How to analyze and troubleshoot the tandem motor motor stator automatic slotting paper machine?
The following are the detailed steps of fault analysis and troubleshooting of the tandem motor motor stator automatic slotting machine:
First, the basic steps of fault analysis
1, collect information
Observe the failure phenomenon: carefully observe the specific performance of the equipment at the time of failure, such as whether the equipment completely stops running, or part of the function is out of order; slot paper insertion whether there is a deviation, jamming, or can not be inserted at all; whether the motor has an abnormal sound, smoke and so on. Record the details of these phenomena, including the frequency of malfunctions, whether they occur after a particular operation, etc.
Ask the operator: Communicate with the staff who operated the equipment at the time to find out the operating status of the equipment before the malfunction occurred, for example, whether parameter adjustments were made, the slot paper or stator was replaced, and whether there were any abnormal vibrations or sounds from the equipment. Feedback from the operator may provide important clues about the cause of the fault.
Review equipment operating records and alarms: Check the equipment's own operating record system (if available) for changes in equipment parameters, operating records, and any alarms before and after the failure. These records may help to determine whether the failure occurred suddenly or gradually evolved.
2. Preliminary judgment of the type of fault and the range of possible causes
Based on the information collected, the initial classification of the type of failure, such as mechanical failure, electrical failure, software failure or a combination thereof. For example, if the slot paper transfer is not smooth and accompanied by mechanical noise, it may be a mechanical transmission component problem; if the equipment does not have any action and the control panel has an alarm light on, it may be an electrical system failure.
For different types of failures, list the range of possible causes. For mechanical failure, it may involve wear and tear, loosening, jamming of components, etc.; for electrical failure, it may include power supply problems, motor failure, sensor failure or damage to components in the electrical control cabinet, etc.; for software failure, it may be a program error, improper parameter settings or communication problems.
3, step-by-step investigation of possible causes
From the simple to the complexity of the investigation: first check the parts that are easy to observe and deal with, such as the appearance of the equipment, connecting lines, external sensors and so on. For example, check whether the equipment is obviously blocked by foreign objects, whether the wires are loose or broken. If the simple inspection does not reveal any problems, then go deeper into the interior of the equipment to check the wear and tear of mechanical parts, the performance of electrical components, etc.
Use the isolation method or replacement method for troubleshooting: In the troubleshooting process, the isolation method can be used to determine whether the fault is caused by a particular component or system. For example, for suspected faulty electrical components, you can temporarily disconnect them and observe the operation of other parts of the equipment. Replacement method is also an effective means of elimination, for easy to replace parts, such as sensors, fuses, etc., you can replace the suspected faulty parts with new parts to see if the fault disappears.
Second, the common faults and troubleshooting methods
1, mechanical failure
l Slot paper transfer is not smooth or jammed
Cause analysis:
The surface of the transfer roller or guide wheel is worn, resulting in uneven friction.
Transmission mechanism is blocked by foreign objects, such as dust, paper and so on.
Improper adjustment of slotting paper force, too loose or too tight.
The transmission chain or belt is slack, worn or jumping teeth.
Elimination method:
Check the wear and tear of the transmission rollers and guide wheels, and replace the parts that are badly worn.
Clean foreign matter in the transfer mechanism, either by using compressed air or by disassembling some parts.
Re-adjust the tension of the grooved paper, set the proper tension value according to the equipment manual.
Check the tension and wear of the drive chain or belt, and tension or replace if necessary.
l Deviation of slot paper insertion position or improper depth
Cause analysis:
The accuracy of the positioning device of the slot paper insertion mechanism (e.g., positioning pin, positioning block) is reduced, probably due to wear or positional deviation.
Failure of the insertion power system (motor, cylinder, etc.), such as unstable motor speed, insufficient cylinder pressure.
Insertion tools (pins, push plates) are damaged or deformed.
Remedy:
Use a gauge to calibrate the positioning device and replace the badly worn positioning parts.
Check the working status of the power source, such as whether the motor winding is normal, whether the cylinder air pressure is appropriate, repair or replace the faulty power source.
Check the condition of insertion tools, replace damaged or deformed tools, and ensure that their strength and shape meet the requirements.
l The stator is not fixed firmly or the surface is damaged
Cause analysis:
The clamping device of the stator fixing mechanism (fixture, jaws) is loose or worn, resulting in insufficient clamping force.
