Electrical equipment overhaul paper machine electrical maintenance thesis CNC machine tools electrical maintenance and troubleshooting（电气设备检修论文机床电气维修论文数控机床的电气维修与故障的排除）

《Electrical equipment overhaul paper machine electrical maintenance thesis CNC machine tools electrical maintenance and troubleshooting（电气设备检修论文机床电气维修论文数控机床的电气维修与故障的排除）》由会员上传分享，免费在线阅读，更多相关内容在工程资料-天天文库。

ElectricalequipmentoverhaulpapermachineelectricalmaintenancethesisCNCmachinetoolselectricalmaintenanceandtroubleshooting（电气设备检修论文机床电气维修论文数控机床的电气维修与故障的排除）Electricalequipmentoverhaulpapermachineelectricalmaintenancethesis:ElectricalmaintenanceandtroubleeliminationofNCmachinetools[Abstract]thispaperdescribestheclassificationofcommonelectricalfaultsofCNCmachinetools,theinspectionandanalysismethodsofelectricalfaults,themaintenanceandtroubleshootingofcommonelectricalfaults.CNCmachinetools;electricalmaintenance;failure;Withtherapiddevelopmentofelectronictechnologyandautomationtechnology,theapplicationofnumericalcontroltechnologyismoreandmoreextensive.CNCequipmentbasedonmicroprocessorandlarge-scaleintegratedcircuitasasymbolhascreatedconditionsforthedevelopmentofthemachinerymanufacturingindustry,andhasbroughtgreatbenefits.Butatthesametime,becauseoftheiradvanced,complexandintelligentcharacteristics,thefaultdiagnosis,maintenancetheory,technologyandmeanshaveundergoneleapsandbounds.Inthispaper,CNCmachinetoolsforelectricalmaintenanceandfaultremovalarebrieflydiscussed.1Classificationofcommonelectricalfaults TheelectricalfaultsofNCmachinetoolscanbeclassifiedaccordingtotheappearance,nature,causeorconsequenceofthefault.1.1,tothelocationofthefaultcanbedividedintohardwareandsoftwarefaults.Hardwarefaultreferstotheelectroniccomponents,wires,cables,printedcircuitboards,connectorsandotherabnormalstate,orevendamage,whichistheneedtorepairorevenreplacethefaultcanbeexcluded.SoftwarefaultsgenerallyrefertofaultsinPLCprograms,whichrequireinputormodificationofcertaindataandevenmodificationstothePLCprogram.1.2,thereisnoalarmwhenthefaultoccurs,dividedintodiagnosticalarm,faultandnodiagnosticalarmfault.TheCNCsystemisdesignedwithselfdiagnosticprocedures,combinedwiththefaultindicator,softwareandhardwareperformanceofreal-timemonitoringofthewholesystem,oncefoundfaultwillimmediatelyalarmortextdisplayedonthescreen,withthediagnosticmanualsystemisequippedwithnotonlytofindthereason,thesiteofthefault,butalsoexcludedpromptmethod.Machinetoolmanufacturerswillalsohavespecificfailurealarmsanddiagnosticmanualsforspecificmachinetools.Thetwopartshavethefaultofdiagnosisandalarm,plusallkindsofalarmlightsoneachelectricaldevice,whichmakesmostoftheelectricalfaultseasiertoremove.Thereisnodiagnosticindicationofthefault,anditisdifficulttoremovesuchfaults.Weshouldrelyontheworkprocessbeforeandafterthefailureandthefailurephenomenonandconsequences,andrelyonmaintenancepersonneltomachinetoolfamiliarityand technicalleveltobeanalyzedandruledout.Theprobabilityoffaultoccurrenceisdividedintosystematicfaultandstochasticfault.Thefaultisdividedintodestructiveandnondestructivefaultsandsoon.Butinanycase,theproductionofanykindoffailureisoftenmixed,whichrequiresthemaintenancepersonneltocarryoutspecificanalysisofthespecificproblems,taketheappropriateanalysis,troubleshooting,andultimatelysolvetheproblem.2troubleshootingandanalysisThisisthefirststepintroubleshootingandacriticalpartofit.2.1workbeforetroubleshooting2.1.1inquiryafterreceivingmachinefaultsiterequiredtheexclusionofinformation,shouldfirsttrytokeepthesiterequirestheoperatortofaultstate,withoutanytreatment,whichisbeneficialtotherapidandaccurateanalysisofthecausesoffailure.Atthesametime,carefullyinquireaboutthefaultinstructionsandthebackgroundofthefault,andmakeapreliminaryjudgment.2.,1.2on-siteinspection,arrivedatthescene,firstofalltoverifytheaccuracyofthevariouscircumstancesprovidedbytheoperator,integrity,soastoverifytheaccuracyoftheinitialjudgment.Donotrushtohandle,carefullyinvestigatevariouscircumstances,soasnottodamagethescene,sothattroubleshooting,increasingthedifficulty. 