What are the common mechanical failures and solutions for series excitation motor motor stator press end plate machine?
1、Insufficient or unstable pressure failure
Failure phenomenon
The end plate is not firm and easy to loosen after pressing. This is because the pressure does not reach the set value, resulting in the connection between the end plate and the stator is not tight enough.
The pressure fluctuates during the press-fitting process, which makes the quality of the end plate press-fitting uneven. This may be manifested in the case that some end plates are qualified, while some end plates are skewed or not tightly bonded with the stator.
Solution
Check the pressure source of the hydraulic system (if it is a hydraulic end plate press) or the pneumatic system (if it is a pneumatic end plate press). For the hydraulic system, see if the hydraulic pump is working properly and check the level and quality of the hydraulic fluid. If the hydraulic pump is damaged, it needs to be replaced or repaired; if the hydraulic oil is insufficient, replenish the hydraulic oil to the proper level, and if the hydraulic oil is contaminated, it needs to be replaced.
For the pneumatic system, check whether the output pressure of the air compressor is stable and whether there are leaks in the air line. Repair leaks and adjust the pressure regulator valve of the air compressor to ensure that the output pressure is stable within the set range.
Check the pressure sensor and pressure controller. If the pressure sensor is faulty, it will result in an inaccurate pressure feedback signal, which in turn will affect the pressure control. Use a standard pressure source to calibrate the pressure sensor or replace the faulty sensor. At the same time, check whether the parameter settings of the pressure controller are correct, such as proportional-integral-derivative (PID) parameters, and adjust them according to the actual situation.
2、Mechanical parts wear failure
Failure phenomenon
The pressure head is worn, resulting in the surface of the end plate being uneven. The press head and end plate are prone to wear under prolonged contact and pressure, and the worn out press head will cause the end plate to be unevenly pressurized.
Wear of transmission parts (e.g., screws, guide rails, etc.) causes vibration and positional deviation in the press fitting process. Wear of the screw will lead to unstable up and down movement of the press head, while wear of the guide rail will affect the straightness of the press head, resulting in inaccurate press fitting position of the end plate.
The solution
Repair or replace the worn indenter depending on the degree of wear. If the wear is light, the surface of the indenter can be repaired by grinding, etc., so as to make it flat again; if the wear is serious, the indenter should be replaced with a new one, and make sure that the size and material of the new indenter meet the requirements.
Regularly check and lubricate the transmission parts, such as silk rod and guide rail. When the transmission parts are found to be worn, for the silk rod, if the wear is within the scope of repairable, it can be repaired by chrome plating and other processes; for the guide rail, you can replace the worn slider or guide rail bar. At the same time, adjust the clearance of the transmission components to ensure the precision and stability of the indenter movement.
3、Fixture failure
Failure phenomenon
The stator fixture is loose, causing the stator to shift in the press fitting process. This will make the relative position of the end plate and stator inaccurate, affecting the quality of press fitting.
The clamping force of the fixture is insufficient to securely hold the stator. During press fitting, the stator may be displaced due to pressure, causing the end plate press fitting to be skewed or not fit the stator completely.
Solution
Check whether the fixing bolts of the fixture are loose. If loose, retighten the bolts and check and tighten them periodically. At the same time, check whether the positioning pins of the fixture are worn or damaged. Worn positioning pins will lead to inaccurate positioning of the stator and need to be replaced.
Check the clamping mechanism of the fixture, such as pneumatic chuck or hydraulic chuck. Check whether the clamping force meets the requirements, you can measure the clamping pressure by manometer. If the clamping force is insufficient, adjust the pressure regulating valve of the clamping mechanism or check whether there is any leakage of the clamping cylinder/hydraulic cylinder, etc., and repair accordingly.
4、Vibration and noise failure
Failure phenomenon
The equipment generates abnormal vibration during operation, which affects the accuracy of press fitting. Vibration may lead to changes in the relative position between the end plate and stator, resulting in lower product quality after press fitting.
A loud noise, which interferes with the working environment and may indicate a potential problem with the equipment. Noise can be caused by friction between mechanical parts, collisions, or abnormalities in the hydraulic/pneumatic system.
Solution
Check that the equipment is on a secure foundation. If the equipment is mounted on an unstable foundation that generates vibration, the equipment needs to be reinstalled to ensure that it is mounted on a solid, level foundation and secured with ground bolts, etc.
For vibration and noise generated by mechanical parts, check whether the transmission parts are installed correctly, such as whether the belt and chain are properly tensioned and whether the gear mesh is good. Adjust the tension or replace the worn transmission parts. At the same time, check whether there is any interference between the moving parts and eliminate the interference points.
For noise generated by the hydraulic/pneumatic system, check that the hydraulic pump/air compressor is working properly and that air is not entering the hydraulic system (cavitation). If it is the phenomenon of air pockets, check the level of hydraulic oil and suction line leakage, to rule out the possibility of air entry; if it is the air compressor, check the air intake filter, muffler and other components, cleaning or replacement.
5、Automatic control system failure (if any)
Failure phenomenon
The automated operation process of the equipment is in disarray, such as the wrong sequence of press-fitting and the inability to cycle automatically. This may be caused by the program error of the control system or abnormal sensor signals.
The equipment is unable to communicate with the upper computer or other devices, affecting production management and data transmission. This may be caused by damaged communication lines, incompatible communication protocols or faulty control modules.
Solution
Check the program code of the automation control system. If there is an error in the program, debug and modify it through the programming software. Check whether the input sensor signals of the control system (e.g. position sensor, pressure sensor, etc.) are normal or not, and use tools such as a multimeter to detect, repair or replace the faulty sensor.
For communication faults, check whether the communication lines are intact, including data lines and signal lines. Check whether the communication interface is loose or damaged, re-plug or replace the damaged interface. At the same time, check whether the communication protocol is set correctly to ensure that the devices can communicate with each other normally. If the control module is faulty, it may be necessary to replace the faulty module and reconfigure and test it.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. technical specialists through the page chat tool to seek help.
