How to Troubleshoot and Troubleshoot Motor Motor Rotor Duplex Spot Welder?
Motor motor rotor duplex spot welding machine fault analysis and troubleshooting methods:
First, the basic process of fault analysis
l Observe the fault phenomenon
First of all, observe the overall operating status of the welder. Check whether the welder completely stops working, or some of the functions are abnormal, such as whether the electrode can be normally pressurized, whether the welding current can be output, etc..
Pay attention to the sound emitted when listening to the operation of the equipment, such as whether the transformer has an abnormal humming sound, whether the relay has a frequent beating sound, whether the electrode movement mechanism has a jam or friction sound. Abnormal sounds may indicate failure of electrical components, wear and tear of mechanical parts, or obstruction of movement.
Observe the phenomena during the welding process, including the quality of the welded joints (e.g., whether there is spattering, false welding, too small or too large welded joints, etc.), and the contact between the electrode and the workpiece (whether there is any sparking, poor contact, etc.).
Check the status of the indicator lights of the equipment, such as the power indicator light, fault indicator light, welding process indicator light, etc. Indicator lights of different colors and blinking status can provide clues about the type of equipment failure.
l Collect relevant information
Ask the operator before the failure of the operation of the equipment, such as whether the parameter adjustment, whether to replace the welding material, whether the equipment has been subject to external shock or overload operation. This information helps to make a preliminary judgment on the possible scope of the failure.
Check the operation records of the equipment, including maintenance records, repair history, parameter setting change records, etc.. Understanding the equipment's previous failures and maintenance measures is important for determining whether the old problem is recurring or the new problem is related to the previous maintenance.
l Determine the scope of failure
Based on the observed phenomena and collected information, initially determine whether the fault lies in the mechanical system, electrical system, software system or the welding process itself. For example, if the electrode can not move normally, the problem may be in the mechanical transmission part or the electrical control part; if the quality of the welded joints is poor but the equipment is running normally, it may be that the parameters of the welding process are not set properly.
Second, the mechanical system failure analysis and troubleshooting
l electrode mechanism failure
Failure phenomenon
Electrode does not move: the electrode can not be pressed down or lifted up normally, resulting in welding can not be carried out.
Electrode movement is not smooth: the electrode jerks and jams during the movement, affecting the quality of the welded joint.
Excessive electrode wear: the electrode head is worn out severely, resulting in irregular shape of the welded joint and reduced welding strength.
Possible causes and elimination methods
Failure of mechanical transmission parts: Check the transmission mechanism of electrode movement, such as wire rod, guide rail, connecting rod, etc.. If the wire rod is damaged or the guide rail is jammed with foreign objects, it will lead to electrode inactivity or unstable movement. Clean the guide rail of foreign objects and replace the damaged silk rod or other transmission parts.
Drive motor or cylinder failure (if electric or pneumatic drive): Check whether the drive motor is running normally, whether the motor winding is disconnected or short-circuited, or check whether the cylinder has insufficient air pressure, piston jamming and other problems. For motor failure, repair or replace the motor; for cylinder problems, check the air pressure, clean or replace the piston and seals.
Improper installation of electrode: The electrode is not firmly installed or interferes with other parts, which will lead to abnormal electrode movement. Reinstall the electrode to make sure the installation position is correct and there is no interference with other parts. For electrodes with excessive wear, replace the electrode head in time.
l Pressurizing mechanism failure
Failure phenomenon
Insufficient pressure: The pressure of the electrode on the workpiece does not reach the set value, resulting in false welding or weak welding.
Unstable pressure: In the process of welding, the electrode pressure is high or low, resulting in uneven quality of welded joints.
The pressurizing mechanism can not pressurize: the electrode can not apply pressure, and normal welding can not be carried out.
Possible causes and elimination methods
Pneumatic or hydraulic system problems (if pneumatic or hydraulic pressurization): check whether the pressure of the gas source or hydraulic source is normal, whether there is leakage in the gas pipe or oil pipe, and whether the pressure regulating valve is damaged. Repair leaking pipes, adjust the pressure regulator valve to ensure that the pneumatic or hydraulic system works properly.
Mechanical pressurized parts failure: for mechanical pressurization mechanism, check whether the spring failure, connecting rod is loose or deformation. Replace the failed spring, tighten or replace the deformed connecting rod.
Pressure sensor failure: The pressure sensor is used to detect the electrode pressure, if the sensor fails, it will lead to inaccurate pressure control. Check for loose connecting wiring to the sensor and damage to the sensor. Reconnect the loose wiring, replace the damaged sensor and calibrate.
l Clamping system failure
Failure phenomenon
Fixture fails to clamp the workpiece: the motor rotor is loose in the fixture, causing the welding position to shift.
The fixture is damaged: the collet, positioning pin and other parts of the fixture are damaged, affecting the positioning accuracy of the workpiece.
Fixture opening and closing is not flexible: the fixture cannot clamp and loosen the workpiece quickly and accurately, which reduces the working efficiency.
Possible causes and elimination methods
Failure of fixture mechanical parts: Check whether the collet of the fixture is worn out, whether the positioning pin is broken, whether the connecting rod is jammed. Replace worn collets and broken locating pins, and clean or repair seized connecting rods.
Pneumatic or hydraulic fixture problems (if any): Check pneumatic or hydraulic fixture air or oil lines for leaks and solenoid valves for proper operation. Repair leaks and replace damaged solenoid valves.
