How to Troubleshoot and Troubleshoot Motor Motor Rotor Manual Six Station Double Flying Fork Winding Machine?
Motor motor rotor manual six-station double flying fork winding machine fault analysis and troubleshooting:
First, the basic steps of fault analysis
1, observe the fault phenomenon
l When the winding machine failure, the first thing to carefully observe the performance of the fault. For example, record whether the equipment is completely stopped running or part of the malfunction, observe whether the flying fork normal movement, winding is accurate, there is no abnormal sound or vibration, etc.. At the same time, pay attention to observe the status of the equipment's indicator lights, including those on the controller, drives, sensors and other components, to see if any alarm lights are on or flashing.
2. Collect relevant information
l Ask the operator about the operation of the equipment before the failure, for example, whether the parameter adjustment, replacement of raw materials, whether the equipment is subject to external impact, etc.. You also need to check the operating records of the equipment, including previous failure records, maintenance records, parameter setting records, etc., to understand the history of the equipment, which helps to determine whether the failure is new or the previous problems that have not been completely resolved recur again.
3、Determine the scope of the fault
l According to the observed phenomena and collected information, initially determine the possible scope of the fault involved. For example, if the flying fork does not move but the motor has a sound, then the fault may be in the driving mechanism of the flying fork; if the number of winding turns is inaccurate, it may be related to the counting sensor or the parameter settings of the controller. The scope of the failure is gradually narrowed down to the mechanical system, electrical system, software system and so on a specific part or several, in order to carry out a more targeted inspection.
Second, the mechanical system failure analysis and troubleshooting
1, flying fork motion fault
l Failure phenomenon: the flying fork can not start, the movement speed is not stable, the movement trajectory is not accurate or stuck.
Possible reasons and troubleshooting methods:
l Damage of transmission parts: check the transmission parts such as belt, chain, gear and so on. If the belt is slack or broken, need to re-tension or replace the belt; for the chain, check whether there is a chain link off or wear and tear, if so, should be replaced; gear wear may lead to transmission inaccuracy, need to replace the worn gear.
l Flying fork guide rail or slider problem: guide rail wear or slider jamming will affect the movement of the flying fork. Clean the guide rail and slider, remove dirt and debris, if the guide rail is seriously worn, you need to replace the guide rail; slider damage, replace the slider, and add the right amount of grease after installation to ensure that the flying fork movement is smooth.
l Flying fork motor failure: check whether the flying fork motor is running normally. Use a multimeter to measure the winding resistance of the motor to determine whether the motor has a broken circuit or short circuit. If the motor is damaged, it is necessary to replace the motor with the same model and check whether the driver setting of the motor is correct.
2、Fixture failure
l Failure phenomenon: the fixture can not clamp or loosen the rotor, resulting in the rotor shifted in the winding process, affecting the quality of winding.
l Possible causes and troubleshooting methods:
l Mechanical structure of the fixture is damaged: check whether the collet, connecting rod and other parts of the fixture are deformed or broken. If the collet is worn out and can not clamp the rotor firmly, the collet should be replaced; the damaged connecting rod will affect the opening and closing action of the fixture, so it is necessary to repair or replace the connecting rod.
l Fixture pneumatic or hydraulic system failure (if pneumatic or hydraulic fixture): check whether the pressure of the gas or hydraulic source is normal, whether there is leakage in the pipeline. For pneumatic fixture, check whether the air pipe is broken, whether the connector is loose, if there is any problem, repair or replace it in time; for hydraulic fixture, check whether the hydraulic oil is enough, whether the oil pump is working normally, to ensure that the hydraulic system can provide enough clamping force.
3, indexing mechanism failure
l Failure phenomenon: inaccurate rotor indexing, winding position deviation.
l Possible causes and elimination methods:
l Wear of the mechanical parts of the indexing mechanism: Check whether the cam, roller, ratchet and other parts in the indexing mechanism are worn. Worn cams will lead to a decrease in indexing accuracy and need to be replaced; worn rollers will affect the smoothness of the transmission and should also be replaced.
l Indexing sensor failure: the indexing sensor is used to detect the indexing position of the rotor. Check whether the sensor is covered by dust and oil, and clean the surface of the sensor. Use a multimeter to check whether the output signal of the sensor is normal, if the signal is abnormal, the sensor may be damaged, need to replace the same type of sensor.
