What are the common sensor failures and their solutions for series excitation motor motor automatic terminal press?
First, the pressure sensor failure
1, pressure detection value deviation is too large
Cause:
Sensor zero drift: prolonged use, temperature changes or mechanical vibration may cause the zero point of the pressure sensor to drift, making the measured initial value inaccurate.
Improper calibration of the sensor: If the pressure sensor is not properly calibrated after installation or maintenance, it will lead to measurement errors.
Sensor impacted or damaged by external forces: During the operation of the equipment, the pressure sensor may be subjected to external forces such as accidental collision, excessive extrusion, etc., resulting in damage to the internal components and affecting the measurement accuracy.
Solution:
For the zero drift problem, it can be solved by recalibrating the zero point. Usually after the unit has been turned on and warmed up for a period of time (e.g., 10 - 15 minutes), the zero point is calibrated using a standard pressure source in accordance with the sensor's operating manual to adjust the measurement deviation to within the allowable range.
Calibrate the pressure transducer correctly, using specialized calibration equipment and methods according to the pressure range and accuracy requirements of the equipment. The calibration period can be determined according to the frequency of use and working environment of the equipment, generally calibrated every 3 - 6 months.
Check the sensor for obvious physical damage, such as deformation of the housing, broken leads, etc.. If damage is found, replace the pressure sensor with a new one and make sure it is installed correctly to avoid external impact again.
2, pressure signal instability or no signal output
Cause:
Sensor connection line problems: loose lines, poor contact, broken wires or short circuits may lead to signal transmission interruption or instability.
Sensor power supply abnormalities: unstable power supply voltage, power line failure or power module damage may make the sensor can not work properly, so there is no signal output.
Failure of internal components of the sensor: such as damaged strain gauges, signal processing circuit failure, etc., will lead to unstable or no signal.
Solution:
Check the connection lines of the sensor, including plugs, sockets, welding points, etc. Ensure that the wiring is firmly connected and not loose or oxidized. For loose connections, reinsert and tighten; for damaged lines, replace with new wires.
Check the power supply of the sensor, use a multimeter to measure whether the power supply voltage is within the rated range. If the power supply voltage is abnormal, check the power supply line and power supply module, and repair or replace the damaged parts.
If a sensor internal component failure is suspected, use the replacement method to replace the potentially faulty sensor with a known normal sensor and observe whether the signal returns to normal. If it is determined that the sensor internal component failure, should be replaced with a new sensor.
Second, the position sensor failure
1, position detection inaccuracy
Cause:
Improper sensor installation position: If the installation position of the position sensor is offset, the angle is incorrect or the distance to the measured object is not appropriate, it will lead to deviation in position detection.
Sensor is contaminated: dust, oil, metal shavings and other pollutants attached to the sensor's sensing surface will affect the sensor's position detection accuracy.
Sensor aging or wear and tear: prolonged use may lead to a decline in the performance of the sensor, such as the lens of the optical sensor is worn out, the magnetic sensor of the magnetic weakening, and so on.
Solution:
Re-adjust the installation position of the sensor, according to the installation manual of the device, use the appropriate tools to accurately measure and adjust the distance and angle between the sensor and the object to be measured. For example, for photoelectric position sensors, the distance between the sensor and the object to be measured should generally be within the specified range of the sensor, usually a few millimeters to tens of millimeters.
To clean the sensing surface of the sensor, use a clean soft cloth or a special cleaner to gently wipe to remove contaminants. For oil contamination that is difficult to clean, you can use a small amount of organic solvent (such as alcohol) to wipe, but be careful to avoid damage to the sensor.
Check the aging or wear and tear of the sensor, and replace the sensor with a new one if it is badly worn or its performance is significantly reduced. When replacing, choose the same model as the original sensor or a sensor with equivalent performance.
2, position signal loss or abnormal
Cause:
Sensor line failure: similar to the pressure sensor, the position sensor line problems, such as broken circuit, short circuit or poor contact, may lead to signal loss or abnormality.
External interference: electromagnetic interference, vibration interference or strong light interference (for optical sensors) and other external factors may affect the sensor's signal output.
Failure of the sensor itself: such as internal component damage, signal processing circuit failure, etc., which can lead to abnormal or lost position signals.
Solution:
Check the wiring of the sensor, follow the method of checking the wiring of the pressure sensor to find the wiring fault and repair it.
For external interference, take appropriate anti-interference measures. For electromagnetic interference, you can use shielded wires to connect the sensor and ground the equipment well; for vibration interference, check whether the sensor is firmly installed, and if necessary, increase the vibration damping measures; for strong light interference, adjust the sensor's mounting position or increase the light shield.
If the sensor itself is suspected of failure, use the replacement method to verify. If it is determined that the sensor failure, replace the new sensor, and the new sensor debugging and calibration.
Third, the proximity sensor failure
1, proximity detection failure
Cause:
Improperly set detection distance: the proximity sensor has a certain detection distance range, if the set detection distance does not meet the actual needs, it may lead to failure to correctly detect the proximity of the target object.
Sensor sensitivity changes: due to environmental factors (such as temperature, humidity), component aging or interference, etc., the sensitivity of the sensor may change, affecting the proximity detection effect.
Target object characteristics do not meet the requirements: proximity sensors have certain requirements for the material, shape and surface characteristics of the target object. If these characteristics of the target object change, such as a change in surface coating, irregular shape, etc., it may lead to detection failure.
Solution:
Reset the detection distance of the proximity sensor according to the actual situation of the target object. Generally, you can set the parameters through the adjustment knob on the sensor or in the equipment control system, so that the detection distance meets the working requirements of the equipment.
Check the sensitivity of the sensor and restore its normal sensitivity by adjusting the sensor's sensitivity adjustment device (if any) or replacing the sensor's sensitive components. At the same time, minimize the impact of environmental factors on the sensor, such as controlling the temperature and humidity of the working environment.
Confirm that the characteristics of the target object meet the sensor's detection requirements. If the characteristics of the target object changes, you can consider replacing the appropriate proximity sensor, or pre-processing of the target object, such as removing surface coatings, changing the shape, etc., so that it can be correctly detected by the sensor.
2, proximity signal false triggering or continuous triggering
Cause:
Surrounding environmental interference: nearby metal objects, electromagnetic fields or vibration and other factors may lead to proximity sensor false triggering.
Loose sensor installation: If the sensor is not firmly installed, shaking during the operation of the equipment may lead to signal false triggering or continuous triggering.
Sensor internal failure: such as internal circuit short-circuit, component damage, etc., may lead to malfunctioning of signal control, false triggering or continuous triggering phenomenon.
Solution:
Check the surrounding environment and exclude factors that may cause interference. For metal object interference, you can adjust the installation position of the sensor or increase the shielding measures; for electromagnetic field interference, use anti-electromagnetic interference sensors or electromagnetic shielding of the equipment; for vibration interference, reinforce the installation of the sensor to reduce shaking.
Check the installation of the sensor to ensure that it is firmly installed. If the installation is loose, reinstall the sensor and use suitable fixings (e.g. bolts, clips) to secure it.
If an internal sensor failure is suspected, test using the replacement method. If it is determined that the sensor has an internal fault, replace the sensor with a new one and test the new sensor to ensure that it works properly.
※ 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.
