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What should we do if the automation equipment fails?

What should we do if the automation equipment fails?


With the continuous improvement of technical level and production technology, the field of using automation equipment is also increasing. Any set of automated production equipment consists of the following parts:

1. Actuator

In the actuator part, including electrical components, pneumatic components and hydraulic components. The difference between the three different actuators is limited to the driving mode and control medium. Actuators mainly include motors, electric cylinders, cylinders, and hydraulic cylinders.

2. Sensor part

Sensors are mainly capacitive, inductive, photoelectric, magnetic induction, piezoresistive, etc.

3. Controller part

In addition to the robot part and PLC, if the actuator is a motor, there must be a corresponding dedicated stepping or servo controller.

The so-called fault diagnosis is divided into fault diagnosis during debugging and fault diagnosis during operation. The only difference between the two is that debugging is the initial operation of the equipment, and failures can occur in any link before it can work normally. The fault diagnosis during operation indicates that the equipment has been able to work normally, but due to some reasons, it suddenly does not work or does not work according to the normal motion sequence.

The fault diagnosis under the two different states is different in thinking. If there is a problem during debugging, it may be that the controller or program is faulty.

However, if there is a sudden problem during operation, do not focus on the controller and the program, because the program will not change by itself without manual modification. Today's controllers are of very good quality and rarely fail inexplicably. Unless there is serious electromagnetic interference.

Here we focus on fault diagnosis during equipment operation .

Some people say that fault diagnosis relies on experience, and that older engineers are more experienced and better able to handle fault diagnosis. But does age represent qualifications? Does age represent experience? What really determines the level is thinking! Dealing with different problems depends on whether your thinking is correct and whether your working method is regular!

When a device suddenly fails to work, or the work sequence is out of order. Many people will wonder if the program is wrong? The PLC is broken? Many engineers often think so. That would be very wrong.

If the program is wrong, how did your device work before? No matter what brand of PLC, it is impossible to suddenly break down during normal operation, and the probability of this is lower than winning the 80 million prize. So how should we consider the problem?

First of all, we have already understood that the equipment is divided into three parts, so we will perform fault diagnosis step by step in the following fixed order. Just follow the following sequence, no matter what kind of equipment, you will find the problem easily!

1. Check all power, air, and hydraulic sources

Power supply, including the power supply of each equipment and the power supply of the workshop, that is, all the power sources, air sources (including air pressure required by pneumatic devices), and hydraulic sources (including the working conditions of hydraulic pumps required by hydraulic devices) that the equipment can involve ).

In 50% of the fault diagnosis problems, the errors are the power supply, air supply and hydraulic supply. For example, power supply problems, including power supply failures in the entire workshop, such as low power supply, burned insurance, poor contact of power plugs, etc.

The air pump or hydraulic pump is not turned on, the pneumatic triple or double piece is not turned on, the relief valve in the hydraulic system or some pressure valves are not turned on. These basic problems are usually the most common.

 2. Check whether the sensor position is offset

Due to the negligence of the equipment maintenance personnel, the position of some sensors may be wrong, such as not in place, sensor failure, sensitivity failure, etc. Always check the sensing position and sensitivity of the sensor, adjust in time if there is a deviation, and replace the sensor immediately if it is broken.

In many cases, if the supply of power, air and hydraulic pressure is ensured, the more problem is the failure of the sensor.

Especially for magnetic induction sensors, due to long-term use, it is likely that the internal ground irons will stick to each other and cannot be separated, resulting in a normally closed signal. This is also a common problem of this type of sensor and can only be replaced.

In addition, due to the vibration of the equipment, most of the sensors will become loose after long-term use. Therefore, during routine maintenance, always check whether the position of the sensor is correct and whether it is firmly fixed.

3. Check the relay, flow control valve, pressure control valve

Relays are the same as magnetic induction sensors, they will also have ground adhesion after long-term use, so that the electrical circuit cannot be guaranteed and needs to be replaced. In a pneumatic or hydraulic system, the opening degree of the throttle valve and the pressure adjustment spring of the pressure valve will also loosen or slip with the vibration of the equipment.

These devices, like sensors, are parts of equipment that require routine maintenance. Therefore, these devices must be checked carefully in daily work.

4. Check the electrical, pneumatic and hydraulic circuit connections

If no problems are found in the above three steps, then check all circuits. Check whether the wires in the circuit are disconnected, especially whether the wires in the wire groove are cut by the wire groove due to pulling. Check the trachea for damaged creases. Check if the hydraulic oil pipe is blocked.

When checking the circuit in this step, use the necessary multimeter, adjust to the buzzer file, and check the path of the circuit. If the trachea has severe creases, replace it immediately. The hydraulic tubing should also be replaced.

After ensuring that the above steps are correct, the fault may appear in the controller, but it can never be a program problem! First of all, don't be sure that the controller is destroyed. As long as there is no serious short circuit, the controller has short-circuit protection inside. A general short circuit will not burn the controller.

First, check whether there are high-frequency interference devices near the controller. If so, remove it immediately. If you are outdoors, strong lightning may also cause the controller to not work normally for a moment. At this point, first remove all possible interfering devices, and then restart the controller.

Secondly, if restarting is invalid, check whether the controller wiring is loose or has poor contact.

Finally, if the wiring is correct. Determine whether there is a problem with the memory card of the PLC. Replace with a new card, download the program, and check whether the previous memory card is faulty.

If all the above measures are ineffective, then you are honored that you have encountered a failure with a probability of no more than 0.01% in the world, congratulations! Please contact our engineer or replace with a new device.

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