lubricant was applied to the positioning surface of the fixture to reduce the friction between the rotor and the fixture and further improve the positioning accuracy.
3、Drive system
The tension of the belt was adjusted to a suitable state. During the adjustment process, a belt tension measuring tool was used to control the belt tension within the specified range. At the same time, the pulley was cleaned to remove the oil and dust on the surface to prevent the belt from slipping.
4、Spindle system
Replaced the lubricating oil in the spindle box and cleaned the lubricating oil filtration system to ensure the cleanliness of the lubricating oil. At the same time, the spindle box was sealed and inspected to prevent dust and impurities from re-entering.
The effect after the fault is solved:
After the above series of maintenance and adjustment measures, restart the fine turning machine for rotor commutator processing. After processing, the surface roughness of the rotor commutator reached the design requirements, and the dimensional accuracy was stabilized within the tolerance range, the abnormal cutting sound disappeared, and the equipment resumed normal machining accuracy and productivity.
