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How to troubleshoot and analyze a series excitation motor motor stator press end plate machine?

2024-12-30 15:24:02
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How to troubleshoot and analyze the series excitation motor motor stator press end plate machine?


1. Failure analysis steps


l Observe the fault phenomenon


Observation of the operation state: When the equipment fails, first observe the overall operation state of the equipment. See whether the equipment completely stops working, or part of the function is still running but abnormal. For example, whether the motor is still running, whether the press head is able to press down normally, or whether there is abnormal vibration and noise in the process of pressing and loading.


Appearance inspection: Look carefully at the appearance of the equipment and check whether there are obvious signs of damage. For example, whether there are traces of burnt or short-circuited wires, and whether the mechanical parts (such as press head, drive belt, chain, etc.) are broken, worn or loose. At the same time, observe whether there is any liquid leakage, such as whether there is hydraulic oil leakage in the hydraulic system.


Indicator lights and instrumentation check: Check the status of the indicator lights on the equipment and determine whether any fault indicator lights are on. Check the display of pressure, temperature, speed and other parameters on the instrument panel to see if there are abnormal readings, which can provide clues for fault analysis.


l Collect equipment information


Equipment history query: Understand the use history of the equipment, including the equipment's service life, past maintenance records, replaced parts and so on. This information can help determine whether the failure is due to equipment aging, recurring problems or newly emerged conditions.


Operation inquiry: Ask the operator about the operation of the equipment before the failure occurred. For example, whether abnormal operation was carried out, such as overload operation, wrong parameter setting, sudden power off or on, etc. At the same time, understand the equipment at the time of the failure is being carried out in the work task, such as whether in the normal pressure loading or in the commissioning process failure.


l Preliminary judgment of the scope of the fault


Classification according to the phenomenon: According to the observed fault phenomenon, the preliminary classification of faults into electrical faults, mechanical faults or other system failures. For example, if the motor does not run and there is no sound, it may be a failure of the electrical system; if the indenter does not move smoothly but the motor is normal, it may be a failure of the mechanical transmission part.


Refer to the schematic diagram of the equipment: With the help of the electrical schematic diagram of the equipment, mechanical assembly diagrams and other technical information, to further narrow down the scope of the fault. Through the schematic diagram, you can understand the connection relationship between various components and the signal flow, so as to determine the possible location of the fault. For example, according to the electrical schematic diagram, you can check the part of the circuit that controls the motor, including relays, contactors, motor controllers and other components.


l In-depth inspection of suspected parts


Inspection of electrical parts: For suspected electrical faults, use tools such as a multimeter to perform the inspection. Parameters such as voltage, resistance, and current can be measured. For example, check whether the resistance of the motor winding is normal, whether the output signal of the sensor meets the requirements, and whether the power supply is stable. For electronic components (such as controllers, drivers, etc.), you can check whether their operating temperature is too high, whether there is a burning odor, etc.


Inspection of mechanical parts: For parts suspected of mechanical failure, carry out appearance and function checks. Check the appearance of mechanical parts for damage (e.g., wear, deformation, rupture, etc.) and for loose connections. For example, check for loose or broken drive belts, and check for seized or badly worn bearings. For some parts that require precise movement (such as the guide rail of the press head, silk rod, etc.), you can check the precision and smoothness of its movement.


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2、Common troubleshooting methods


l Electrical faults


Power failure


Failure phenomenon: the equipment can not start at all, all the indicator lights do not light.


Troubleshooting methods: first check whether the external power supply is normal, to see whether the power plug is plugged in, whether the socket is powered. You can use other electrical equipment to test the socket. Then check whether the fuse inside the device is blown, if it is blown, you need to replace the fuse with the same specification. At the same time, check whether the power line is broken, short-circuit, etc., if necessary to repair or replace.


Motor Failure


Failure phenomenon: the motor does not run or abnormal operation (such as unstable speed, abnormal sound, etc.).


