How to fault analyze and troubleshoot motor motor rotor duplex tester?
Motor motor rotor duplex tester fault analysis and troubleshooting methods:
First, the basic steps of fault analysis
l Collect information
Observe the fault phenomenon: carefully observe the specific performance of the tester when the fault occurs. For example, whether it stops working completely, or some of the functions are abnormal, such as a certain station can not be tested, test data inaccurate, and so on. Pay attention to the operating status of the equipment, including whether the mechanical parts have abnormal movement, electrical components have smoke or make abnormal sounds and so on.
Ask the operator: Communicate with the person who operated the equipment at that time to understand the time, process and operation details of the failure. Ask whether there is a special operation, such as parameter adjustment, replacement of the type of rotor of the motor under test, the equipment is subject to external shocks, etc. This information may be very helpful in determining the cause of the failure.
Check the history of the equipment: check the maintenance records of the test machine, repair records, test data records and other historical documents. Understand whether the equipment before the occurrence of similar failures, as well as at that time to take measures to solve the problem; check whether the equipment's recent operating parameters have abnormal changes, such as the gradual decline in test accuracy and so on.
l Preliminary judgment of the scope of the fault
According to the collected information, initially determine whether the fault is in the mechanical system, electrical system, software system or other aspects. For example, if the mechanical components have abnormal sound and movement jams, it is likely to be a mechanical system failure; if the test data can not be displayed or transmitted normally, it may be the electrical system or software system problems.
Second, mechanical system failure analysis and troubleshooting
Fixture failure
l Failure phenomenon and causes
Fixture can not clamp the rotor: may be the fixture collet wear and tear is serious, can not provide sufficient clamping force; may also be the fixture drive mechanism (such as cylinders, hydraulic cylinders or electric actuators) failures, such as insufficient air pressure or hydraulic pressure, motor damage, etc.; may be the fixture mechanical transmission components (such as connecting rod, screw) is damaged, resulting in the failure of the clamping action can not be completed.
Inaccurate positioning of the fixture: Worn positioning pins, loose fixture mounting base or faulty positioning sensors may lead to inaccurate positioning of the fixture, thus affecting the test accuracy.
l Remedy
Replace the collet in time if the collet is worn out; check and repair or replace the faulty parts of the drive mechanism, such as replenishing air pressure or hydraulic pressure, repairing the motor, etc.; for the damaged mechanical transmission parts, replace or repair them.
Replace the worn positioning pins and tighten the screws of the fixture mounting base; check whether the connection lines of the positioning sensors are loose, calibrate the sensors using standard parts or replace the faulty sensors.
Failure of transmission mechanism
l Failure phenomenon and cause
Transmission components abnormal sound or vibration: belt, chain, gears and other transmission components wear, slack or improper installation will lead to abnormal sound and vibration in the transmission process. For example, belt wear will lead to slippage, resulting in sharp sounds; gear wear will cause poor meshing between the teeth, resulting in periodic vibration and noise.
Transmission components do not move smoothly or jammed: poor lubrication of transmission components, foreign objects into the parts or the parts themselves are damaged (such as screw bending, guide deformation) may lead to poor movement or jamming.
l Remedy
For worn or loose transmission parts, such as belts and chains, adjust or replace them according to the degree of wear; for worn gears, replace them with new ones and make sure that they are installed correctly and meshed well between the teeth.
Clean up the foreign matter on the transmission parts, add or replace the appropriate lubricant; for the damaged screw, guide rail and other parts, replace them, and check whether the support structure and connecting parts related to them are normal.
Third, the electrical system failure analysis and troubleshooting
Sensor failure
l Failure phenomenon and causes
No signal output from the sensor: the sensor itself is damaged, the line connecting the sensor is broken or short-circuited, the sensor power supply failure may lead to no signal output. For example, the displacement sensor's internal components are damaged, the signal line is cut off or the power plug is loose may make the sensor can not work properly.
Sensor signal inaccuracy: the sensor probe is contaminated, the installation position is shifted, the sensor's calibration parameters are lost or subject to external interference may lead to signal inaccuracy. For example, the probe of the temperature sensor is covered with oil, which will make the measured temperature lower than the actual temperature.
l Remedy
Use a multimeter or other tools to check whether the power supply of the sensor is normal, and check whether the line conducts; if the sensor is damaged, replace the sensor with the same model and re-calibrate it.
Clean the probe of the sensor and readjust the installation position of the sensor; check and restore the calibration parameters of the sensor, and for the case of external interference, take shielding measures, such as using shielded wires to connect the sensor or installing electromagnetic shielding cover.
Controller Failure
l Failure phenomenon and cause
Controller can not start or dead: controller (such as PLC, industrial control machine) power module failure, internal program errors or hardware damage (such as CPU, memory and other components) may lead to failure to start or dead. For example, the fuse of the power supply module is blown, the program is in a dead loop, or the CPU chip is damaged by overheating.
Controller output signal abnormality: Controller output interface damage, output signal line failure or program setting error may lead to abnormal output signal. For example, the output relay of PLC is damaged, and it can not control the action of external devices (such as motors, solenoid valves) normally.
l Remedy
Check the power module of the controller, replace the fuse or repair the power failure; for the case of program error, try to restart the controller, restore the factory settings or re-download the correct program; if the hardware is damaged, you need to replace the faulty parts.
Check the output interface and connection lines of the controller, repair or replace the damaged parts; check the output signal settings in the program to ensure that the logic is correct, reprogramming and debugging as needed.
Fourth, the software system failure analysis and troubleshooting
Software startup and operation failure
l Failure phenomenon and causes
Software can not start: the software installation files may be damaged, the lack of the necessary operating environment (such as operating system components, runtime libraries), software and hardware device compatibility issues or software license expiration and other reasons for the software can not start.
Software runs slowly or stutters: Insufficient computer system resources (e.g., CPU, memory, hard disk), loopholes in the software itself, or excessive data volume (e.g., too much test data storage) may cause the software to run slowly or stutter.
l Remedy
Reinstall the software, make sure the installation file is complete; install the required runtime environment components and runtime libraries; check the compatibility between the software and hardware devices, update the software version or hardware drivers if necessary; check the software license status and update the license in time.
Close other programs that take up system resources and increase the computer's hardware resources (e.g., add memory, replace faster hard disk); update software patches and fix software vulnerabilities; clean up useless data in the software, such as expired test data records.
Test data and parameter setting failure
l Failure phenomenon and causes
Abnormal or incorrect test data: Failure of the data acquisition module of the software, communication failure between the sensor and the software, or incorrect test parameter settings may lead to abnormal or incorrect test data. For example, the data acquisition module can't read the sensor signal correctly, the communication line is disturbed, or the setting of test parameters (such as range and accuracy) is not in line with the actual test situation.
Parameters can not be saved or loaded incorrectly: the software's storage function failure, storage path error or parameter file corruption may lead to parameters can not be saved or loaded incorrectly.
l Remedy
Check the data acquisition module of the software to ensure that the sensor signals can be read correctly; check the communication line to eliminate interference factors; recheck and set the test parameters to ensure that the parameters are consistent with the actual test.
Check the storage function of the software to ensure that the storage path is correct; repair or re-create the damaged parameter files; if the problem is caused by the storage function of the software itself, contact the software supplier for a solution.
※ 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 to seek help.
