What are the common sensor failures and their solutions for brushless motor motor automatic rotor bearing press-in machine?
During the operation of brushless motor motor automatic rotor bearing press-in machine, the sensor plays an important role in monitoring the position, pressure, temperature and other key parameters. The following are the common sensor failures and the corresponding solutions:
1、Position sensor failure
l Failure phenomenon
The press-in position is inaccurate, and the bearing press-in depth does not meet the requirements, which may be too deep or too shallow, affecting the assembly quality of the motor.
The equipment cannot correctly recognize the initial position of the rotor or bearing, resulting in the press-in action not being able to start normally or misoperation.
l Cause of failure
The installation position of the position sensor is shifted so that its detected position deviates from the actual position.
The detection surface of the sensor is covered by dust, oil and other impurities, affecting the detection accuracy.
The internal components of the sensor are damaged, such as the failure of the light-emitting diode or photosensitive transistor of the photoelectric switch, or the damage of the induction coil of the proximity switch.
Problems in the signal transmission line of the sensor, such as broken lines and loose connectors, resulting in unstable or interrupted signal transmission.
l Solution
Re-calibrate the installation position of the position sensor to ensure that it accurately detects the position of the target object. Professional measuring tools can be used to make fine preparation adjustments.
Clean the detection surface of the sensor, use a clean cloth or special cleaner to remove dust and oil.
Conduct a performance test of the sensor to determine whether there is damage to the internal components. If it is determined that the sensor is damaged, promptly replace the sensor with the same model.
Check the signal transmission line, repair the broken line, reconnect the loose connector, and replace the line if necessary.
2、Pressure sensor failure
l Failure phenomenon
The displayed value of the press-in force is inaccurate, with a large deviation from the actual press-in force, which may lead to damage to the bearing or rotor due to too large a press-in force, or too small a press-in force, resulting in the installation of the bearing is not solid.
There is no signal output from the pressure sensor, and the equipment can not obtain the information of press-in force, so it can not carry out pressure control and monitoring.
l Cause of Failure
The range of the pressure sensor is not properly selected, and the actual indentation force exceeds the measuring range of the sensor, resulting in inaccurate measurement.
The diaphragm of the sensor is damaged, such as being hit by foreign objects, corrosion, etc., which affects the normal transmission and measurement of pressure.
The amplification circuit or signal processing circuit of the sensor is faulty, resulting in abnormal output signals.
The sensor is installed incorrectly, such as poor sealing, improper size of the mounting hole, etc., affecting the measurement accuracy.
l Solution
According to the range of the actual indentation force, select the pressure sensor with the appropriate range for replacement.
Check the condition of the diaphragm of the sensor, if it is damaged, replace the sensor in time.
Use professional testing equipment to test the amplification circuit and signal processing circuit to find out the faulty components and replace them.
Reinstall the pressure sensor in accordance with the correct installation method to ensure that the seal is good, the installation hole size meets the requirements.
3、Temperature sensor failure
l Failure phenomenon
The displayed temperature value is abnormal, too high or too low, and the actual working temperature does not match, which may lead to equipment due to misjudgment of the temperature and take the wrong protection measures.
The temperature sensor does not work properly, does not display the temperature or displays unstable values, affecting the monitoring of the operating status of the equipment.
l Cause of Failure
The installation position of the temperature sensor is not reasonable, and it does not accurately measure the temperature of the critical parts, or it is interfered by external environmental factors.
The temperature sensing element of the sensor is damaged, such as the thermal electrode of the thermocouple is broken, the resistance wire of the RTD is open.
The compensation wire of the temperature sensor is connected incorrectly or damaged, which affects the accuracy of temperature measurement.
The signal processing circuit of the sensor is faulty, resulting in abnormal output signals.
l Solution
Re-select a suitable installation location to ensure that the temperature sensor can accurately measure the temperature of the critical parts and avoid external interference.
Test the temperature sensing element, such as using a multimeter to measure the thermal potential of the thermocouple or the resistance value of the RTD to determine whether it is damaged. If damaged, replace the temperature sensing element or the entire temperature sensor.
Check the connection of the compensation wires, repair or replace damaged wires to ensure proper connection.
Detect and repair the signal processing circuit and replace the faulty components.
4、Displacement sensor failure
l Fault phenomenon
The displayed displacement value is inaccurate, with a large deviation from the actual displacement, affecting the precise control and monitoring of the press-in process.
No signal output from the displacement sensor, the equipment can not obtain the displacement information, and it is impossible to judge the progress and position of the press-in.
l Failure causes
The installation of the displacement sensor is not firm, and it is loosened or shaken during the operation of the equipment, resulting in inaccurate measurement.
The measuring rod or slider of the sensor is affected by wear and tear, jamming, etc., and cannot move normally, affecting the displacement measurement.
The signal processing circuit of the sensor is faulty, resulting in abnormal output signals.
The cable of the sensor is damaged, affecting the signal transmission.
l Solution
Reinstall the displacement sensor, make sure it is firmly installed, and use bolts or clamps to fix it.
Check the condition of the measuring rod and slider, replace the worn parts, clean the jammed parts, and ensure that they can move freely.
Test and repair signal processing circuits and replace faulty components.
Check the condition of the cable line and repair or replace the damaged cable line.
※ If the above ways and means still can't solve the equipment failure, please contact the technical specialists of Xinhui Electromechanical Equipment Co.
