Motor motor rotor duplex tester what are the common control unit failure and solutions?
Motor motor rotor duplex tester common control unit failure and solutions:
First, the programmable logic controller (PLC) failure
failure phenomenon
The test machine can not start or suddenly stop working, PLC power indicator does not light up or flashing abnormally.
The test program is chaotic, such as the test steps in the wrong order, test parameters (such as speed, pressure, displacement, etc.) can not be called or executed correctly.
Input and output signals are abnormal, PLC can not correctly receive sensor signals (such as displacement, speed, pressure, temperature sensors) or control the action of the executive elements (such as motors, solenoid valves, indicator lights, etc.).
Possible causes
Power supply problems: PLC power supply module failure, loose power cord or voltage fluctuations may cause the PLC to work improperly. For example, a damaged capacitor in the power module may cause unstable voltage output.
Program Error: The program is lost or damaged due to errors during uploading or downloading, or due to electromagnetic interference or memory chip failure.
Input/output interface failure: The input/output interface of PLC may suffer from poor contact, chip damage, etc. after a long time of use, affecting the reception and transmission of signals.
Solution
Check the power supply of the PLC, make sure the power cable is firmly connected, and use a multimeter to measure whether the input voltage is in the normal range (generally ±10% of the rated voltage). If the power supply module is faulty, it needs to be replaced with a power supply module of the same model.
For the case of program error, first try to reset the PLC to restore the factory settings (pay attention to backup important parameters). If the problem still exists, check the program backup and re-upload the correct program. If memory chip failure is suspected, it may be necessary to replace the memory chip or the entire PLC module.
Check the input and output interfaces of the PLC, clean the interface pins and re-plug the connection cables. Use a multimeter to check whether the input and output signals of the interface are normal, and for the damaged interface chip, it needs to be repaired or replaced by professional personnel.
Second, industrial computer failure
Failure phenomenon
The industrial computer can not be turned on, the power indicator does not light up, the screen does not display.
The operating system runs slowly, and the delay in software startup and operation is serious, which affects the testing efficiency.
The software appears dead, crashes or blue screen phenomenon, the test program can not run normally.
Communication between the industrial controller and other devices of the test machine (such as PLC, sensors, etc.) is interrupted, and data cannot be acquired or sent.
Possible causes
Hardware problems: power supply failure, hard disk damage, insufficient or damaged memory, motherboard failure, etc. may lead to the ICPC can not work normally.
Software problems: Operating system corruption, test software conflict, virus infection or software update failure may cause software failure.
Communication problem: Communication interface (such as Ethernet port, serial port, etc.) damage, communication line failure or communication parameter setting error may lead to communication interruption.
Solution
Check the hardware: first check whether the power supply is normal, try to replace the power supply. Check if the hard disk has bad sectors, if necessary, repair or replace the hard disk. Add memory or replace damaged memory modules. For motherboard failures, professional repairers are needed.
Solve software problems: Try using the repair tool that comes with the system or reinstall the operating system. Uninstall potentially conflicting software and install antivirus software for virus checking. If the problem is caused by software update failure, try to re-update or rollback to the previous version.
Repair communication problems: Check whether the communication interface is damaged, use a substitute interface for testing. Check whether the communication line is loose or broken, reconnect or replace the communication line. Check the communication parameter settings to ensure consistency with other devices.
III. Relay and contactor failure
Failure phenomenon
During the test, the relay or contactor operates frequently or does not operate, resulting in abnormal circuit turn-on and turn-off of the test equipment. For example, the contactor can not be properly absorbed, so that the motor can not be started or stopped.
Abnormal humming or noise when the relay or contactor is operating, which may be caused by poor core suction or poor contact contact.
The contacts of the relay or contactor are burnt, and there is a short circuit or broken circuit, which affects the normal operation of the test equipment.
Possible causes
Overload operation: The load current controlled by the relay or contactor exceeds its rated capacity, and long-term overload causes the contacts to heat up and burn out, or the coil is damaged by overheating.
Frequent operation: In high-frequency test operation, the relay or contactor is frequently engaged and disengaged, resulting in contact wear, fatigue, and later damage.
Environmental factors: Harsh working environments, such as high temperature, humidity, dust, etc., may affect the performance of the relay or contactor, leading to contact oxidation, degradation of insulation and other problems.
Solution
Check the load current controlled by the relay or contactor to ensure that it does not exceed its rated capacity. If the load current is too high, the relay or contactor needs to be replaced with a higher capacity relay or contactor, or the load needs to be shunted.
For frequent operation, consider using relays or contactors with a higher service life, or optimize the test program to reduce the number of unnecessary operations.
Improve the working environment, ventilate the tester equipment to dissipate heat, and install dust and moisture-proof devices. Regularly clean up the dust and debris on the surface of the relay and contactor, check the oxidation of the contacts, for oxidized contacts, you can use fine sandpaper to gently sand to restore its good conductivity.
Fourth, the control circuit failure
fault phenomenon
Circuit short circuit: the fuse is blown, the equipment smokes or has a burning odor, part of the electrical components are damaged.
Circuit break: some functions of the test equipment can not be realized, such as the inability to control the motor operation, the inability to obtain sensor data, etc., the relevant electrical components can not work properly.
Circuit signal interference: the test parameters are not stable, and the equipment has malfunction, such as the motor starts or stops automatically without operation, and the sensor data is abnormal.
Possible causes
Broken wires: The insulation of the wires in the control circuit is broken, resulting in a short circuit between the wires or a short circuit with the equipment shell. For example, wires are susceptible to breakage due to long-term mechanical wear, chemical corrosion or high temperature.
Component Damage: Damage to components such as resistors, capacitors, diodes, etc. in the control circuit, resulting in circuit breakage or abnormal signals. Component damage may be caused by aging, over-voltage, over-current and other reasons.
Electromagnetic interference: Electromagnetic interference generated by other electrical equipment around the tester (e.g., large motors, high-frequency generators, etc.) affects the signal transmission and normal operation of the control circuit.
Solution
Check the wires of the control circuit, use an insulation resistance meter to check the insulation resistance, find broken wires and repair or replace them. At the same time, check whether the connections of the wires are firm to avoid poor contact caused by looseness.
For suspected damaged circuit components, use a multimeter to test, such as measuring the resistance of the resistor, capacitance of the capacitor, diode forward and reverse resistance. For damaged components, replace components of the same type and check whether the surrounding circuit is affected.
For electromagnetic interference problems, take shielding measures, such as using shielded wires to connect sensitive signal lines and electromagnetic shielding of the control cabinet of the control circuit. At the same time, reasonable arrangement of tester equipment and other electrical equipment location, as far as possible away from the source of interference.
※: If through the above ways and means still can not solve the equipment failure, please contact Xinhui mechanical and electrical equipment through the page chat tool to seek help from technical specialists.
