What are the common sensor failures and their solutions for brushless motor motor automatic press-fit end-capping machine?
Brushless motor motor automatic press-fitting end-capping machine common sensor failure and its solutions are as follows:
1、Position sensor failure
l Failure phenomenon and performance
Inaccurate positioning of the end cap: the position sensor is used to determine the precise position of the end cap and the motor, if there is a failure, the position of the end cap in the conveying or press-fitting process will be deviated, resulting in press-fitting not in place or press-fitting offset, affecting product quality.
Mis-action of the equipment: the sensor fails to feed back the position information accurately, so that the control system receives the wrong signal, which may lead to the action of the equipment at an inappropriate time, such as early or delayed press-fitting, or even cause collision damage to the equipment components.
l Failure causes
Installation position change: the vibration generated by the long-term operation of the equipment may cause the installation position of the position sensor to shift, deviating from the original accurate detection position.
Sensor damage: by mechanical collision, dust or moisture erosion and other factors, the sensor's internal electronic components may be damaged, resulting in its inability to work properly.
Electromagnetic interference: Strong electromagnetic fields generated by the surrounding electrical equipment may interfere with the signal transmission of the position sensor, making the sensor output signal inaccurate.
l Solution
Re-calibrate the installation position: Use professional measuring tools to re-install the position sensor to the correct position and fix it to ensure that it can accurately detect the position of the end cap and motor.
Replace the damaged sensor: If it is determined that the sensor has been damaged, replace it with a new sensor of the same model in time and debug it to make it work properly.
Take anti-interference measures: add shielding for the sensor to reduce electromagnetic interference; reasonable arrangement of the sensor line, avoid close to the line with strong electromagnetic equipment.
2, pressure sensor failure
l Fault phenomenon and performance
Abnormal pressure display: the pressure sensor is used for real-time monitoring of the pressure value in the process of pressing and loading, if there is a failure, the pressure value shown on the display may be inaccurate, and there is a large deviation from the actual pressing and loading force.
Pressing force control failure: The control system adjusts the pressing force according to the signal feedback from the pressure sensor, if the sensor fails, the control system can not get the accurate pressure information, which may lead to too large or too small pressing force, affecting the quality of assembly of the end cap and motor.
l Failure causes
Pressure overload: In the process of press-fitting, if the press-fitting force exceeds the rated range of the pressure sensor, it may damage the pressure-sensitive components of the sensor.
Zero drift: After a long time of use, the zero point of the pressure sensor may drift, resulting in its output signal is not zero even under no-pressure state, affecting the accuracy of the measurement.
Loose connection line: The connection line between the sensor and the control system may be loose due to equipment vibration, resulting in unstable or interrupted signal transmission.
l Solution
Replace the pressure sensor: When it is determined that the sensor is damaged due to pressure overload, replace it with a new one that meets the range requirement in time.
Re-calibrate the zero point: Use professional calibration equipment to calibrate the zero point of the pressure sensor to eliminate the effect of zero drift and ensure the accuracy of measurement.
Check and tighten the connection line: carefully check the connection line between the sensor and the control system to ensure that the line is firmly connected, if damaged, replace it in time.
3, photoelectric sensor failure
l Failure phenomenon and performance
End cap detection error: the photoelectric sensor is used to detect whether the end cap reaches the specified position, if there is a failure, it may misjudge the position of the end cap, resulting in equipment in the end of the end cap is not in place when the press-fit operation, or the end cap is in place after the equipment does not move.
Counting error: In the production process, the photoelectric sensor may be used to count the end caps. If the sensor fails, the counting result will be inaccurate, affecting the production statistics and management.
l Failure Causes
Lens contamination: Dust and oil in the production environment may adhere to the lens of the photoelectric sensor, blocking the transmission and reception of light and affecting the normal operation of the sensor.
Light interference: Strong light in the surrounding environment, such as sunlight, lighting, etc., may interfere with the photoelectric sensor's light detection, resulting in sensor misjudgment.
Aging of internal components: With the growth of the use of time, the photoelectric sensor internal light-emitting diodes, photosensitive components, etc. may be aging, performance degradation, affecting the accuracy of detection.
l Solution
Clean the lens: use a clean soft cloth to gently wipe the lens of the photoelectric sensor to remove dirt and dust, to ensure that the light can normally pass through the lens.
Adjust the installation position or add a hood: Reasonable adjustment of the installation position of the photoelectric sensor to avoid its direct exposure to strong light; you can also add a hood for the sensor to reduce the interference of external light.
Replacement of aging components or sensors: If it is determined that the failure is caused by the aging of internal components, timely replacement of aging components; if it can not be repaired, then replace the entire photoelectric sensor.
4, temperature sensor failure
l Failure phenomenon and performance
Temperature display abnormality: temperature sensors are used to monitor the temperature of key parts of the equipment (such as motors, hydraulic systems, etc.), if there is a failure, the temperature value shown on the display may be inaccurate, and can not truly reflect the actual temperature of the equipment.
Equipment overheating protection failure: When the temperature of a part of the equipment is too high, the control system should trigger the overheating protection mechanism according to the signal from the temperature sensor, but if the sensor fails, it may not be able to send out the overheating signal in time, which will cause the equipment to continue to run at high temperature and damage the equipment parts.
l Failure causes
Improper installation: The temperature sensor is installed in an incorrect position, not in full contact with the measured part, or the installation is squeezed or damaged by external forces, which will affect its accurate measurement of temperature.
Sensor damage: long-term exposure to high temperatures, humidity and other harsh environments, the temperature sensor's internal thermal element may be damaged, resulting in its inability to work properly.
Signal transmission failure: the signal transmission line between the sensor and the control system may be broken, short-circuit and other faults, so that the temperature signal can not be properly transmitted to the control system.
l Solution
Reinstall the temperature sensor: In accordance with the correct installation method, install the temperature sensor in a suitable position, ensure that it is in full contact with the measured part, and fix it.
Replace the damaged sensor: If it is determined that the temperature sensor has been damaged, replace it with a new one in time and debug it so that it can accurately measure the temperature.
Check and repair the signal transmission line: Use a multimeter or other tools to check the signal transmission line, find out the fault and repair to ensure that the temperature signal can be transmitted normally.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
