Serial excitation motor motor automatic terminal press machine what are the common mechanical failures and solutions?
1, transmission system failure
l Belt slippage
Reason:
The belt tension is insufficient, which may be due to the slackness of the belt after a long time of use, or the belt tension is not adjusted properly during the initial installation.
The belt wears out, the surface becomes smooth and the friction is reduced, resulting in slippage.
There is oil or other impurities between the belt and pulleys, affecting the friction between them.
Solution:
Adjust the belt tension. For flat belts, the tension can be increased by moving the motor position. For V-belt, you can use a tensiometer to measure and adjust it, the general tension value should be determined according to the belt model and pulley diameter and other factors, so that the belt is under medium load, the sagging does not exceed 1.5% - 2% of the center distance between the two pulleys.
Check the wear of the belt, if the wear is serious, the belt should be replaced with a new one, and make sure that the model of the new belt is consistent with the original belt.
Clean the oil and impurities on the surface of the belt and pulleys, wipe them with a clean cloth dipped in a small amount of detergent, and then dry them with a dry cloth.
l Loose chain or jumping teeth
Reason:
The chain elongates after a long time of use, resulting in loosening.
The chain wheel is worn and the tooth shape is deformed, which makes the chain and chain wheel mesh poorly and easy to jump teeth.
The chain tensioning device fails to maintain the proper tension of the chain.
Solution:
For elongated chains, if the elongation is within a certain range, the chain can be tightened by adjusting the tensioning device. If the elongation is excessive, the chain should be replaced with a new one.
Check the wear of the sprocket, if the teeth are badly worn, it is necessary to replace the sprocket and make sure that the specifications of the sprocket and the chain are matched.
Repair or replace the failed tensioning device to make sure it can work properly and keep the proper tension of the chain. If spring-type tensioning device is used, check whether the spring is weakened or damaged.
l Worn or damaged gears
Reason:
Long-term overload operation, gears are subjected to excessive load, which accelerates the wear.
Poor lubrication, resulting in increased friction between gears, so that the tooth surface wear.
The installation precision of gears is not enough, such as inaccurate center distance, axis is not parallel, etc., resulting in poor gear meshing and increased local wear.
Solution:
Check the load of the equipment to avoid overloaded operation. If the load is too high, you need to re-evaluate and adjust the operating parameters of the equipment, or replace the motor with a more powerful one.
Ensure good lubrication of gears, check and add lubricant regularly. For high-speed and heavy-duty gear transmission, lubricants containing extreme pressure additives can be used, and attention should be paid to the cleanliness of the lubricant to prevent impurities from entering.
Check the installation accuracy of gears, use professional tools to measure parameters such as center distance and axis parallelism. If the installation accuracy does not meet the requirements, re-adjust the installation position, the general gear center distance tolerance control in ± 0.05 - 0.1mm, axis parallelism error does not exceed 0.05mm / m. For wear or damage to the gear, to be replaced in a timely manner.
2, crimping mold failure
l mold wear
Reason:
Frequent crimping operation, so that the working surface of the mold and the terminal constantly friction, resulting in wear.
Higher hardness of the terminal material enhances the wear effect on the mold.
Poor material or improper heat treatment of the mold affects the wear resistance of the mold.
Solution:
Regularly check the wear of the mold, when the mold is worn to a certain extent, such as crimping dimensional deviation exceeding the specified range or crimping surface quality is significantly reduced, the mold should be replaced.
According to the hardness of the terminal material, select the appropriate mold material, such as for higher hardness copper alloy terminals, you can choose carbide mold.
Optimize the heat treatment process of the mold to improve the hardness and wear resistance of the mold. In the process of mold manufacturing, use suitable quenching, tempering and other processes, so that the surface hardness of the mold to reach a suitable value, generally HRC58 - 62.
l Mold damage (e.g. chipping, fracture)
Cause:
The crimping pressure is too high, exceeding the tolerance limit of the mold.
Improper installation of the mold, such as inaccurate installation position, poor fixation, generating bias load in the crimping process, resulting in damage to the mold.
There are defects inside the mold, such as cracks in the manufacturing process, etc., and the defects expand during use, resulting in damage to the mold.
Solution:
Check the crimping pressure setting to ensure that the pressure is within the rated pressure range of the mold, and reasonably adjust the crimping pressure according to the specification and material of the terminal.
Install the mold correctly, adjust the installation position of the mold accurately according to the operating instructions of the equipment, and use suitable bolts and other fixings to install the mold firmly on the equipment.
Before the use of the mold, carry out quality inspection, such as using flaw detection and other methods to check whether there are defects inside the mold. For defective molds, do not use, timely replacement.
3、Feeding mechanism failure
l Inaccurate feeding
Cause:
The feeding wheel is worn out and the friction with the terminal is reduced, resulting in a decrease in feeding accuracy.
The control parameters of the feeding motor are inaccurate, such as rotational speed, number of pulses and other improper settings, affecting the feeding length and position.
The feeding track has impurities or deformation, which hinders the normal feeding of terminals and makes the feeding position inaccurate.
Solution:
Check the wear of the feeding wheel, if the wear is serious, replace the feeding wheel, and make sure that the surface roughness and hardness of the feeding wheel meet the requirements to provide sufficient friction.
Check the control parameters of the feeding motor, and readjust the motor's speed, pulse number and other parameters according to the size of the terminal and the feeding requirements. Precise settings can be made through the control system of the equipment and the feeding test can be carried out until the feeding accuracy meets the requirements.
Clean the feeding track, remove impurities and check whether the track is deformed. For the deformed track, it can be repaired by straightening or replaced with a new feeding track.
l Feeding jam or blockage
Reason:
Terminal size deviation, such as too large or too small, and feeding mechanism does not match, resulting in jamming.
Failure of the transmission parts of the feeding mechanism, such as gears, chains and other problems, affecting the smoothness of the feeding.
The terminals are placed in the material tray in a chaotic manner, such as intertwined, stacked irregularly, etc., resulting in feeding blockage.
Solution:
Check whether the size of the terminals meets the requirements, do not use the terminals with large size deviation, or make appropriate adjustments to the feeding mechanism, such as replacing the appropriate feeding wheel or adjusting the width of the feeding track.
Check the transmission parts of the feeding mechanism, repair or replace the faulty gears, chains and other parts to ensure smooth transmission of the feeding mechanism.
Organize the terminals in the material tray so that the terminals are neatly arranged to avoid mutual entanglement and irregular stacking. If the terminals are easily entangled, use a separator to separate the terminals.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