Fixture accuracy degradation: Long-term use may result in degradation of the fixture's positioning accuracy and clamping accuracy. Use a gauge to check the precision of the fixture, if found that the precision does not meet the requirements, adjust or calibrate the fixture.
Third, the electrical system failure analysis and troubleshooting
l power supply and transformer failure
Failure phenomenon
Welding machine can not start: power indicator does not light up, the equipment does not have any response.
Welding current abnormality: the welding current is too large or too small, not in line with the set value.
Power supply short-circuit or overload protection: the fuse is blown and the equipment stops working.
Possible causes and troubleshooting methods
Power input problem: Check whether the power cord is connected correctly, whether the plug is loose, and whether the power switch is damaged. Reconnect the power cord and replace the damaged power switch. Check whether the input voltage is within the range allowed by the equipment, if the voltage is abnormal, use a voltage regulator to adjust.
Transformer failure: Transformer windings may be short-circuited, disconnected, or have damaged insulation. Use an insulation resistance meter and multimeter to check the winding resistance and insulation resistance of the transformer. If the windings are damaged, the transformer needs to be replaced.
Rectifier failure (if DC welder): The rectifier is used to convert AC power to DC power, and damage to the rectifier components (e.g., diodes, thyristors, etc.) will result in abnormal DC output. Check whether the rectifier components are breakdown or open circuit, replace the damaged rectifier components.
l Controller and circuit board failure
Fault phenomenon
Welding parameters can not be set: the parameter setting function on the operating panel is invalid, unable to adjust the welding current, time, pressure and other parameters.
Controller does not respond: the controller does not respond to the operating instructions, the equipment can not run in accordance with the set program.
Circuit board failure alarm: the equipment displays the circuit board failure code, but the specific cause of the failure is not clear.
Possible causes and elimination methods
Problems with the operating panel: Check whether the keys on the operating panel are damaged and whether the connection lines are loose. Replace the damaged keys and reconnect the loose lines.
Controller program error: The controller program may be confused or lost. Try a reset operation on the controller to restore the factory settings. If the problem persists, contact the equipment manufacturer to update or reprogram the controller.
Circuit Board Hardware Failure: Check the electronic components on the circuit board (e.g., capacitors, resistors, chips, etc.) for obvious signs of damage, such as bulging capacitors and burnt chips. For damaged components, replace them with components of the same model. If it is impossible to identify the faulty components, send the circuit board for repair or replace the whole board.
l Sensor and signal transmission failure
Fault phenomenon
Sensor signal abnormality: pressure sensor, temperature sensor (if any), displacement sensor (if any) and other output signals do not match the actual situation.
Equipment can not receive the sensor signal: the controller can not read the data of the sensor correctly, resulting in the welding process out of control.
Signal interference: The sensor signals are interfered with during the operation of the equipment, resulting in jumps or errors.
Possible causes and elimination methods
Damaged sensor: Use professional equipment to check the performance of the sensor, such as using a pressure calibrator to check the pressure sensor. Replace the damaged sensor and calibrate it.
Signal line problem: Check whether the signal line of the sensor is firmly connected, broken or short-circuited. Reconnect loose wires and repair or replace broken signal wires.
Electromagnetic interference: nearby large motors, high-frequency equipment, etc. may produce electromagnetic interference to the sensor signal. Take shielding measures, such as the use of shielded wires connected to the sensor, or equipment away from the source of interference.
Fourth, the welding process failure analysis and troubleshooting
l welding point quality problems
Fault phenomenon
False soldering: the solder joints appear to be connected on the surface, but the actual strength is very low, gently pulled off.
Spatter: During the welding process, the molten metal droplets splash around, affecting the appearance and quality of the welded joint.
Welded joints are too large or too small: the size of the welded joints does not meet the requirements, too large may lead to waste of materials and increase costs, too small affects the welding strength.
Possible causes and elimination methods
Unreasonable welding parameters: check the welding current, welding time, electrode pressure and other parameters. If the current is too small, the time is too short or the pressure is insufficient, it is easy to lead to false welding; too large a current, too long a time or too much pressure may cause spattering and too large a welded joint. According to the welding material and workpiece thickness, adjust the appropriate welding parameters.
Improper surface treatment of the welding material: oil, oxidized layer, moisture and other impurities on the surface of the welding material will affect the welding quality. Before welding, clean the surface of the workpiece, such as using sandpaper grinding, chemical cleaning and other methods.
Poor electrode condition: Worn electrode head, dirt on the surface or irregular shape will affect the quality of the welded joint. Clean or replace the electrode head to ensure good contact between the electrode and the workpiece.
l Unstable welding process
Fault phenomenon
Fluctuation of welding current: During the welding process, the welding current is unstable, resulting in inconsistent quality of welded joints.
Poor contact between electrode and workpiece: the contact resistance between electrode and workpiece is unstable, resulting in flaming, arc breaking and other phenomena in the welding process.
Possible causes and elimination methods
Power supply fluctuation: check whether the power supply is stable, such as grid voltage fluctuation is large, you can use a voltage regulator to stabilize the voltage.
Welding circuit problems: welding cables, electrode clamps, workpiece clamps and other components of the welding circuit, check whether the circuit is loose, oxidized or poor contact. Clean or replace oxidized parts and tighten loose connection points.
Workpiece differences: There may be differences in the material, size or shape of motor rotors from different batches, affecting the welding process. Classify the workpieces and adjust the welding parameters according to their characteristics.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for help.
