What are the common control unit failures and solutions for the series excitation motor motor semi-automatic spring brush machine?
What are the common control unit failures and solutions for series excitation motor motor semi-automatic spring brush machine?
1, controller hardware failure
Failure phenomenon:
Damage to the control board card: resulting in the device can not start, suddenly crash during operation or garbled code and other phenomena. For example, a chip on the control board is damaged due to overheating, overvoltage, etc., so that the whole control system can not work properly.
Loose or damaged interface: cause interruption or instability of control signal transmission, so that the motor can not start normally, unstable speed or brush maneuvering is not coordinated. If the connection interface between the motor and the controller is loose, it will cause the motor to receive control signals sometimes and sometimes not.
Power module failure: so that the control unit can not get a stable power supply, there may be too low or too high a voltage, which leads to abnormal operation of the control unit, or even burned. For example, the aging of the capacitors in the power module will cause the output voltage to fluctuate.
Solution:
Check the board and components: carry out an external inspection of the control board to see if there are obvious signs of damage such as burning and deformation, and if so, replace the damaged board or components.
Tighten and clean the interfaces: Check and tighten all the connection interfaces to ensure that they are firmly connected. At the same time, use special cleaner to clean the interface to remove the oxidized layer and dirt to ensure good signal transmission.
Detect the power module: use a multimeter to measure the output voltage of the power module, if the voltage is abnormal, you need to further check the internal circuit components of the power module, such as capacitors, resistors, diodes, etc., and replace the damaged components.
2、Control program failure
Fault phenomenon:
Program loopholes or errors: lead to abnormal behavior of the device during operation, such as wrong brush sequence, inaccurate motor speed control, etc.. For example, a logic judgment error in the program may cause the motor to accelerate when it should not.
Program version incompatibility: When the hardware or software of the device is upgraded, the original control program may be incompatible with the new system, resulting in problems such as the device failing to operate normally and some of its functions failing.
Solution:
Update and repair the program: Contact the equipment manufacturer to obtain a new version of the control program, or have the professional technicians repair and optimize the loopholes and errors in the program.
Compatibility testing and adjustment: After the hardware or software upgrade, conduct all the compatibility tests on the control program, find and solve the incompatibility problems in time, and modify and adjust the program if necessary.
3、Sensor feedback failure
Fault phenomenon:
Sensor signal abnormality: such as position sensors, speed sensors and other feedback signals are inaccurate or unstable, which will lead to the control unit can not accurately grasp the motor and brush the working state of the motor, which will lead to motor speed out of control, spring installation position deviation and other problems.
Sensor failure leads to false alarms: make the equipment stop running or enter the protection state for no reason, affecting productivity. For example, the temperature sensor false alarm will make the control system think that the motor is overheated and stop the motor operation.
Solution:
Check the sensor and wiring: Refer to the checking method of sensor failure mentioned earlier, check whether the sensor itself is damaged, and whether the connecting wiring is loose or disconnected, etc. Repair or replace the damaged sensor and wiring.
Calibrate the sensor: according to the calibration procedure of the sensor, use standard calibration equipment to calibrate the sensor to ensure that the sensor's measurement precision and accuracy.
Optimize the sensor signal processing procedure: optimize the sensor signal processing procedure in the control unit to improve the signal's anti-interference ability and processing accuracy, and avoid false alarms and control abnormalities caused by signal interference.
4、Communication failure
Fault phenomenon:
Internal communication failure: the communication between the control unit and the motor, brush and other parts is interrupted or there is a data transmission error, resulting in the device can not coordinate the work, such as the motor and the brush can not be synchronized between the operation.
External communication failure: when the device needs to communicate with external devices, such as communication with the upper computer control system or other automation equipment, communication connection failure, data transmission packet loss and other problems may occur, affecting the overall automation control and production management of the device.
Solution:
Check the communication lines and interfaces: check whether the communication lines are well connected, whether the interfaces are loose, damaged, etc., and repair or replace them in time if there are any problems.
Check the communication protocol and parameter settings: make sure that the communication protocol between the control unit and other devices is consistent, and check whether the communication parameter settings are correct, such as baud rate, data bits, stop bits, etc., if there is any error, modify it in time.
Adoption of anti-interference measures: If the communication line is subject to electromagnetic interference, shielding lines, increase filters and other anti-interference measures can be used to improve the stability and reliability of communication.
※ 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.
