Series excitation motor motor stator automatic slotting paper machine what are the common sensor failure and its solution?
First, photoelectric sensor failure
(A) failure phenomenon
Inaccurate slot paper positioning
The photoelectric sensor can not accurately detect the position of the slot paper, resulting in the slot paper in the transmission process can not accurately stop in the insertion position, so that the slot paper inserted into the stator slot deviation.
Frequent malfunctioning of equipment
The photoelectric sensor may misjudge the position signal of the slot paper, causing the equipment to start the insertion action before the slot paper is ready, or to repeat the insertion action after the slot paper has already been inserted.
Device fails to start or stops abnormally
Due to the failure of the photoelectric sensor, the equipment may not be able to start because it does not receive the correct slot position signal, or it may not be able to stop normally during operation.
(ii) Cause analysis
Sensor surface contamination
Dust, oil, paper and other pollutants in the working environment are attached to the transmitting and receiving ends of the photoelectric sensor, affecting the emission and reception of light, thus interfering with the sensor's judgment of the slot paper position.
Light blocking or interference
The light path of the sensor is blocked by foreign objects, such as parts falling off inside the device, pieces of slotted paper, etc.. In addition, strong light in the surrounding environment (e.g., nearby welding light, bright light exposure, etc.) may also interfere with the normal operation of the photoelectric sensor.
Damage to sensor components
Long-term use, frequent vibration or electrical overload may lead to photoelectric sensor internal light-emitting diode, photosensitive components, etc. damage, so that the sensor loses the normal detection function.
(iii) Solution
Clean the sensor surface
Regularly clean the photoelectric sensor, use a clean, soft cloth to gently wipe the transmitting and receiving ends of the sensor to remove dust and oil on the surface. For stubborn contaminants, a small amount of alcohol can be used for wiping, but be careful to avoid alcohol entering the sensor interior.
Check and clear the light path obstacles
Check whether the light path of the sensor is blocked, open the device case and carefully check whether there is any foreign matter around the sensor. If you find any obstructions such as parts falling off or pieces of grooved paper, clear them off in time. At the same time, avoid strong light shining directly on the sensor, you can adjust the position of the device or install a light shield to reduce light interference.
Replace damaged sensor elements or sensors
If you suspect that the sensor element is damaged, you can use a multimeter or other tools to conduct a simple test. If it is determined that the element is damaged, the element should be replaced with one of the same type. After replacement, the sensor needs to be calibrated to ensure that it can accurately detect the slot paper position. If the entire sensor is seriously damaged, directly replace the new photoelectric sensor, and install and debug according to the equipment instructions.
Second, the proximity sensor failure
(A) fault phenomenon
Stator positioning error
The proximity sensor is used to detect the position of the stator, and if it fails, it may lead to inaccurate positioning of the stator in the slot paper insertion equipment, affecting the precision of slot paper insertion.
Disordered working sequence of the equipment
Proximity sensor signal error will make the equipment can not be in accordance with the correct order of operation, for example, in the case of the stator is not completely in place before the start of the slot paper insertion, or after the slot paper insertion can not be carried out in a timely manner for the next stator processing.
(ii) Cause analysis
Change in sensing distance
The sensing distance of the proximity sensor may change due to changes in the installation position, the influence of surrounding metal objects, or the drift of the parameters of the sensor itself. If the sensing distance is too close or too far, it may result in failure to accurately detect the position of the stator.
Sensor subject to electromagnetic interference
The electromagnetic environment around the equipment (e.g., large motors, high-frequency equipment, etc. nearby) may interfere with the normal operation of the proximity sensor, causing the sensor to output incorrect signals.
Sensor Damage
Similar to photoelectric sensors, proximity sensors may be damaged due to mechanical collision, long-term use of internal components, thus losing normal detection function.
(iii) Solution
Adjust the sensing distance and reinstallation
Use professional tools or the adjustment device that comes with the equipment to readjust the sensing distance of the proximity sensor so that it can accurately detect the position of the stator. If the installation position of the sensor has been shifted, reinstall the sensor according to the requirements of the equipment manual to ensure that it is installed in the correct position and firmly fixed.
Reducing electromagnetic interference
Check the electromagnetic compatibility of the equipment, and keep a certain distance between the equipment and the equipment that may generate electromagnetic interference. Electromagnetic shielding measures can be used, such as the installation of shielding around the sensor, the use of shielded cables, etc., to reduce the impact of external electromagnetic interference on the sensor.
Replacement of damaged sensors
When it is determined that the proximity sensor is damaged, replace the sensor with the same model. After replacement, performance tests should be carried out to ensure that the sensor can work properly, and there will be no signal error.
Third, Hall sensor failure (if the device has a Hall sensor for detecting motor speed and other related functions)
(A) fault phenomenon
Motor speed detection error
Hall sensor is used to detect the speed of the motor, if there is a failure, it will lead to the motor speed displayed by the device does not match the actual speed, which in turn affects the speed control of slot paper insertion.
Unstable operation of the device
The wrong motor speed signal may make the control system of the equipment unable to correctly adjust the rhythm of slotting paper insertion and other operations, resulting in unstable operation of the equipment, poor slotting paper insertion or frequent malfunction alarms and other situations.
(ii) Cause analysis
Magnetic field interference
Changes in the surrounding magnetic field environment or the proximity of other strong magnetic field sources may interfere with the Hall sensor's detection of the motor's magnetic field, resulting in an incorrect rotational speed signal.
Damaged sensor element
The Hall element itself may fail due to high temperature, electrical overload or mechanical damage, so that the sensor can not normally output a signal corresponding to the motor speed.
Connection line problems
Loose, broken or short-circuited connection lines between the Hall sensor and the control system can also lead to abnormal signal transmission, so that the equipment can not correctly obtain the motor speed signal.
(iii) Solution
Reduce magnetic field interference
Examine the magnetic field environment around the equipment and move away the equipment that may generate magnetic field interference. If it can not be moved away, magnetic field shielding measures can be used, such as wrapping magnetic shielding material around the Hall sensor to reduce the interference of the external magnetic field on the sensor.
Replace the damaged sensor element or sensor
If it is determined that the Hall element is damaged, the Hall sensor should be replaced with the same model. After replacement, the sensor needs to be calibrated to ensure that it can accurately detect the motor speed.
Check and repair the connecting wiring
Check the connection wiring between the Hall sensor and the control system for loose, broken or shorted wiring. For loose wiring, re-insert and fix it; for broken or shorted wiring, repair or replace the damaged wires.
※ 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.
