What are the common sensor failures and their solutions for brushless motor motor manual four-station internal winding machine?
Brushless motor manual four-station internal winding machine common sensor failure and its solutions are as follows:
1、Counting sensor failure
Failure phenomenon
Inaccurate counting: the number of winding turns does not match the set value, resulting in deviation in the number of winding.
Non-counting: the sensor cannot sense the winding action normally, and the counter does not work.
Failure causes
Improper installation position of the sensor: the installation position is shifted, so that the sensor can not accurately sense the winding action.
Sensor sensitivity problem: the sensitivity setting is too high or too low, too high may lead to false counting, too low will not be able to detect the winding action.
Sensor damage: after long-term use, the internal components of the sensor are aging and damaged, and cannot work normally.
Signal interference: nearby electromagnetic interference or unreasonable wiring affects the transmission of the sensor signal.
Solution
Adjust the installation position: Re-adjust the installation position of the counting sensor to ensure that it can accurately sense the winding action, generally by fine-tuning the position and testing to determine the optimal installation point.
Calibrate sensitivity: Recalibrate the sensitivity of the sensor according to the actual operating conditions of the winding machine, which can be adjusted by testing the count at different winding speeds and wire diameters.
Replacement of sensor: If the sensor has been damaged, it should be replaced with the same type of sensor in time, and make sure the quality and performance of the new sensor meet the requirements.
Anti-interference processing: check whether the wiring is reasonable, try to separate the sensor signal lines and strong power lines laid; can be used to shield the line or installed around the sensor shield to reduce electromagnetic interference.
2, locate the sensor failure
Failure phenomenon
Inaccurate positioning: when switching between four stations, the sensor can not accurately stop at the specified position, resulting in deviation of the winding position.
Positioning delay: the sensor can not send out the positioning signal in time, so that the winding machine is delayed in the positioning process, affecting work efficiency.
Failure causes
Dirty sensor surface: Dust, oil and other pollutants are attached to the sensor surface, affecting its sensing of the target.
Irregular installation of target: the positioning target (such as positioning block, stopper, etc.) is not firmly installed or inaccurately positioned, resulting in the sensor not being able to accurately identify.
Sensor performance degradation: after long-term use, the detection accuracy and response speed of the sensor decreases.
Problems with line connection: The connection line of the sensor is loose, broken or short-circuited, resulting in abnormal signal transmission.
Solution
Clean the sensor: Clean the surface of the sensor regularly with a clean soft cloth or special cleaner to ensure that its sensing window is free of contaminants.
Check and adjust the target: Check the installation of the positioning target to ensure that it is firm and in the exact position; if there is any deviation, adjust it in time.
Replace or calibrate the sensors: For sensors with reduced performance, try to calibrate them; if the calibration still fails to meet the requirements, replace the sensors with new ones.
Check the line connection: carefully check the sensor connection line to ensure that the connection is solid, no broken or short-circuit phenomenon; for damaged lines, timely replacement.
3、Tension sensor failure
Failure phenomenon
Tension instability: in the winding process, the tension of the wire is sometimes large and sometimes small, resulting in inconsistent winding tension.
Tension display abnormality: the tension value displayed by the tension sensor does not match the actual tension, or the display value fluctuates greatly.
Failure causes
Tension sensor calibration error: the initial calibration parameters set incorrectly, or long-term use of the calibration value deviation.
Uneven force on the sensor: The force points of the sensor are not uniform during installation, resulting in inaccurate measurement.
Elastic element fatigue: the elastic element of the tension sensor is fatigued after long-term use, affecting the measurement accuracy.
Electrical Connection Problems: Poor contact of the electrical connection part of the sensor leads to unstable signal transmission.
Solution
Re-calibration: Re-calibrate the tension sensor according to its instruction manual to ensure that the calibration process is accurate.
Adjust the installation: Check the installation of the sensor and adjust its installation position and method to ensure that the force is uniform.
Replace the elastic element: If the elastic element is fatigued, replace the elastic element with a new one or the whole tension sensor.
Check the electrical connection: Tighten the electrical connection to ensure good contact; check the wiring for breakage, aging, etc., and replace it if there is any problem.
※ 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.