2.、1.3failureanalysis,accordingtotheknownfaultconditions,analysisoffaulttypes,soastodeterminetheprincipleoftroubleshooting.Sincemostfaultsareindicated,itispossibletolistawiderangeofpossiblecausesofthefailure,incomparisonwiththediagnosticmanualsandinstructionsusedinmachinetools.2.1.4determinethecauseoftherealcauseofthisfailuretofindoutseveralpossiblereasonsinthecoursemayrequireseveraltests,thisisacomprehensivetestofmaintenancepersonnelfamiliarwiththedegreeandlevelofknowledge,experienceandabilitytoanalyzeandjudgeonthemachine.Theprocessofinvestigation,analysisanddiagnosisofcommondiagnosismethods2.2electricalfaultsofelectricalsystemofCNCmachinetoolisthetroubleshootingprocessinthetroubleshootingperiod,shouldmakefulluseoftheCNCsystemselfdiagnosisfunctiontojudge,commonlyuseddiagnosticmethodsbutalsoflexibleuseofelectricalfault.2.,2.1intuitivemethod,thisistheinitialmethodofanalysisofthefault,thatis,theuseofsensoryinspection.Everypartofitismainlytoobservevariousabnormalphenomenawhenthefaultoccurslight,soundandtastebyhumansensesandinspectthesystem,followtheoutsideafterthefirst"principle,withhope,smell,touch,askthemethodoffaultdiagnosis,fromoutsidetoinsidecheck,Therangeoffaultscanoftenbereducedtoonemoduleora printedcircuitboard.Thisrequiresthemaintenancepersonneltohavetherichpracticalexperience,musthavethemulti-disciplinarybroadknowledgeandthecomprehensivejudgmentability.2.,2.2interfacestatuscheckmethod,modernnumericalcontrolsystemintegratesPLCamongthem,andCNCandPLCcommunicatewitheachotherinaseriesofinterfacesignalforms.Someofthemarewrongorlostandinterfacesignalsrelatedtothesignalinsomeoftheseinterfacescaninterfaceboardandthecorrespondinginput/outputpanellights,somecanbethroughasimpleoperationontheCRTscreendisplay,andinterfacesignalsallcanusePLCprogrammerorthecorrespondingPC.TheinspectionmethodrequiresthemaintenancepersonneltobefamiliarwiththeinterfacesignalofthemachinetoolandtobefamiliarwiththeapplicationofthePLCprogrammer.2.,2.3parameteradjustmentmethodisknowntoall,numericalcontrolparameterscandirectlyaffecttheperformanceofCNCmachinetools.Numericalcontrolsystem,PLCandservodrivesystemareequippedwithmanymodifiableparameterstomeettherequirementsofdifferentmachinetoolsanddifferentworkingconditions.Theseparameterscannotonlymaketheelectricalsystemmatchthespecificmachinetools,butalsomakethefunctionsofthemachinetoolsbeoptimized.Therefore,itisnotallowedtochangeorevenloseanyparameters;andthechangeofmechanicalorelectricalperformancecausedbythelong-termoperationoftherandombedwillbreaktheinitialmatchingstateandtheoptimumstate.Manyofthesefaultsneedtobereadjusted,andoneormoreargumentscanbeexcluded.Thismethodisverydemandingformaintenancepersonnel,not onlytounderstandthespecificparametersofthesystem,butalsotoknowitsaddressanditsrole,andtohavemoreexperienceinelectricaldebugging.2.,the2.4exchangemethodofexchangeisasimpleandeasymethod.Whenthefaultplateisfoundorcannotbedeterminedwhetherthefaultyboardhasnospareparts,thetwoorthesamecompatibleplatesinthesystemcanbecheckedinterchangeably.Intheexchangebeforemustpayattentiontothetemplateisintact,butthestateisconsistent,soitisnotonlythehardwareconnectiontocorrectexchange,butalsowillexchangeaseriesofcorrespondingparameters,otherwiseitcannotachievethepurpose,itwillcauseconfusioninthinkingofnewfault,beforesomeconsideration,exchangeofsoftwareandhardwaredesignplan,accurateforexchangecheck.3electricalmaintenanceandtroubleshootingThisisthesecondstepintroubleshootingandtheimplementationphase.Electricalfaultanalysisprocess,thatis,thetroubleshootingprocess,thislistofseveralcommonelectricalfaultstodoabriefintroduction,foryourreference.3.1CNCsystempositionringfault3.,1.1positionringalarm.Itispossiblethatthepositionmeasuringcircuitisopen;themeasuringelementisdamaged;thepositioncontrolisnotestablished;theinterfacesignal