Troubleshooting method: If the motor does not run, first check whether the power input of the motor is normal, including whether the motor wiring is firm and whether the controller has output signal. For brushed motors, check whether the brushes are badly worn or have poor contact, if the brushes are problematic, replace the brushes. If the motor runs but the speed is unstable, check whether the speed sensor works normally and whether its connection is good, and also check the parameter setting and working status of the speed controller, and adjust or replace it if there is any problem. If the motor makes abnormal sound, it may be that the bearing inside the motor is damaged or there are foreign objects entering, it is necessary to disassemble the motor for inspection and cleaning, and replace the damaged bearing.


Sensor failure


Failure phenomenon: material level sensor failure leads to inaccurate material level detection, or speed sensor failure makes speed control ineffective.


Troubleshooting method: For the material level sensor, check whether its installation position is correct and whether it is blocked by materials. Clean the surface of the sensor and check if the sensor's connection wiring is loose or damaged. Use a standard test object to check whether the output signal of the sensor is normal, if not, it may be necessary to replace the sensor. For speed sensors, similarly check the mounting, connections and clean the surface, check the accuracy of the output signal by comparison testing (e.g. using a tachometer) and replace or calibrate the faulty sensor.


Controller Failure


Failure phenomenon: the sequence of action of the device is confused, parameter settings can not be saved or the device can not respond to control commands.


Troubleshooting method: For programmable logic controller (PLC) control system, check whether there is any error in the program (e.g., logic confusion, program loss, etc.), and re-download or correct the program through programming software. Check whether the input/output (I/O) module of the PLC is working properly and replace the damaged module. For human-machine interface (HMI) failure, check whether the connection line is loose, whether the screen is damaged, try to restart or update the HMI software. At the same time, check whether the transmission line of the control signal is disturbed, and take shielding measures to reduce electromagnetic interference.


 


l Mechanical Failure


Insufficient or unstable pressure


Failure phenomenon: the end plate is not firm after pressing and loosening easily, or the pressure fluctuates in the process of pressing and loosening.


Troubleshooting method: 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 the leaks and adjust the pressure regulating valve of the air compressor to ensure that the output pressure is stable within the set range. Also, check the pressure sensor and pressure controller, and calibrate or replace faulty parts.


Mechanical parts wear failure


Failure phenomenon: Wear of the press head, resulting in uneven surface of the end plate; wear of the transmission parts (such as screws, guide rails, etc.), resulting in vibration and positional deviation in the press-fitting process.


Troubleshooting method: For the worn press head, repair or replace it according to the degree of wear. If the wear is light, the surface of the press head can be repaired by grinding or other means to restore its flatness; if the wear is serious, the press head should be replaced with a new one, and make sure that the size and material of the new press head 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 range of repairable, it can be repaired by chrome plating and other processes; for the guide rail, the worn slider or guide rail bar can be replaced. At the same time, adjust the clearance of the transmission parts to ensure the precision and stability of the indenter movement.


Failure of fixture


Failure phenomenon: the stator fixture is loose, causing the stator to shift in the press fitting process; the clamping force of the fixture is insufficient to firmly fix the stator.


Remedy: Check whether the fixing bolts of the fixture are loose. If loose, retighten the bolts and check and tighten them regularly. 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 the clamping cylinder/hydraulic cylinder for leaks, etc. and repair accordingly.


Vibration and noise faults


Phenomenon: Abnormal vibration occurs during operation, affecting the accuracy of the press fit; loud noise occurs, interfering with the working environment and may indicate a potential problem with the equipment.


Troubleshooting method: Check whether the foundation of the equipment is solid. If the equipment is installed on an unstable foundation, vibration will be generated, the need to re-install the equipment to ensure that it is installed on a solid, flat foundation, and the use of ground bolts and other fixed. 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 a cavitation phenomenon, check the level of hydraulic oil and the suction line for leakage to exclude the possibility of air entry; if it is a problem with the air compressor, check the intake filter, muffler and other parts, and clean or replace them.


※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.

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