How to Troubleshoot and Troubleshoot a Motor Motor Rotor Automatic Receiver?
The following are the general steps for fault analysis and troubleshooting of motor motor rotor automatic receivers:
First, fault analysis
1、Observe the fault phenomenon
l Mechanical part: check the overall structure of the rewinding machine, including the conveyor belt, fixture, mechanical arm and other parts. Observe whether there is any deformation, jamming, abnormal vibration or abnormal sound from the parts. For example, if the conveyor belt stops running, the belt may be broken, the motor is damaged or the transmission wheel is faulty; if the mechanical arm is not flexible, the joints may be worn out, jammed or the drive motor is faulty.
l Electrical parts: Observe the status of the indicator lights on the control panel. If any indicator light flashes or goes out, it may indicate that the corresponding circuit has problems. At the same time, check whether the wires are broken or burnt, and whether the plugs are loose. For example, a motor that does not run may be due to a broken power line, a damaged contactor, or a burned out motor winding.
l Control system: observe whether the automated operation process of the reclaimer is normal. For example, whether it is in accordance with the preset program for receiving, sorting and stacking. If there is confusion in the program, it may be that the software of the control system is faulty, such as program error, improper parameter setting or controller hardware damage.
l Receiving effect: Check whether the collected rotors are neatly arranged, whether there is any omission, damage or too slow receiving speed. This may involve problems with the synergistic work between the various components, such as sensor failure resulting in the inability to accurately detect the position of the rotor, or inaccurate actuator action.
2、Collect relevant information
l Equipment operating records: Check the operating logs of the equipment to understand the operating status of the equipment before the failure, whether there has been an abnormal alarm, what operations have been carried out (such as maintenance, replacement of components, parameter adjustment) and other information. These records can help locate whether the failure is related to recent operations.
l Operator Feedback: Communicate with the operator and ask about the specifics of the failure, such as whether there is an abnormal odor, the location of the sound, whether the failure process is sudden or gradual, and other details. Operators are more familiar with the equipment in their daily work, their feedback may provide important clues.
3, to determine the possible causes of failure
l Based on the principle and structure of the equipment analysis: According to the working principle and mechanical and electrical structure of the automatic skimmer, the observed failure phenomena and the information collected are comprehensively analyzed to speculate on the components or systems that may have problems. For example, the workflow of the skimmer usually includes rotor conveying, detecting, gripping and stacking, etc., each of which involves multiple components working together. If rotors are stacking up during conveying, there may be a mismatch between the conveying speed and the detection speed, or there may be insufficient friction in the conveyor belt.
l Make a list of failure causes: List the possible failure causes one by one, and sort them according to the possibility. For example, for the case of the motor does not rotate, the possible causes include power supply problems, motor failure itself, controller failure, transmission component failure and so on.
Second, troubleshooting
1, the initial troubleshooting of simple problems
Check the power supply and connecting lines: Make sure the power supply of the equipment is normal, check whether the plug is tight, whether the socket is energized, and whether the fuse is blown. At the same time, check whether the wire connection inside the equipment is firm, there is no loose, off or broken. For loose connections, they can be re-plugged or tightened; for broken wires, they need to be replaced with new ones.
Reboot the equipment and control system: Try to reboot the skimmer and the related control system, sometimes the equipment may be abnormal due to software failure or temporary interference, and it may return to normal after reboot. During the restarting process, pay attention to observe whether there is any abnormality in the starting process of the equipment, such as whether there is any alarm sound and whether the starting time is too long.
Cleaning and lubrication: Perform a simple cleaning of the equipment and wipe off the dust, oil and debris on the surface of the mechanical parts, as these substances may affect the normal operation of the parts. At the same time, add the right amount of lubricant to the parts that need to be lubricated (such as bearings, rails, chains, etc.) to reduce friction and wear.
2、Explore and repair for possible causes of failure
Failure of mechanical parts
l Conveyor belt problem: If the conveyor belt is slack, the proper tension can be restored by adjusting the tensioning device; if the belt is worn out seriously, it needs to be replaced with a new one. For the drive wheel, check whether it is worn, eccentric or jammed; if there is any problem, the drive wheel needs to be repaired or replaced.
l Fixture and mechanical arm failure: check whether the clamping force of the fixture is normal or not; if the clamping force is insufficient, it may be due to insufficient cylinder air pressure, wear and tear of the clamping mechanism or spring failure. For robotic arms, check the flexibility at the joints, clean the debris at the joints, replace worn bearings or seals, and repair or replace damaged motors and actuators.
Electrical Component Failures
l Motor failure: Use a multimeter to check if the resistance value of the motor windings is normal, and to determine if the motor is short-circuited or disconnected. If the motor is damaged, it needs to be replaced with a new one. At the same time, check whether the starting capacitor, contactor and relay of the motor are working properly. Damage to these parts may also cause the motor to fail to start or run properly.
l Sensor failure: Automatic receivers are usually equipped with a variety of sensors, such as photoelectric sensors, proximity sensors, etc., which are used to detect the position and status of the rotor. Check the working condition of the sensors and clean the surface of the sensors to ensure that they can detect properly. If the sensor is damaged, you need to replace the sensor with the same model and recalibrate its parameters.
l Circuit board failure: For complex electrical control systems, the possibility of circuit board failure also exists. Check the components on the circuit board for signs of charring or bulging, and use specialized testing equipment (e.g., oscilloscope) to check for normal signals. If the circuit board is damaged, it may be necessary to contact the manufacturer for repair or replacement.
Control System Failures
l Software problem: If you suspect a software failure, try reloading the program or updating the software version. Check whether the parameter settings in the program are correct, such as receiving speed, sorting rules, stacking position and other parameters are in line with the actual demand. If there is an error in the program, it may be necessary to debug and modify the program code.
l Controller hardware failure: check the controller (such as PLC, microcontroller, etc.) of the working state, including power supply, communication interface. If the controller hardware failure, it may be necessary to replace the new controller, and reprogramming and configuration.
3、Testing and verification after troubleshooting
l Local testing: After repairing the faulty part, conduct local testing first to ensure that the part can work normally. For example, after repairing the motor, start the motor individually to check whether it is running smoothly, whether the speed is normal, and whether there is any abnormal sound.
l Overall test: After completing all the troubleshooting, carry out the overall test of the equipment, simulate the actual receiving process, check whether the various aspects of the equipment can work together, whether the effect of receiving material to meet the expected requirements. In the test process, pay close attention to the operating status of the equipment to ensure that the fault has been completely eliminated.
When analyzing and troubleshooting faults, maintenance personnel need to have solid knowledge of mechanical, electrical and automation control, and should operate in strict accordance with the equipment's operating manual and regulations. ※ If you still can't solve the problem through the above ways and means, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