doesnotexist.3.,the1.2axisproducesmotionwithoutinstructions.Thedriftmaybetoolarge;thepositionlooporspeedloopisconnectedtopositivefeedback;thefeedbackwiringisopen;themeasuringelementisdamaged.3.2machinecoordinatecannotfindreferencepointThesignalreturnedfromthereferencepointdecelerationswitchorthezeromarksignalisinvalid.Whendiagnosing,weshouldfindoutthemethodfirst,thencomparethefaultphenomenon,findthefaultlocationfromoutsidetoinsideandsignaltrackingmethod.Outsidemaybezerodirection,awayfromthezeropoint,checktheoutsideofthemachineblockandswitch,mainlyreferencepoint,switchblockpositioniscausedbyimproperconfiguration,youneedtoreadjust,youcancheckthePLCorinterfacestatus.Thezeromarkfailure,whethertheencoderisdamagedorthewiringisopen,thezeromarkshiftofthegratingmakesthezeroreturnswitchfail,andthesignalcanbecheckedbytheoscilloscope.3.3accidentaldowntime.Herearetwopossiblescenarios:oneiscausedbyenvironmentalconditions,suchasstronginterference(powergridsorperipheralequipment),excessivehumidity,andhightemperature.Theenvironmentalfactorsareoftenoverlookedbypeople,suchasmanymachineryfactorywillputintothecommonmachinetoolplantorevenneartheopendoornearthecabinet,openthedoorforalongtime,therearealotofdust,scraporsprayequipmentnear;anothersituationisasbeforetherelevantsoftwaredesignproblemscausedby downtimeincertainoperationsandfunctionsofthecombinedgeneralmachinetoolpowerafterreenergizedwilldisappear.Thesefactorswillnotonlycausefailure,butalsodamagethesystemandmachinetools,andpayattentiontoimprovement.4exampleanalysisoftroubleAXK5040CNCmillingmachineinthenormaluseoftheFANUC-3MAsystem,duringoperation,theZshaftproducesalarmnumber31.4.1preparationbeforemaintenanceViewthemaintenancemanual,#31alarmcontent:errorregistercontentisgreaterthanthespecifiedvalue.Faultcharacteristicis:Zaxisfollowserrorsoftwarealarm.Analysisofthephenomenon:followingtheerrorisrelatedtothelocationofthering,butalsobecauseitisdrivingtheZshaftwhenthealarmoccurs,itcanbeestimated:largefaultlocationintheZaxisring.Analysisofclosedloopworkingprinciple:positionloopsystem,Itisaclosedloopwhichconsistsofthecontrolunitandthedriveunitasthemainchainandthepositiondetectionfeedbackloopasthesubchain.Theprincipleofclosedloopcontrol(seeFigure1):Controlcommand=CNCworkinstruction-positionmeasurementfeedbacktheactualvalue,thetoleranceistoosmall,thefeedbacksignallosswillcausetheactualfeedvalueistoolarge,thecommandvalueisnotnormal,cancausesuper differentialalarm.Mayinvolvefaulttypes:softwarefaultsformachineparametersettings,andhardwarefaultsinthepositionloop.4.2,listingthecausesofthefault,leadingtotheestablishmentofthealarmconditions,therearethreepossibilities,nowusingexclusionmethodtoselectthemostlikelycauses.4.,2.1work/controlinstructionvalueistoobigortoosmall.ItmaybethattheCNCdeviceorcontrolleriscorruptedordisturbed,butthepossibilityisverysmall.Canexclude.4.,2.2allowdifferenceistoosmall.Possiblecausesare:A.parametersettingerror.Thisisimpossiblebecausethemachinetoolsarenotinthecommissioningphase.TheB.parameterhasbeenmodified.Itmaybeexternalinterferenceormemoryloss.Iftheinterferenceresultsinparameterconfusion,thenmorethanoneparameterismodified.First,theparametersarechecked.4.,2.3measuredvalueistoosmallortoolarge,andtheworkorderisnormal.Possiblecauses:A.feedbacksignallineinsteadof"positivefeedback",therootwiththeerroristoolarge.Itisimpossiblebecausethemachinetoolsarenotrepairedordebugged.IncreaseorlossofB.feedbacksignal.Becausethesignallineandmonitoringsystemofshieldingandgroundingisbad,thereareinductiveloadinterference,sensorlooseningandswing, poorinstallationandsoon.Itisnecessarytochecktheshieldingandgroundingofthepositiondetectionsystem,andinvestigatetheenvironment.ThehysteresisoftheC.feedbacksignalresultsinthemeasuredvalueofthesignalwithin0ofthespecifiedmonitoringtime.Overalongperiodoftimeitiseasytooccuronthemachinetools,suchaspollutionofpositionsensors,damageofsignalline,badcontact,positiondeviationordamage.Therefore,thepositiondetectiondevice,thesystemandthewiringsystemthereofshallbeinspected.D.hasnofeedbacksignal.A)thesensorisnotinstalledorconnected,andthesensorisdamagedanddoesnotwork.Therefore,thesensorsysteminthepositiondetectiondeviceshouldbechecked.B)theservounitdoesnotwork/theservoshaftdoesnotoperate.Analysisandjudgment:themostlikelyfaulttype:Hardwarefailure.Themostlikelycauseofthefailureisthelocationdetectionsystem(largefaultlocation)andcannoteliminatetheenvironmentalinterferencefactors.4.3determinethediagnosticprocedure4.