What are the common sensor failures and their solutions for series excitation motor motor stator winding machine?
What are the common sensor failures and their solutions for series excitation motor motor stator winding machine?
1、Tension sensor failure
Fault phenomenon:
Tension display abnormality: the tension sensor may display inaccurate tension value, large fluctuations or no display and other problems, resulting in the inability to accurately control the winding tension, which in turn affects the quality of the winding, so that the winding appears slack or too tight.
Uneven winding: Due to unstable tension control, the wires cannot be evenly arranged in the stator groove or on the winding mold during winding, resulting in the phenomenon of uneven spacing between the wires.
Solution:
Check the sensor connection: Make sure that the connecting wire plug between the tension sensor and the control system of the winding machine is firm and free from looseness, poor contact and other problems. If there is any looseness, the plug needs to be re-inserted and tightened; if the connecting wire is found to be broken, it should be replaced in time.
Clean and calibrate the sensor: The measuring parts of the tension sensor may be affected by dust, oil and other impurities, resulting in inaccurate measurement. Clean the sensor regularly with a clean cloth or solvent. Also, calibrate the tension sensor using standard weights and other tools as required by the equipment manual to ensure its measurement accuracy.
Replacement of the sensor: If the tension sensor still does not work properly after inspection and calibration, the internal components of the sensor may be damaged, and it is necessary to replace the tension sensor with a new one.
2, position sensor failure
Failure phenomenon:
Array position error: the position sensor is used to control the moving position of the arranger, if there is a failure, it may lead to the arranger can not be accurately arranged in the stator slot or winding molds, there are problems such as overlap, cross or deviation from the intended position of the arranger, which affects the neatness of the windings and the performance of the motor.
Inaccurate winding axis position: affects the starting position of the winding and the termination position of each layer of winding, resulting in uneven winding, and may even cause the wire to collide with the stator core or other parts, damaging the wire insulation.
Solution:
Check the sensor installation and fixing: make sure that the position sensor is firmly installed and the position is not offset. If the sensor is found to be loosely installed, it needs to be re-fixed; if the position is offset, it should be adjusted in accordance with the requirements of the equipment, so that the sensor can accurately detect the position of the wire arranger or winding shaft.
Detect the sensor signal: use professional testing tools to check whether the output signal of the position sensor is normal. If the signal is abnormal, it is necessary to further check whether the power supply of the sensor is stable, whether there is interference in the signal transmission line and other issues, and take appropriate measures to repair, such as replacing the power supply module, exclude the source of signal interference.
Adjustment or replacement of the sensor: If the sensor itself is damaged and can not normally output accurate position signals, it is necessary to replace the new position sensor, and carry out the corresponding debugging and calibration to ensure that the position of the row of wires and the accuracy of the position of the winding axis.
3, speed sensor failure
Failure phenomenon:
Unstable winding speed: the speed sensor failure will lead to the winding machine can not accurately monitor and control the winding speed, so that the winding speed fluctuations, fast and slow and other phenomena, affecting the efficiency and quality of the winding, and may lead to serious interruptions in the winding.
Misalignment with other components: Due to the unstable winding speed, it may be misaligned with the work of other components such as the wire arranging mechanism, tension control system, etc., which further aggravates the quality problems of winding, such as uneven wire arranging and unstable tension.
Solution:
Check the sensor components: check whether the inductor head, gear and other components of the speed sensor are worn, damaged or attached with foreign objects. If there is wear and tear, the corresponding parts need to be replaced; if there is foreign matter, it should be cleaned up in time.
Check the signal transmission and processing: check whether the signal transmission line between the speed sensor and the control system is normal, and whether there is any broken circuit, short circuit or poor contact and other problems. At the same time, check whether the processing of speed signal by the control system is correct, whether there is any parameter setting error and so on, and make corresponding adjustment and repair.
Replace the speed sensor: If after checking and processing, the speed sensor still can't work properly and output a stable and accurate speed signal, it is necessary to replace the new speed sensor and re-tune and calibrate to ensure the stability of the winding speed.
4、Temperature sensor failure
Fault phenomenon:
Temperature display abnormality: the temperature sensor may display inaccurate temperature values, abnormal temperature fluctuations or no temperature display and other problems, which can not accurately reflect the actual working temperature of the key components of the winding machine (such as motor, winding shaft, etc.).
False alarm or no alarm: When the temperature exceeds the set threshold, the temperature sensor should trigger an alarm signal, but the faulty sensor may have a false alarm or no alarm when the temperature is too high, resulting in the risk of overheating and damage to the equipment.
Solution:
Check the sensor mounting position: Make sure the temperature sensor is mounted in a position where it can accurately measure the temperature of the critical component and has good contact with the component under test. If the installation position is improper or poor contact, need to readjust the installation position and ensure close contact.
Check the performance of the sensor itself: Use professional temperature testing equipment to test the performance of the temperature sensor to check whether there is any deviation or damage. If there is any deviation, it can be calibrated; if it is damaged, it is necessary to replace the temperature sensor with a new one.
Check the alarm setting and control system: Confirm whether the threshold setting of the temperature alarm is correct, and whether the control system's reception and processing of the temperature sensor signal is normal. If there is any problem, it is necessary to reset the alarm threshold or check and repair the control system to ensure the normal operation of the temperature alarm function.
※ If you still can't solve the equipment failure by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
