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What are the common electrical faults and solutions for series excitation motor motor automatic terminal press?

2025-01-02 15:02:40
21

What are the common electrical faults and solutions for series excitation motor motor automatic terminal press?


 


1、Motor failure


l Motor does not rotate


Reason:


Power supply problems: such as the power supply is not connected, missing phase, too low or too high voltage. Damage to the power supply line, blown fuse or poor contact of the plug and socket may result in the power supply not being able to supply the motor normally.


Motor winding damage: may be due to long-term overload, overheating, moisture or insulation aging, resulting in a short circuit, disconnection or grounding fault winding.


Control circuit failure: such as relays, contactors are not properly absorbed, the control signal can not be transmitted to the motor, or the components in the control circuit are damaged, such as capacitors, resistors, integrated circuits, etc. failure.


Solution:


Check the power line, use a multimeter to measure whether the voltage is normal, check whether the fuse is blown, make sure the plug and socket are connected tightly. If there is a lack of phase, check the three-phase power line to find the faulty phase and repair it.


For damaged motor windings, use an insulation resistance meter to check the insulation resistance. If the windings are shorted, disconnected or grounded, the windings need to be rewound or the motor replaced.


Check the control circuit, check the working status of relays and contactors, and check whether the control signal is normal. For damaged control components, replace them according to the model and parameters of the components.


 


l Abnormal motor speed


Cause:


Load change: if the load of the terminal press machine suddenly increases or decreases, such as terminal material jamming, increased friction of transmission parts, etc., it will cause the motor speed to change.


Power supply voltage fluctuation: unstable power supply and voltage fluctuation will affect the speed of the motor, especially for the series excitation motor, whose speed is directly related to the voltage.


Failure of the speed control device: If the motor speed is controlled by the speed control device, the failure of the speed control itself, such as damage to the potentiometer, the failure of the speed control circuit components, etc., will lead to the speed can not be adjusted normally.


Motor internal failure: such as brush wear, commutator damage, etc., will affect the electromagnetic torque of the motor, which will lead to abnormal speed.


Solution:


Check the load condition, clear off the jammed part of the terminal material, check the lubrication of the transmission parts and reduce the friction. If the change in load is caused by a change in process requirements, it may be necessary to readjust the power of the motor or use a suitable transmission device.


Stabilize the supply voltage, using equipment such as a voltage regulator or UPS, to ensure that the motor operates within the rated voltage range. For large voltage fluctuations, check the power supply line and power supply equipment to find out the cause and solve the problem.


Check the speed regulating device, use a multimeter to check the input and output voltages of the speed regulator, and check whether the potentiometer is working properly. For the damaged speed control components, replace or repair them.


Check the brushes and commutator inside the motor, replace the worn brushes, and repair or replace the damaged commutator. At the same time, check whether the magnetic field winding and armature winding of the motor are normal.


 微信图片_20250102145150.png


2、Sensor failure


l Position sensor failure


Cause:


Sensor damage: may be subject to mechanical collision, electromagnetic interference, long-term use of components caused by aging and other reasons, so that the sensor can not work properly.


Improper sensor installation position: position sensor if the installation position is inaccurate, such as too far away from the detection target or too close, angular deviation, etc., will lead to inaccurate detection signal.


Sensor line failure: line breakage, short circuit or poor contact will make the sensor signal can not be transmitted to the controller.


Solution:


Replace the damaged sensor, choose the right type and specification of the sensor to ensure that its performance meets the working requirements of the terminal press. When installing the new sensor, pay attention to avoid collision and electromagnetic interference.


Adjust the installation position of the sensor, according to the installation instructions of the equipment, accurately adjust the distance and angle between the sensor and the detection target, generally the distance error is controlled within ±1mm, and the angle deviation does not exceed ±5°.


Check the sensor line, use a multimeter to check the line through and through the situation, to see whether the line joints are firm. For broken or short-circuited lines, repair or replace.


 


l Pressure sensor failure


Cause:


Overload damage: If the pressure of the terminal press is too high during the working process, exceeding the range of the pressure sensor, it may lead to sensor damage.


Sensor zero drift: long-term use or environmental temperature changes and other factors may lead to pressure sensor zero drift, so that the measurement results are inaccurate.


Poor sealing of the sensor: If the seal of the pressure sensor is damaged, resulting in liquid or gas entering the inside of the sensor, it will affect the performance of the sensor.


Solution:


Avoid overloading the pressure sensor, according to the great working pressure of the terminal press, choose the appropriate range of the sensor, the general working pressure should be between 60% - 80% of the sensor range. For damaged sensors, replace them in time.


Regular zero calibration of the pressure sensor, the use of standard pressure source for calibration of the sensor, adjust the zero drift. The calibration period depends on the frequency of use and accuracy requirements of the equipment, generally 1 - 3 months.


Check the sealing condition of the sensor, replace damaged seals, and ensure that the inside of the sensor is not affected by external liquids or gases. In the installation of the sensor, in accordance with the specified installation methods to ensure good sealing.


 


3、Electrical control box failure


l Damage to components in the control cabinet


Cause:


Overheating damage: the components in the control cabinet will generate heat during the work process, if the heat dissipation is poor, such as blocked vents, radiator failure, etc., it will lead to the component temperature is too high, and thus damaged.


Electrical overload: If the circuit design is unreasonable or improper selection of components, it may lead to the components to withstand the current, voltage exceeds its rated value, thus triggering overload damage.


Electromagnetic interference: strong electromagnetic sources around the control cabinet, such as large motors, transformers, etc., may cause electromagnetic interference to the components in the control cabinet, resulting in abnormal operation or damage to the components.


Solution:


Improve the heat dissipation conditions of the control cabinet, clean the vents to ensure good ventilation. Check whether the heat sink is working properly, for components with large heat generation, you can increase the heat sink or fan for heat dissipation.


Check the circuit design and component selection to ensure that the rated parameters of the components can meet the actual working requirements. Set suitable protection devices in the circuit, such as fuses, thermal relays, etc., to prevent electrical overload.


Take electromagnetic protection measures, such as shielding the control cabinet and using shielded wires to connect the electrical components to reduce electromagnetic interference. At the same time, keep the control cabinet away from strong electromagnetic sources, such as at least 2 - 3 meters away from large motors.


 


l Control program error


Reason:


Program writing error: in the process of writing the control program, there may be logical errors, instruction errors, etc., resulting in the equipment can not work properly.


Program interference: External interference signals, such as electromagnetic interference, electrostatic interference, etc., may cause the program to run wrong.


Program Update Failure: When updating the program, if the operation is not proper or there are unexpected situations during the updating process, such as power failure, data transmission error, etc., it may lead to program error.


Solution:


Check the control program, through the program debugging tool, debug the program step by step, find out the wrong code segment and modify it. For complex programs, you can ask professional programmers or equipment manufacturers for assistance.


Take anti-interference measures, such as setting up filtering circuits in the control cabinet to filter the input and output signals. At the same time, make sure the equipment is well grounded to reduce static interference.


When updating the program, operate in strict accordance with the operating instructions to ensure that the power supply is stable during the update process. If the program update fails, try to update it again, or restore to the previous backup program.


 


※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical and Electrical Equipment Co.


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