、3.1siteworkprocedure:environmentinvestigation,interfacesignalmethod,inspectionpositionloopparameter,signaltrackingmethod,checkbitsystem,faultlocation. Findthenormalvalueoftherelevantparameter.CheckthemaintenancemanualforX,YandZthreeaxispositionloopdiagnosisparameternumber(address)objectsandcontentandthediagnosis:threeaxiscorrespondingto800,801and802stateparameters,undernormalconditions,theyshouldchangein-1and+1.Fieldworkenvironment,powergridandappearancesurvey:nointerferencesource,nopowergridfluctuation,noabnormalenvironmentandmachinetoolappearance.4.,3.2checkthereal-timestatusvalueofrelatedparameters:afterstartingthesystem,thereal-timepicturesoftherelatedparametersoftheparametersettingsscreenandthediagnosticscreenaretransferredrespectively.Parametersettingsscreen:parametersdonotappearchaotic,indicatingnointerferenceandpowerdown.Eachservoshaftispulledbyhand,andthestatechangesofthereal-timeparametersareobservedonthediagnosticscreen.Itisfoundthatthevaluesofparameters800and801canbeoperatedbyrandombeds,varyinginthenormalrange,while802remainunchangedat0.Parameterstatuscomparison:normal/standard/theoreticalstatevaluesarecomparedwithreal-timestatevalues,andonly802parametersdonotchangeinrealtimewithactions.Largefaultlocation:Zshaftpositionring.Thesignaltrackingmethodisusedtochecktheoutputbefore,after,first,aftertheinput,thentheoutput.4.,3.3observationandexamination Startwithwiringandsensors.Check:themachinetoolZaxisfeedbacksignallineisgood.TurntheZaxlemotorshaftbyhandandcarefullylistentotheabnormalsound.Suspectpositionencoderloose.4.4troubleshooting4.,4.1,faultcheck:turnontheZshaftmotor,foundthattheencoderandthecrossbetweenthemotorblockfalloff.4.,4.2causesoffailure:thefixedscrewontheencoderisbroken,resultingintheZaxisencoderisnotconnectedtothemotor,soitdoesnotworkwithoutfeedbacksignal.Reconnecttheencoderproperlytotroubleshoot.5SummaryofmaintenancetroubleshootingAfterthetroubleshooting,themaintenanceworkcannotbecompleted,butitstillneedstoanalyzethedeep-seatedcausesofthefailurefromtwoaspectsoftechnologyandmanagement,andtakeappropriatemeasurestoavoidthefailureoccurredagain.Whennecessary,theequipmentcanbemodifiedandimprovedaccordingtothesiteconditionsandthematuretechnology.Finally,themaintenanceofthefailurephenomenon,analysisofthecause,theprocessofsolving,replacementcomponents,theremainingissuestokeepagoodrecord.Ifthereisreform,CompleteandaccuratesupplementaryDrawingsandrelevantdatainaccordancewiththerelevantstatestandardsshallbe arrangedintheequipmentinformation.Atthesametime,fromtheprocessoftroubleshooting,foundthattheirlackofknowledge,makeplansforlearning,andultimatelyenrichthemselves.6ConclusionCNCmachinetoolisamechanical,hydraulic,electricalintegrationofequipment,itsfailuremustbemechanical,hydraulic,electricalthesethreepartsofacomprehensivereflection.ButinthefailureofCNCmachinetools,electricalfaultratioisrelativelyhigh,onlythecorrectuseandstrengthenthemaintenance,in-depthanalysisoftheproblems,andconstantlysumuplearning,inordertoimprovethelevelofmaintenancetheoryandmaintenancecapability,canquicklysolvetheequipmentfault,canreducethefailurerate.Toensurethenormaloperationofequipment.[References][1]WangGuicheng.FaultdiagnosistechnologyofCNCmachinetools[M].Beijing:ChemicalIndustryPress,2005(FirstEdition)[2]PanHaili.FailureanalysisandmaintenanceofCNCmachinetools[M].Xi'an:Xi'anElectronicandScienceUniversitypress,2006(FirstEdition)[3]WangKanfu.CNCmachinefaultdiagnosisandmaintenance[M].Beijing:MechanicalIndustryPress