How to analyze and troubleshoot the serial excitation motor motor automatic terminal press?
First, fault analysis steps
1、Observation of fault phenomenon
Observation of the overall state of the equipment: After the equipment failure, the first observation of the operating state of the equipment. Including whether the motor is running normally, there is no abnormal sound or vibration, crimping action is able to perform normally, whether the feeding process is smooth, whether the equipment's indicator lights and display screen has abnormal tips. For example, if you hear a harsh noise from the motor, it may be that the motor bearings are damaged or there are foreign objects inside the motor.
Product quality check: Check the quality of the terminals after crimping, which is also an important basis for judging the fault. Check whether the crimping of the terminals is firm, whether there is any looseness or deformation; whether the dimensions of the crimped terminals are in accordance with the requirements, such as whether the height and width are within the standard range; whether there are any defects on the surface of the terminals, such as burrs and cracks. For example, if the terminal is easy to fall off after crimping, it may be that the crimping pressure is insufficient or the mold is worn out.
2、Collect relevant information
Equipment operating records view: check the operating log of the equipment to understand the operation of the equipment before the failure. Including the length of time the equipment has been running, whether the recent parameter adjustments, whether there has been maintenance or replacement of parts of the record. For example, if the equipment fails after parameter adjustment, then it is likely to be caused by improper parameter settings.
Ask the operator for details: Communicate with the person who operated the equipment at the time and ask about the specific situation when the failure occurred. For example, ask whether there are abnormal signs in the equipment before the failure, such as whether there has been a short pause, speed changes, etc.; whether the operator has carried out a special operation, such as mistakenly pressed a button, change the working mode, and so on.
Second, fault classification and investigation
1、Electrical system troubleshooting:
Power supply check: use a multimeter to check whether the power supply voltage is normal and whether there is a lack of phase. For three-phase power supply, three-phase voltage should be balanced and within the rated voltage required by the equipment. At the same time, check whether the power line is broken, short-circuited or disconnected, including plugs, sockets, fuses and other parts.
Motor check: check whether the motor can start and run normally. Check to see if the wiring of the motor is firm and there are no signs of looseness or burning. For series-excited motors, also check the wear of the brushes; excessive brush wear may cause the motor to run abnormally. In addition, use an insulation resistance meter to check the insulation resistance of the motor windings to determine whether there is a short circuit or grounding fault in the motor windings.
Electrical control components inspection: Check the relays, contactors, sensors and other electrical control components. Check whether the contacts of the relays and contactors are normal, and whether there is any sticking or ablation; whether the sensors can work normally, and whether their signals can be correctly transmitted to the control system. For example, if the position sensor fails, it may lead to inaccurate feeding or uncoordinated crimping action.
2、Mechanical system troubleshooting:
Transmission parts inspection: check the belt, chain, gears and other transmission parts. Check whether the belt is slack, worn or broken; whether the chain is loose, jumping teeth; gear teeth are worn, there are foreign objects embedded. For example, a slack belt will cause the power of the motor to not be effectively transmitted to the crimping mechanism, making the crimping speed unstable.
Crimping mechanism check: Check the status of the crimping die, including whether the die is worn and deformed, and whether the die is firmly installed. If the mold is badly worn, it will lead to a decline in the quality of terminal crimping; poor installation of the mold may cause the crimping position to shift. At the same time, check the moving parts of the crimping mechanism, such as slider, guide rail, etc., to see whether it can move smoothly, there is no stagnation phenomenon.
Feeding mechanism check: check the feeding wheel, feeding track and other parts of the feeding mechanism. Whether the surface of the feeding wheel is worn, whether the friction between it and the terminal is enough; whether the feeding track is smooth, whether there is any foreign matter blocking or deformation. For example, deformation of the feeding track may lead to inaccurate feeding of terminals.
3, control system troubleshooting:
Control program check: If the device uses a programmable logic controller (PLC) or computer control system, check the control program for errors. This can be checked by viewing the program's running log, monitoring the program's running status or reloading the program. For example, logic errors in the program may cause the sequence of actions of the device to be confused.
Control signal check: Use tools such as an oscilloscope or multimeter to check whether the control signals from the control system are correct. This includes the motor speed control signal, the trigger signal for the crimping action, the control signal for the feed length and speed, etc. If the control signal is wrong, it may lead to the equipment can not run in accordance with the expected way.
Third, common troubleshooting methods
1, motor troubleshooting:
The motor does not rotate:
Power supply problems: If the power supply voltage is abnormal, check the power lines and power supply equipment, repair the power supply failure or replace the voltage regulator. If the fuse is blown, replace the fuse with the same specification, and check whether there is a short circuit.
Problems with the motor itself: If the motor winding is short-circuited or grounded, rewind the winding or replace the motor. For excessive brush wear, replace the brushes with new ones. At the same time, check whether the bearing of the motor is stuck, if there is any foreign matter stuck, clear the foreign matter; if the bearing is damaged, replace the bearing.
2、Abnormal motor speed:
Power supply voltage fluctuation: use voltage regulator to stabilize the power supply voltage and make sure the motor works under rated voltage.
Load changes: check the load of the equipment, such as whether there is a terminal jammed, the friction of the transmission components increased. Clear off the jammed terminals, lubricate the transmission parts or replace the worn parts, so that the load returns to normal.
Electrical component failure: check whether the governor, sensor and other electrical components work properly. For example, if the governor is damaged, replace the governor; if the sensor signal is inaccurate, calibrate or replace the sensor.
Fourth, poor quality crimping troubleshooting:
1, crimping is not solid:
Insufficient crimping pressure: check the crimping mechanism of the pressure regulator, increase the crimping pressure appropriately. At the same time, check whether the mold is worn, if the mold is badly worn, replace the mold.
Problems with terminals or wires: Check the quality of the terminals and wires, such as whether the material of the terminals meets the requirements, and whether the diameter of the wires matches the mold. Replace the unqualified terminals or adjust the size of the wire to make it fit with the equipment.
2、Crimp size does not meet the requirements:
Mold problems: check whether the mold is installed correctly, whether the size of the mold meets the terminal crimping standards. If the mold is improperly installed, reinstall the mold; if the mold size is wrong, replace the correct mold.
Parameter setting problem: Check the parameter setting of the equipment, such as crimping height, width and other parameters are correct. According to the specifications of the terminal, readjust the parameter settings.
Fifth, inaccurate feeding troubleshooting:
1, feeding length is not accurate:
Feed wheel wear: check the wear of the feed wheel, if the wear is serious, replace the feed wheel. At the same time, check whether the friction between the feed wheel and the terminal is sufficient, if the friction is insufficient, you can increase the pressure of the feed wheel or replace the feed wheel with the appropriate surface roughness.
Motor or control signal problem: Check whether the feeding motor works normally and whether its speed is stable. Check whether the signal to control the feeding length is correct, such as whether the pulse signal is accurate. If the motor is faulty, repair or replace the motor; if the control signal is wrong, adjust the control program or replace the control components.
2、Inaccurate feeding position:
Feeding track problem: check whether the feeding track is smooth and deformed. Clean up the foreign matter in the feeding track, and repair or replace the deformed feeding track.
Sensor failure: Check whether the position sensor can accurately detect the position of the terminal. Calibrate or replace the position sensor to ensure that it can correctly feedback the position information of the terminal.
※ If you still can not solve the equipment failure through the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
