How to analyze and troubleshoot a fully automatic rotor bearing press-in machine for brushless motor motors?
Brushless motor motor automatic rotor bearing press-in machine failure will affect the production efficiency and product quality, the following mechanical, electrical, hydraulic (if any), software control and other aspects of the detailed introduction of fault analysis and troubleshooting methods:
First, mechanical failure analysis and troubleshooting
1, abnormal indentation force
Phenomenon: press-in force is too large or too small, resulting in bearings can not be pressed into the normal or pressed into place.
Analysis:
The indenter is worn or damaged, resulting in uneven pressure transfer.
Poor lubrication or wear of transmission parts (e.g., wire rod, guide rail) increases the resistance to movement.
Inaccurate positioning of the fixture causes the bearing to fit improperly with the rotor, increasing press-in resistance.
Ruling out method:
Check the indenter and replace it promptly if it is worn or damaged.
Clean and lubricate the transmission parts and replace worn parts if necessary.
Adjust the position of the fixture to ensure that it is accurately positioned to ensure that the bearings and rotor fit correctly.
2、Moving parts jamming or strange noise
Phenomenon: the slider of the press-in machine, screw and other moving parts in the process of running jamming, or accompanied by abnormal sound.
Analysis:
There are debris in the guide rail, hindering the normal sliding of the slider.
Wear and tear of the screw nut sub, resulting in poor movement.
The transmission belt is too loose or too tight, affecting power transmission.
Elimination method:
Clean up the debris in the guide rail and ensure that the surface of the guide rail is clean.
Check the wear of the screw nut vice, and replace it if it is seriously worn.
Adjust the tension of the drive belt, so that it is in a suitable state.
3、Inaccurate positioning
Phenomenon: bearing press-in position deviation, affecting the assembly quality of the motor.
Analysis:
The positioning sensor is damaged or the installation position is offset, resulting in inaccurate detection signals.
Loose or worn fixtures, unable to accurately fix the rotor and bearings.
The mechanical structure is deformed, affecting the relative position of the components.
Ruling out method:
Check the positioning sensor, replace it in time if it is damaged, readjust the installation position and calibrate it.
Tighten the fixture, repair or replace the worn fixture.
Check the mechanical structure, correct the deformed parts or replace the damaged parts.
Second, electrical fault analysis and troubleshooting
1、Equipment can not start
Phenomenon: After pressing the start button, there is no response from the press-in machine.
Analysis:
The power switch is damaged and can not be connected to the power supply.
The fuse is blown, resulting in circuit interruption.
Control circuit failure, such as relays, contactors do not operate.
Remedy:
Check the power switch and replace it promptly if it is damaged.
Replace blown fuses and check the circuit for short circuits and other problems.
Check the coil and contacts of the relay and contactor, and repair or replace the faulty parts.
2、Motor failure
Phenomenon: the motor does not rotate or rotates abnormally, such as unstable speed, abnormal noise and so on.
Analysis:
The motor winding is short-circuited or disconnected, resulting in the motor not working properly.
Motor driver failure, unable to provide the correct drive signal.
The motor is overloaded, which may be caused by excessive resistance of mechanical parts.
Troubleshooting method:
Use a multimeter or other tool to test the resistance of the motor winding to determine whether it is short-circuited or disconnected, and replace the motor if there is a problem.
Check the output signal and parameter settings of the motor driver, repair or replace the faulty driver.
Troubleshooting mechanical components to eliminate overload factors, such as lubrication of drive components, adjusting fixtures and so on.
3, sensor failure
Phenomenon: the display shows the pressure, displacement and other parameters are inaccurate, or the equipment can not be based on the sensor signal normal operation.
Analysis:
The sensor is damaged and cannot detect the signal normally.
The installation position of the sensor is loose or offset, resulting in inaccurate detection results.
The connecting wire of the sensor is damaged, affecting the signal transmission.
Ruling out method:
Test the sensor and replace it promptly if it is damaged.
Readjust the installation position of the sensor to ensure that it is firmly installed and the detection position is accurate.
Check the connection line, repair or replace the damaged cable.
Third, the hydraulic failure analysis and troubleshooting (if the device uses a hydraulic system)
1, insufficient pressure
Phenomenon: The pressure of the hydraulic system does not reach the set value, resulting in insufficient indentation force.
Analysis:
Wear and tear of the hydraulic pump, the output pressure is reduced.
Relief valve failure, can not properly adjust the pressure.
Hydraulic line leakage, resulting in pressure loss.
Remedy:
Check the hydraulic pump and repair or replace it if it is worn.
Adjust or replace the relief valve to ensure that it works properly.
Check the hydraulic pipeline, find out the leakage point and sealing treatment.
2, hydraulic oil contamination
Phenomenon: the hydraulic system is not stable, jamming, noise and other problems.
Analysis:
Hydraulic oil mixed with impurities, such as metal particles, dust, etc., affecting the normal work of hydraulic components.
Hydraulic oil used for too long, the performance decline.
Elimination method:
Replace the hydraulic oil and clean the hydraulic system to remove impurities.
Install a suitable filter to prevent impurities from re-entering the hydraulic system.
Fourth, software control failure analysis and troubleshooting
1, abnormal program operation
Phenomenon: the equipment can not run in accordance with the preset program, such as the wrong order of press-in, invalid parameter settings.
Analysis:
The control software has loopholes or faults, resulting in program logic errors.
The software parameters are set incorrectly and do not match the actual production requirements.
Computer hardware failure, affecting the normal operation of the software.
Troubleshooting method:
Contact the software supplier to upgrade or repair the control software.
Re-check and set the software parameters to ensure that they meet the production requirements.
Check the computer hardware, such as memory, hard disk, etc., repair or replace the faulty hardware.
2、Communication failure
Phenomenon: the equipment and the host computer or other equipment can not communicate normally, data transmission is interrupted or incorrect.
Analysis:
The communication line is damaged, affecting the signal transmission.
The communication protocol is set incorrectly, resulting in the data can not be correctly parsed.
Communication interface failure, unable to send and receive data normally.
Troubleshooting method:
Check the communication line, repair or replace the damaged cable.
Reset the communication protocol to ensure that the protocol between the devices is consistent.
Check the communication interface, repair or replace the faulty interface module.
When analyzing and troubleshooting the problem, follow the principle of first easy then difficult, first outside then inside, and gradually narrow down the scope of the problem to find the root cause of the problem and solve it.
※ 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.
