Serial motor motor semi-automatic spring brush machine what are the common sensor failure and its solution?
1、Position sensor failure
Fault phenomenon:
Inaccurate position detection: lead to spring installation position deviation, brush machine workflow error, etc.. For example, in the spring installation link, due to the failure of the position sensor, the spring installation position may deviate from the predetermined position, affecting the normal operation of the brush machine.
No Position Signal Output: The device is unable to obtain the position information of the components, resulting in the interruption of the workflow. For example, if there is no signal output from the position sensor when the motor is started, the brusher is unable to determine the initial position of the motor rotor and thus cannot start normally.
Solution:
Check the sensor installation: Make sure the position sensor is firmly installed and the installation gap meets the requirements, generally the installation gap is between 0.5-1.5mm. If the gap is too large or too small, it is necessary to readjust the installation position.
Clean the sensor surface: regularly clean the sensor surface of dust, oil and other impurities, you can use a clean non-woven cloth dipped in a small amount of detergent gently wipe.
Detect the sensor circuit: use a multimeter to check the sensor's power supply voltage, signal output voltage and other parameters are normal. If the power supply voltage is abnormal, need to check the power supply line; if the signal output voltage is not normal, may be the sensor internal damage, need to replace the sensor.
2, current sensor failure
Fault phenomenon:
Current measurement value deviation is large: so that the actual working current of the motor does not match the display current, which may lead to motor overload or underload operation. For example, in the brush work, the current sensor measured current value is much larger than the actual current value, which will make the control system misjudged motor overload, thus limiting the motor power output.
Unstable current signal: cause motor speed fluctuation and unstable work. For example, during the operation of the motor, the signal of the current sensor is sporadic, which will cause the motor speed to fluctuate, affecting the effect of brushing.
Solution:
Calibrate the sensor: According to the calibration procedure of the sensor, use the standard current source to calibrate the sensor to ensure that the measurement accuracy is within the permissible range, and the general measurement accuracy is required to be within ±5%.
Check the sensor connection line: check whether the line is loose, broken, etc., if there is any problem repair or replace the line in time. For loose connectors, re-insertion and tightening; for broken lines, need to replace the new wire.
Solve the problem of electromagnetic interference: If there is strong electromagnetic field interference around, shielding measures can be taken, such as using shielded wires to connect the sensor, or installing a shielded cover on the outside of the sensor. At the same time, to ensure that the sensor away from large motors, transformers and other sources of electromagnetic interference.
3, speed sensor failure
Fault phenomenon:
Inaccurate speed measurement: make the motor speed display error, can not accurately control the brushing speed. For example, in the process of brushing, the speed sensor measured speed is slower than the actual speed, which will lead to poor spring installation or poor brushing.
Loss of Speed Signal: Loss of speed feedback from the motor may cause the motor to go out of control or not be able to regulate the speed properly. For example, if the speed sensor suddenly has no signal output during motor acceleration, the motor may continue to accelerate until it fails.
Solution:
Check the sensor probe: see if the probe is damaged, worn or has debris attached. If the probe is damaged, replace it with a new one; if there is debris, wipe it off with a clean cloth.
Adjust the sensor gap: ensure that the gap between the sensor and the measured part is appropriate, generally between 1-3mm gap. Too large or too small a gap will affect the measurement accuracy, need to re-adjust.
Check the magnetic element of the sensor: For speed sensors using the magnetic principle, check whether the magnetism of the magnetic element is weakened. If the magnetism is weakened, the magnetic element needs to be magnetized or replaced.
4、Temperature sensor failure
Fault phenomenon:
Abnormal temperature measurement value: the displayed temperature does not match the actual temperature, which may lead to motor overheating protection misoperation or no protection. For example, when the motor is running normally, the temperature displayed by the temperature sensor is too high, which makes the control system misjudge that the motor is overheating and stop the motor running; or the motor is actually overheating, but the temperature displayed by the temperature sensor is normal, so the overheating protection cannot be triggered in time.
No temperature signal output: the control system cannot obtain the temperature information of the motor, and there is a risk that the motor will be damaged due to overheating.
Solution:
Check the thermal element of the sensor: check whether the thermal element is aging or damaged. If the thermal element is aged or damaged, the temperature sensor needs to be replaced with a new one.
Check the installation position of the sensor: Make sure the sensor is installed in a position where it can accurately measure the temperature of the motor, usually near the stator windings or bearings of the motor. If the installation position is improper, need to be re-installed.
Check the sensor's connecting wire: See if the connecting wire is loose, disconnected, etc. For loose connecting wires, re-insert and tighten; for broken connecting wires, replace with new wires.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