Excessive or uneven clamping force causes damage to the surface of the stator.
Remedy:
Check whether the connecting screws of the clamping device are loose, tighten the screws. Check the wear of the clamping surface, replace the badly worn parts or repair the clamping surface.
Adjust the pressure of the clamping device, use pressure sensors and other tools to recalibrate the clamping force to ensure that it can both fix the stator and not damage the stator surface.
2、Electrical faults
l Motor does not rotate or rotates abnormally
Cause analysis:
Power supply problems, such as low voltage, lack of phase, loose or damaged power cord.
Motor winding short circuit, broken circuit or brush wear (for brushed motor).
Motor driver failure, such as parameter setting error, internal circuit damage.
Troubleshooting method:
Use a voltmeter to check whether the power supply voltage is normal, check whether the power cord is intact and whether it is firmly connected. For cases where the power supply is out of phase, check the power supply line and related electrical equipment (e.g., contactors, circuit breakers).
Measure the resistance value of the motor winding with a multimeter to determine whether there is a short circuit or broken circuit. For brushed motors, check the wear and tear of the brushes. If the motor winding is damaged, repair or replace the motor; if the brushes are badly worn, replace the brushes.
Check whether the parameter settings of the motor driver are correct and readjust the parameters according to the device manual. If it is suspected that the internal circuit of the driver is damaged, professional personnel are required to repair or replace the driver.
l Sensor failure leads to abnormal action
Cause analysis:
The sensor surface is contaminated, affecting the signal transmission and reception.
Sensor damage, such as photoelectric sensor light-emitting diode or photosensitive element failure, proximity sensor induction coil damage.
The sensor installation position is offset, resulting in inaccurate detection.
Troubleshooting method:
Clean the surface of the sensor by wiping the sensor with a clean soft cloth and an appropriate cleaning agent (e.g. alcohol).
Check whether the output signal of the sensor is normal with a tool such as a multimeter, and for damaged sensors, replace the sensor with the same model.
Re-adjust the installation position of the sensor to ensure that it can accurately detect the target object.
l Failure of the electrical control cabinet (such as control system failure, component damage, etc.)
Cause analysis:
Control program error, may be program writing error, program loss or electromagnetic interference.
Aging or quality problems of the electrical components, such as burnt relays, contactors and other components, contact sticking and so on.
The wiring in the control cabinet is chaotic or the insulation is damaged, resulting in short circuit or leakage.
Troubleshooting method:
Use programming software to check the control program to find and correct errors in the program. Take electromagnetic shielding measures to prevent the program from being disturbed.
Check the working condition of the electrical components, and for the components that are burnt or have sticky contacts, replace them with new ones of the same model and adjust their action parameters.
Organize the wiring in the control cabinet to ensure that there is sufficient clearance between wires to avoid crossover. For insulation damage to the wire, use insulation tape or replace the wire with a new one to repair.
3、Software failure
l Program running errors lead to uncoordinated equipment action
Cause analysis:
Program logic errors, such as slot paper insertion sequence confusion, inaccurate action time, may be a programming error or software update compatibility problems.
Software parameter setting errors, such as slot paper insertion depth, position or transfer speed and other parameters are not set properly.
Elimination methods:
Check the program logic through software debugging tools, set breakpoints, observe the program execution path and variable values, find out and correct the wrong code logic. For compatibility problems after software update, carry out compatibility test and adjust the software interface or data reading method.
Check the parameter settings in the software related to the operation of the equipment, refer to the operation manual of the equipment, and correct the wrong parameters to the correct values. Specify the unit of the parameters in the software interface, set parameter limitations and prompt information to prevent parameter setting errors.
l Software operation stability problems (e.g., software crash, slower operation speed)
Cause analysis:
Memory leakage or excessive resource occupation, leading to software exhaustion of memory resources or CPU and other resources occupancy rate is too high.
Software conflict or virus infection, affecting the normal operation of the software.
Troubleshooting method:
Check the software code to find the part that may lead to memory leakage, and optimize it with memory detection tools. Reasonably allocate software resources and lower the priority of non-critical tasks.
Troubleshoot software conflicts, close other software one by one, and observe the operation of the control software. Install antivirus software on the device, conduct regular virus checking, clear the virus and repair the software.
※ If you still can't solve the equipment failure through the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
