How to fault analyze and troubleshoot a series excitation motor motor stator drip paint machine?
I. Failure analysis steps
1、Collect information
Observe the failure phenomenon: carefully observe the paint dripping machine in the failure of various manifestations, such as whether the equipment emits abnormal sound (such as harsh friction, humming, etc.), whether there is a strange smell (such as burnt smell, paint smell is too heavy, etc.), whether there is smoke, whether the drip paint is normal (the amount of paint, the location of the drip paint, the drip paint speed, etc.), the stator conveying whether the smoothness of the drying effect in line with the expectations, and so on. These phenomena can provide clues for the initial judgment of the type of failure.
Ask the operator: ask the person who was operating the equipment about the specific circumstances of the failure, including the operating state of the equipment before the failure, whether any special operation (such as parameter adjustment, replacement of components, cleaning and maintenance, etc.), whether the failure is sudden or gradual and other information. Feedback from the operator can often provide some useful background information to help further narrow down the scope of the fault.
2. Analyze possible causes
l Mechanical:
If it is found that the stator is not being conveyed smoothly, it may be a problem with the conveyor chain or conveyor belt, such as broken or slack chain, runaway or worn conveyor belt. It is also possible that the fixture failure, such as loose fixture, deformation or clamping mechanism failure, resulting in the stator fixed insecure.
Uneven dripping of paint may be due to clogged or damaged nozzle, or improper working of the paint pump, such as damaged impeller or leaking seals of the paint pump, which makes the supply of paint unstable.
Poor drying effect may be due to the failure of heating element (such as damaged heating tube, burnt heating wire), ventilation system failure (such as fan does not rotate, ventilation pipe blocked), resulting in uneven temperature distribution or heat can not be effectively circulated in the drying box.
l Electrical:
The equipment can not start or suddenly stop running, it may be a power problem, such as lack of phase, too low or too high voltage, fuse blown and so on. It may also be motor failure, such as motor winding broken, short circuit, or motor start capacitor damage.
Abnormal control functions (e.g., inability to adjust parameters, the program can not run normally, etc.) may be due to controller failures, including hardware failures (e.g., damaged circuit boards, aging components) and software failures (e.g., program errors, communication interruptions).
Sensor failure is also one of the common causes, for example, failure of temperature sensor, liquid level sensor, flow sensor, etc., which will cause the equipment to be unable to accurately obtain the information of the operation status, thus resulting in improper temperature control, insufficient or excessive supply of lacquer and other problems.
l Step-by-step troubleshooting
Mechanical parts troubleshooting: Start from simple mechanical parts, such as checking whether the chain and conveyor belt of the conveying system are firmly connected and whether the tension is appropriate; checking whether the nozzle is clogged or not, and you can use special cleaning tools to clean up the nozzle; checking the clamping force of the clamps and positioning accuracy, and so on. For complex mechanical components, such as paint pumps and heating systems, need to be further disassembled to check whether the internal impeller, piston, heating element is damaged.
Electrical system troubleshooting: first use a multimeter to check whether the power supply is normal, measure whether the voltage and current are within the rated range, and check whether the fuse is blown. Then check the winding resistance of the motor to determine whether the motor is normal. For controllers and sensors, troubleshooting is carried out by checking whether the connecting lines are loose, broken or short-circuited, and checking whether the signals are transmitted normally by using professional testing equipment (e.g., oscilloscope, signal generator, etc.). When checking software problems, you can check the running log of the control program to look for error messages, or try to reprogram and update the software to solve the problem.
Second, the common faults and troubleshooting methods
1, uneven paint drops
Reason: nozzle clogging.
Remedy: Turn off the paint pump, soak the nozzle in a special solvent for a period of time to dissolve the clogging, and then use compressed air to blow inside the nozzle, clean up and reinstall and test the effect of dripping paint.
Reason: Paint pump failure leads to unstable paint supply.
Elimination methods: check whether the inlet and outlet pipes of the paint pump are clogged, clean up the pipes; check whether the seals of the paint pump are damaged, replace the seals if they are damaged; if the impeller or piston of the paint pump is damaged, it is necessary to replace the corresponding parts.
2、Drying temperature abnormality
Reason: heating element is damaged.
Elimination method: use a multimeter to check the resistance of the heating element, if the resistance is infinite, it means that the heating element is disconnected and needs to be replaced; at the same time, check whether the connection line of the heating element is firm to make sure that the current can pass through normally.
Reason: temperature sensor failure.
Remedy: calibrate the temperature sensor, use a standard thermometer to compare measurements, adjust the calibration parameters of the sensor; check whether the sensor's connection line is loose, short-circuit or disconnection, if any problem repair in time; if the sensor itself is damaged, you need to replace the new temperature sensor.
3、Stator conveying fault
Reason: conveyor chain or conveyor belt problem.
Elimination methods: for chain breakage, replace the damaged chain links or the whole chain; chain slack can be adjusted through the tensioning device to restore tension; for conveyor belt deflection, check and adjust the position of conveyor belt rollers so that it is parallel to the serious wear and tear of the conveyor belt needs to be replaced.
Cause: conveyor motor failure.
Elimination method: check whether the power supply of the motor is normal, including wire connection and fuse; if the motor has abnormal sound, it may be bearing damage, need to disassemble the motor to check and replace the bearings; unstable speed may be the problem of the speed regulator device, can be repaired or reset the regulator parameters; the motor can not be started and exclude the problem of the power supply, it may be the damage of the motor windings, the need to repair or replace the motor.
4、Equipment can not start
Reason: power supply problems.
Elimination method: check whether the power line is connected correctly, there is no broken circuit, short circuit, check whether the fuse is blown, if there is any problem timely repair or replacement.
Cause: electrical control components failure (such as contactors, relays, etc.).
Remedy: check whether the coil of the control element is damaged, if so, replace the coil; check whether the contact is poor contact or ablation, use sandpaper to polish the contact or replace the control element.
Control program failure
Cause: program error or software conflict.
Elimination methods: reprogramming or updating the control program to repair known errors and vulnerabilities; check the compatibility of the control program with other software or equipment, if incompatible, upgrade or replace the relevant software.
※ 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.
