Tool change device failure The general procedure of the CNC tool change is: after the tool change motor receives the tool change signal, the tool holder rotates by the worm gear speed reduction, and the tool position signal is sent by the Hall element, and the numerical control system reuses the signal and the target value. Compare to determine if the tool is in place. After the knife is changed into position, the motor reverses and tightens the tool holder. In the process of repairing the CNC car, I encountered the following fault phenomena. Fault 1: A four-blade CNC lathe, the failure of the No. 1 tool position can be found, and other tool positions can be changed normally. Fault analysis: Since only the No. 1 knife can not find the tool position, the problem of mechanical transmission can be ruled out, and it is determined that it is an electrical fault. It may be that there is a problem with the Hall element of the tool position and its surrounding circuit, so that the tool position signal cannot be sent to the PLC. The control circuit diagram uses a multimeter to check that the 24V power supply of the No. 1 tool position Hall element is normal, and the GND line is normal. The T1 signal line is normal. Therefore, it can be concluded that the Hall element is damaged and the position signal cannot be emitted. Solution: After replacing the new Hall element, the fault is solved and the first knife is found normally. Fault 2: A six-knife CNC lathe, all the tool positions can not be found when the tool is changed, the tool holder rotates after several weeks, and the CNC system displays the tool change alarm: the tool change timeout or no signal input. Fault Analysis Find: For this fault, mechanical faults can still be eliminated, due to electrical faults. The electrical causes for this fault are as follows: 1 the magnetic component is off; 2 the six Hall components are all damaged at the same time; 3 the power supply of the Hall component and the open signal line result in no voltage signal output. Among them, the third reason is the most likely. Therefore, the circuit diagram is found, and the power supply line of the electric circuit of the Hall element is inspected by the multimeter. It was found that the 24V supply voltage on the terminal block of the tool post detection line was 0V, and the other lines were normal. Looking along the line with this line as a clue, it was found that the 24V wire lead drawn from the electrical cabinet fell off and remained unresponsive after the connection. Therefore, it should be judged that the line is broken and caused a malfunction. Solution: After replacing the broken wire with the same specification wire, the fault is eliminated. Fault 3: A six-tool lathe equipped with FANUC-0imate system Dalian Machine Tool Plant, the knife selection is normal, but the lock can not be locked normally when the selected tool position is in place. System alarm: Tool change timed out. Fault analysis and finding: the tool holder is normal, and it is normal, that is, it cannot be locked in reverse. It shows that the worm gear transmission is normal, and it is initially determined to be an electrical circuit problem. On the electrical schematic diagram of the machine tool holder control, it is found that the tool reverse locking in-position signal is controlled by a position switch. Is there a problem with the switch, that is, the surrounding line? In order to confirm the cause of the fault, open the top cover of the tool holder. And the side cover, use the multimeter to check the circuit with reference to the circuit diagram, and find that the line has no open circuit and short circuit. By pressing the tool holder to lock the position switch in reverse, observe the ladder diagram to display the signal input, and then eliminate the electrical circuit problem. It is inferred that the movement of the stopper is not in place and the position micro switch does not operate. So I changed the knife again to observe it, and found that the block did not move in place. Then tighten the stopper bolts and try to change the knife once. After changing the knife again, the original fault appeared again, and the sleeve of the worm end was found to slip and climb. Is it caused that the stop of the position switch when the motor is reversed and locked is not located, the axial positioning of the sleeve is processed, and the top cover of the tool holder is installed. As a result, the tool holder is locked properly. Solution: The axial positioning of the bushing is solved. 2 Regulated power supply failure When the machine tool is running, the machine illumination will suddenly not light, the machine operation panel light will not be on, the system power supply is normal, the system will stop the alarm, and the spindle will have no signal alarm. The power failure after power off remains the same. Fault analysis and inspection: After inquiring about the operator at the time, there is no illegal operation, and the human cause is excluded. The mechanical cause can also be excluded, which should be caused by electrical failure. The machine's electrical schematic shows that these power-down areas are related to 24V, and the machine has two regulated power supplies, one for the I/O interface and one for the system. The power loss area is related to the I/O interface. Therefore, the electrical cabinet is turned on and the I/O interface power supply indicator light is not lit, indicating that the power supply is not working properly or is damaged. It is known from the working principle of the regulated power supply that the regulated power supply has the functions of current short circuit and overload protection. When the power supply is short-circuited or overloaded, the power output is automatically turned off to protect the power supply circuit from damage. So I tried to remove the output load line of the power supply and found that the power indicator light was on after the power was turned back on. This means that the power supply itself is not damaged. According to the analysis, the power supply is the I/O interface power supply, the load is not large, and there is no overload phenomenon. It should be a short circuit fault in the output circuit. The reason is obvious: due to the short circuit to the ground between the line and the machine, the regulated power supply is in a self-protection state, causing the power supply of the operation panel and some I/O interface relays to stop, resulting in the above failure. Solution: Re-package the joint with insulating tape, re-power on all faults, and the alarm release light is also on. 3 system program lock failure A CNC car, equipped with FANUC-0i-mate system, can not input parameters such as tool value, can not edit the program, and is accompanied by an alarm. Fault analysis check: This phenomenon first thought of the program protection switch, by comparing the normal system found: the same as when the system is locked. Therefore, it is suspected that the system lock switch is broken, but after shorting, the problem cannot be solved. By observing the ladder diagram of the faulty system, it is found that there is no signal input at the X56 input point, indicating that this input line is open. Along with this line number, the multimeter is used to check that it is found that the line head of the shaft switch is off at the rear of the operation panel, and the line cannot input the signal, so that the PLC logic relationship is incorrect, and the above fault occurs. Solution: Re-solder the wire ends with soldering iron solder, the alarm is released, the parameter input is normal, and the fault disappears. 4 Conclusions The above maintenance cases can be used as a reference for troubleshooting similar problems. Generally, for any fault, first of all, according to the phenomenon, according to the principle to judge the fault point, analyze each possibility, such as a switch, a wire joint, a screw will be the cause of the fault, with reference to the previous operation, maintenance history for analysis, Can help to narrow the scope of search, and help improve the efficiency of maintenance. (Finish)
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