How to fault analyze and troubleshoot a semi-automatic spring brush machine for a series excitation motor motor?
First, fault analysis steps
l Observe the fault phenomenon:
Observation of operation status: When the equipment fails, first observe the overall operation status of the equipment. For example, whether the motor is rotating normally, whether the rotating speed is stable, whether the brush operation is normal, whether there is any abnormal vibration or noise. If the motor has abnormal noise, it may be that the motor bearing is damaged or the contact between the brush and the commutator is poor.
Working effect check: check the working results of the spring brush machine, that is, the processing quality of the spring. Such as whether there are scratches on the surface of the spring, whether the size of the spring meets the requirements, etc.. If there are obvious scratches on the surface of the spring, the brush head may be damaged or the pressure between the brush head and the spring is not set properly.
l Collect relevant information:
Equipment operation records: Check the equipment's operation time records, recent maintenance records, parameter adjustment records. Understand whether the equipment has just carried out maintenance, replacement of parts or parameter modification and other operations, this information may provide clues to the judgment of the cause of the failure. For example, if the brushes have just been replaced, whether the brushes are installed correctly or whether the quality of the brushes is qualified may be one of the factors leading to the failure.
Description of the failure process: Ask the operator about the specifics of the failure, including details such as the equipment's operating status prior to the failure, whether there was any abnormal operation, and whether the failure occurred suddenly or gradually. For example, if the operator mentions that the equipment malfunctions after increasing the brushing speed, then it is necessary to focus on checking the components and parameters related to the speed.
l Check the electrical system:
Power supply check: use a multimeter to check whether the power supply voltage is normal, whether there is a lack of phase, excessive voltage fluctuations and so on. The series excitation motor has certain requirements on the stability of the power supply, and the abnormal power supply may cause the motor to fail to work normally or work unstably.
Electrical components check: check whether the fuse is blown, whether the contactor and relay work normally, whether the sensor has signal output, etc.. For example, the fuse may be blown because there is a short-circuit situation in the circuit, which requires further searching for the short-circuit point.
Wiring inspection: Check whether the electrical wiring is broken, loose, short-circuited or disconnected. Especially the connection line between the motor, controller, sensor, etc., the line problem may lead to signal transmission interruption or error, which may cause failure.
l Check the mechanical system:
Inspection of transmission parts: Check whether transmission parts such as belts, chains, gears, etc. are loose, worn or broken. For example, a loose belt can cause slippage and make the brushing speed unstable; worn gears may cause vibration and noise.
Rotating parts inspection: Check to see if rotating parts such as the motor shaft and brusher shaft are flexible and if the bearings are damaged. If the bearings are damaged, it will lead to increased resistance of the rotating parts, generating vibration and noise, and may even prevent the motor from operating normally.
Spring device inspection: Check whether the spring is deformed, broken or installed in an improper position. Spring problems may affect the normal operation of the brusher. For example, a broken spring may cause insufficient or uneven pressure on the brusher.
l Check the control system:
Control program check: Check whether there is any error or abnormality in the control program. It can be judged by checking the running log of the program or reloading the program. For example, logic errors in the program may cause confusion in the brushing sequence or improper motor speed control.
Controller hardware check: check the controller's circuit board for signs of burnt or damaged boards, loose interfaces etc. If there is a problem with the controller hardware, it may not be able to send or receive control signals correctly.
Common troubleshooting methods
l Motor does not rotate troubleshooting:
Power supply problem: If the power supply voltage is not normal, check the power supply line and power supply equipment, repair the power supply failure or replace the voltage regulator.
Damage to electrical components: If the fuse is blown, replace the fuse with the same specification; if the contactor or relay is damaged, replace the new components and check whether the control circuit is normal.
Mechanical problems: check whether the motor shaft is jammed, if there are foreign objects stuck, clear away the foreign objects; if the motor bearings are damaged, replace the bearings.
Control signal problem: check whether the controller has output signal to the motor, if there is no signal, check the control program and controller hardware, repair or reprogram.
l Abnormal motor speed troubleshooting:
Power supply voltage fluctuation: Use voltage regulator to stabilize the power supply voltage and make sure the motor works under rated voltage.
Load change: check whether the brush part is overloaded or stuck, such as whether the spring is installed correctly, whether the brush head is blocked, etc. Adjust the load to make it within the rated load of the motor.
Failure of electrical components: check whether the governor, sensors and other electrical components work properly, if damaged, timely replacement.
Mechanical transmission problems: check the transmission belt or chain tension, adjusted to the appropriate state; check the gear mesh, such as wear and tear or excessive clearance, repair or replacement.
l Troubleshooting for poor brush quality:
Brush head problem: check whether the brush head is seriously worn, if worn, replace the brush head; at the same time, check whether the installation of the brush head is firm, the brush head and the spring contact angle is correct.
Brush pressure problem: check whether the pressure setting of the spring device is appropriate, adjust the pressure by adjusting the compression of the spring or replacing the spring with the appropriate elasticity coefficient.
Mismatch between motor speed and brushing frequency: Adjust the motor speed and brushing frequency so that they can reach an excellent match to ensure good brushing effect.
l Equipment vibration and noise troubleshooting:
Loose mechanical parts: Check whether the installation bolts and nuts of the equipment are loose, especially the fixed bolts of the motor, brush, transmission parts, etc. If they are loose, tighten them in time.
Unbalance of rotating parts: carry out dynamic balance check and correction on rotating parts such as motor shaft, brush machine shaft, etc., or replace the unbalanced parts.
Wear and tear of mechanical parts: check the wear and tear of bearings, gears, belts and other parts, and replace the parts with serious wear and tear, if any.
Resonance phenomenon: change the working frequency of the equipment or install shock absorbing devices to avoid resonance during the operation of the equipment.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical and Electrical Equipment Co.