Third, the electrical system failure analysis and troubleshooting
1, motor and drive failure
l Failure phenomenon: motor does not rotate, motor overheating, abnormal motor speed or drive alarm.
l Possible causes and troubleshooting methods:
l Power supply problem: Check the power supply of the motor, including whether the power cord is firmly connected and whether the voltage is normal. If it is a three-phase motor, also check whether the three-phase power supply is balanced. For the case of loose power cord, re-insert and tighten it; if the voltage is abnormal, you need to check the power supply line or use a voltage regulator to stabilize the voltage.
l Motor failure: As mentioned earlier, determine whether the motor is damaged by measuring the resistance of the motor winding. In addition, check whether the bearing of the motor is seized or worn. If the bearings are faulty, the bearings need to be replaced; if the motor is damaged, replace the motor, and when installing a new motor, pay attention to adjusting the motor's mounting position to ensure that it is properly connected to the drive components.
l Drive failure: check the drive alarm code, different drives have different alarm information, according to the alarm code can be initially determined the cause of the failure. For example, overcurrent alarm may be too large a motor load or drive internal short circuit; overheating alarm may be poor heat dissipation drive. Check whether the cooling fan of the drive is working properly and clean up the heat sink of the drive. If the internal components of the drive is damaged, you need a professional to repair or replace the drive.
2, sensor failure
l Failure phenomenon: inaccurate winding turns, tension control failure, position detection errors and other sensor-related problems.
l Possible causes and elimination methods:
l Sensor connection problems: check whether the sensor signal line is firmly connected, there is no loose, broken or short-circuit conditions. Re-plug the signal cable to ensure a good connection. If the signal line is damaged, you need to replace the signal line.
l Sensor damage: Use professional testing equipment or tools to check whether the sensor is working properly. For example, for counting sensors, you can manually trigger the sensor to check whether its counting function is normal or not; for tension sensors, you can use a standard tension test tool to compare the measured value of the sensor. If the sensor is damaged, replace it with a sensor of the same model and calibrate the new sensor according to the calibration program of the device.
l Sensor interference problems: Electromagnetic interference in the surrounding area may affect the sensor signal. Check whether there are large motors, transformers and other devices that generate electromagnetic interference around the equipment. If there is, you can take shielding measures, such as using shielded wires to connect the sensor, or keep the device away from the source of interference.
3, controller failure
l Failure phenomenon: the device can not start, running program error, parameter settings can not be saved or loaded.
l Possible causes and methods of elimination:
l Controller power problem: Check the power supply of the controller, including whether the power module is working properly, whether the fuse is blown. If the power module is faulty, you need to replace the power module; if the fuse is blown, check whether there is a short-circuit situation, and replace the fuse after eliminating the short-circuit.
l Controller program error: Try to reset the controller to restore its default settings. If the problem still exists after reset, the program may be faulty or missing. Contact the equipment manufacturer to obtain the correct version of the program and reprogram or update the software.
l Controller internal component damage: For complex controller failure, it may be the internal chip, capacitor and other components are damaged. This requires professional electronic maintenance personnel to use professional equipment for testing and repair, such as using an oscilloscope to check the signal waveform, using a multimeter to check the parameters of the components.
Fourth, the software system failure analysis and troubleshooting
1, parameter setting fault
l Failure phenomenon: winding parameters (such as turns, speed, tension, etc.) can not be set after the normal implementation, or parameter setting after the abnormal operation of the device.
l Possible reasons and troubleshooting methods:
l Parameter input error: double-check the parameter setting interface to make sure that the input parameters are in line with the requirements of the equipment and the actual winding situation. For example, the number of turns cannot be negative, and the speed setting cannot exceed the permissible speed of the equipment. If the parameters are input incorrectly, re-set the parameters correctly.
l Parameter saving or loading problem: Check the parameter saving and loading function of the software. It is possible that the file for storing parameters is corrupted or there is a problem with the storage path of the software. Try to re-save the parameters, or find and fix the problem with the storage path. If the parameter file is corrupted, you can try to restore the parameters from the backup file.
2、Program operation failure
l Failure phenomenon: the winding machine is running according to the wrong program, such as the flying fork action sequence is wrong, the connection between the stations is not normal.
l Possible causes and elimination methods:
l Program logic error: check the programming logic of the software, it may be that the logic of the program is destroyed after updating the software, modifying the program or equipment failure. Contact the software developer or equipment manufacturer to get the correct program logic diagram, check and modify the program.
l Incompatibility between the program and the hardware: If the device has undergone a hardware upgrade or certain parts have been replaced, there may be incompatibility between the software and the hardware. Check the version of the software and the compatibility requirements of the hardware, and upgrade the software version or adjust the hardware configuration to match each other if necessary.
