Common diagnostic methods for machine tool failure
1, visual inspection
This is the method that must be used at the beginning of the failure analysis, which is to use the sensory inspection.
1. Ask the fault site personnel to carefully inquire about the process, fault appearance and fault consequences of the fault, and may ask multiple times during the entire analysis and judgment process.
2. Visually check whether the working status of each part of the machine tool is in a normal state (such as each coordinate axis position, spindle state, tool magazine, robot position, etc.), and each electronic control device (such as numerical control system, temperature control device, lubrication device, etc.) Whether there is an alarm indication, partial inspection of whether there is insurance burnt, component burnt, cracking, wire and cable fall off, the position of each operating component is correct or not.
3. Touch can be found under the condition of power failure of the whole machine by touching the installation status of each main circuit board, the plugging status of each plug, the connection status of each power and signal wires (such as servo and motor contactor wiring). The cause of the failure.
4. Power-on This refers to the power-on analysis in order to check for smoke, fire, abnormal sound, odor, and presence or absence of overheating of the motor and components.
2, instrument inspection method
Use conventional electrical instruments to measure the AC and DC power supply voltages of each group, and to measure related DC and pulse signals to find possible faults. For example, use a multimeter to check the status of each power supply, and measure the relevant signal state measurement points set on some boards. Use an oscilloscope to observe the amplitude, phase, or even the relevant ripple signal. Use the PLC programmer to find the PLC program. The location and cause of the fault.
3. Signal and alarm indication analysis
1. Hardware alarm indication This refers to various status and fault indicators on various electronic and electrical devices including numerical control system and servo system. Combined with the indicator status and corresponding function description, the indication content and the cause of the failure can be known. Method of exclusion.
2. The software alarm indicates that the faults in the system software, PLC program and machining program as described above are usually provided with alarm display. According to the displayed alarm number, the corresponding fault description and manual troubleshooting method can be used to know the possible fault causes and troubleshooting methods. .
4, interface status check method
Modern CNC systems integrate PLCs in them, and CNC and PLC communicate with each other in a series of interface signals. Some faults are related to the error or loss of interface signals. Some of these interface signals can be displayed on the corresponding interface board and input/output board, and some can be displayed on the CRT screen by simple operation, and all interfaces The signal can be called up with the PLC programmer. This inspection method requires the maintenance personnel to be familiar with the interface signals of the machine and to be familiar with the application of the PLC programmer.
5, parameter adjustment method
CNC systems, PLCs and servo drive systems are equipped with a number of modifiable parameters to suit different machine tools and different operating conditions. These parameters not only match the electrical system to the specific machine, but are also necessary to optimize the machine's functions. Therefore, any change in parameters (especially analog parameters) or even loss is not allowed; and changes in mechanical or electrical properties caused by long-term operation of the random bed will break the initial matching state and optimization state. Such faults refer to the latter type of faults in the fault classification section, and one or more related parameters need to be re-adjusted to be excluded.
This method has high requirements for maintenance personnel. It is not only necessary to understand the main parameters of the specific system, but also knows that its address is familiar with its function, and it has to have rich experience in electrical debugging.
6, spare parts replacement method
When the fault analysis results are concentrated on a certain printed circuit board, it is very difficult to implement the fault on a certain area or even a certain component due to the continuous expansion of the circuit integration. In order to reduce the downtime, the same is true. In the case of spare parts, you can replace the spare parts first, and then check the repair fault board. Pay attention to the following problems when replacing spare parts boards.
Any replacement of spare parts must be carried out in the event of a power failure.
Many printed circuit boards have some switches or shorting bars to match the actual needs. Therefore, the original switch position and setting state must be recorded on the replacement spare board, and the new board should be set to the same. OK, otherwise an alarm will be generated and it will not work.
Some printed circuit board replacements also require some specific operations after replacement to complete the software and parameters. This requires careful reading of the instructions for the appropriate board.
Some printed circuit boards cannot be easily removed, such as boards containing working memory, or spare boards, which can lose useful parameters or programs. You must follow the instructions when you have to replace it.
In view of the above conditions, before you remove the old board to replace the new board, you must carefully read the relevant information, understand the requirements and operating procedures before you start, so as not to cause more problems.
7, cross transposition method
When the faulty board is found or the faulty board cannot be determined and there is no spare part, the same or compatible two boards in the system can be interchanged and checked, for example, the exchange of the two coordinate command boards or servo boards can determine the fault board. Or the fault location. This cross-transposition method should pay special attention to not only the correct exchange of hardware wiring, but also a series of corresponding parameters exchange, otherwise it will not achieve the purpose, but will create new faults causing confusion of thinking, must be considered in advance , design a good software and hardware exchange program, and then exchange and check accurately.
8, special treatment
Today's CNC system has entered the development stage of PC-based and open-ended, in which the software content is more and more abundant, there are system software, machine tool maker software, and even users' own software, which is inevitable due to the design of software logic. Some problems will make some fault states unrecognizable, such as crashes. For this kind of fault phenomenon, special measures can be taken to deal with it. For example, the whole machine is powered off, and then restarted after a pause, and sometimes the fault may be eliminated. Maintenance personnel can explore their laws or other effective methods in their long-term practice.
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