What are the common control unit failures and solutions for brushless motor motor automatic end-capping machine?
Brushless motor motor automatic end-capping machine control unit in the stable operation of the equipment plays a key role, the following for you to introduce the common control unit failure and the corresponding solution:
First, the controller failure
1, the system is dead or no response
Failure performance: the controller interface freezes, all operating instructions can not be executed, the device stops running, the indicator state is fixed.
Failure causes: controller running for a long time leading to overheating, affecting the performance of electronic components; software program errors or conflicts, such as memory leaks, logic errors, etc.; unstable power supply, resulting in abnormal controller work.
Solution: Check whether the controller's cooling fan is functioning properly, clean up the dust of the cooling channel, if necessary, increase the cooling device; restart the controller, if the problem persists, try to restore the factory settings or update the software program; the use of voltage regulators to ensure a stable supply of power supply, check the power supply line is loose or damaged.
2、Loss of parameters or wrong settings
Failure performance: the previously set parameters (such as pressure, speed, stroke, etc.) is lost, or display the wrong parameter values, resulting in abnormal operation of the equipment.
Failure causes: the controller's memory chip is damaged or malfunction, resulting in data loss; operator misuse, modify the parameter settings; software system loopholes, resulting in parameter saving and reading errors.
Solution: Contact the controller manufacturer to replace the damaged memory chip; train the operators and emphasize the correct parameter setting method and operation specification; update the software program to fix the known loopholes.
3、Drive failure
Motor can not start or abnormal speed
Failure performance: After pressing the start button, the motor is unresponsive, or the motor speed is unstable, sometimes fast and sometimes slow, unable to reach the set speed.
Failure causes: abnormal power input of the drive, such as insufficient voltage, phase sequence error, etc.; drive and motor connection between the line is loose, broken or short circuit; drive parameters set and motor mismatch, such as current, frequency and other parameters set wrong.
Solution: Check the power input of the drive, use a multimeter to measure whether the voltage is normal, adjust the phase sequence; check the connection lines to ensure that the connection is firm, repair or replace the damaged lines; according to the specifications and requirements of the motor, reset the parameters of the drive.
4、Drive overheating alarm
Failure performance: The overheating indicator of the drive lights up, while the device may automatically stop running to protect the drive.
Fault Cause: The load of the drive is too large, exceeding its rated power; cooling fan failure, resulting in poor heat dissipation; drive internal power module is damaged, generating excessive heat.
Solution: Check the motor and mechanical transmission part, whether there is a stall or overload situation, reduce the load; check whether the cooling fan is functioning properly, clean up the dust on the fan and heat sink, and replace it in time if it is damaged; detect the power module of the drive, and if it is damaged, it needs to be repaired or replaced by the professional personnel.
5、Relay failure
Contacts sticking or not closed
Failure performance: relay-controlled circuit can not be normal on and off, such as the motor can not stop or start, the solenoid valve can not act.
Failure causes: relay for a long time and frequent action, contact wear and tear serious, resulting in adhesion; control relay signal voltage is not stable, too high or too low to affect the normal action of the contacts; relay coil damage, can not produce enough magnetic force to make the contacts closed.
Solution: Replace the badly worn relay; check the control signal voltage to ensure that it is stable within the rated operating voltage range of the relay; use a multimeter to measure the resistance of the relay coil, such as resistance abnormalities, then replace the coil or the entire relay.
6、Malfunction of relay
Failure performance: In the absence of a control signal, the relay operates on its own, resulting in abnormal action of the equipment.
Failure causes: strong electromagnetic interference in the surrounding environment, affecting the normal operation of the relay; relay installation location is unreasonable, close to the heat source or other sources of interference.
Solution: add shielding for the relay to reduce electromagnetic interference; adjust the installation position of the relay, away from the heat source and other equipment that may produce interference.
Second, the sensor and control unit communication failure
1, signal transmission interruption or error
Failure performance: the control unit can not receive the sensor's signal, or receive the signal value and the actual value of the deviation is large, resulting in inaccurate action of the equipment or can not run normally.
Failure causes: the communication line between the sensor and the control unit is loose, disconnected or short-circuited; the sensor itself is faulty, the output signal is abnormal; the communication interface of the control unit is damaged, and it can't receive the signal normally.
Solution: check the communication line to ensure that the connection is firm, repair or replace the damaged line; use a multimeter and other tools to detect the output signal of the sensor, if there is a problem with the replacement of the sensor; check the communication interface of the control unit, if it is damaged, it is necessary to be repaired or replaced by professionals.
2, signal interference
Failure performance: the sensor's signal is interfered with, resulting in unstable signals received by the control unit, fluctuations or jumps.
Failure causes: strong electromagnetic interference sources exist in the surrounding environment, such as large motors, frequency converters, etc.; communication lines do not take effective shielding measures.
Solution: Stay away from strong electromagnetic interference sources, or add shielding for equipment and communication lines; shielding of communication lines, such as the use of shielded cables, and ensure that the shielding layer is well grounded.
※ If the above ways and means still can not solve the equipment failure, please contact Xinhui mechanical and electrical equipment through the page chat tool to seek help.
