Nowadays, the use of numerical control equipment is becoming more and more extensive. The ensuing is how to ensure the effective utilization of the equipment. When the equipment fails, it is necessary to restore the equipment to normal use as soon as possible. In order to solve this problem, maintenance personnel are required to have high quality first, and not only are they required to have rich professional knowledge, such as electromechanical integration technology, computer principle, numerical control technology, PLC technology, automatic control technology, dragging principle, hydraulic technology, etc. We must also master the general knowledge of machining and the simple programming of numerical control devices. In addition, we must have a certain level of English and be able to read English technical materials. Must have enough information, including machine, electricity, liquid drawing, machine parameter backup, system use and maintenance manual, PLC ladder and so on. There must also be a certain amount of spare parts. In addition, maintenance personnel are required to have certain experience and master certain maintenance methods. The author engaged in numerical control equipment maintenance for many years, has accumulated certain experience, summed up a set of methods for maintenance of numerical control equipment, is introduced as follows for reference.
To find out the fault phenomenon
When the numerical control equipment fails, first of all to find out the fault phenomenon, to the operator to understand the first time the fault occurred, observe the process of the fault when possible, observe the fault is under what circumstances, how to happen , what caused the consequences. Only knowing the first-hand situation will help to eliminate the fault and clarify the fault process. The problem will be solved by half. Clearly understand the fault phenomenon, and then according to the working principle of the machine tool and numerical control system, you can quickly diagnose the problem and troubleshooting, so that the device back to normal use.
For example, when a CNC cylindrical grinder using the American Bryant company TEACHABLE III system is used for automatic machining, the grinding wheel wears off one piece of the dresser. In order to observe the phenomenon of failure and prevent accidental recurrence, the grinding wheel was removed to run the machine tool. At this time, the failure phenomenon was observed. It was found that during the automatic grinding process, there was no problem with grinding. After the grinding of the workpiece was completed, the grinding wheel was normal when dressing the grinding wheel. The feed, while the dresser rotates very quickly, quickly presses the upper limit switch. If the grinding wheel is not removed at this time, the grinding wheel must hit the dresser. According to the working principle of the machine tool, the wheel dresser is driven by the E-axis servo motor and the rotary encoder is used as a position feedback element. Normally, when the dresser trims the grinding wheel, the Z-axis slide moves the E-axis dresser to the dressing position, and the dresser makes a 30° to 120° swing to dress the grinding wheel. We observed the failure phenomenon several times and found that when the E axis is at the pressure upper limit switch, the coordinate value of the E axis on the screen is only about 60°, and the actual position is about 180°. Obviously, the position feedback has a problem, but the position is changed. Both the control board and the encoder did not solve the problem. After repeated observations and experiments, we found that: When the E-axis dresser is at the edge of the Z-axis, there is no problem with the reference point and rotary swing. Use the system's alarm information.
Now the self-diagnosis ability of the numerical control system is getting stronger and stronger. Most of the faulty numerical control systems of the equipment can be diagnosed and take corresponding measures, such as shutdown, etc., and generally can generate an alarm display. When the numerical control device fails, sometimes the alarm information is displayed on the display, and sometimes there are alarm indications on the numerical control device, the PLC device and the drive device. At this time according to the manual analysis of these alarm information, some according to the alarm information can directly confirm the cause of the fault, as long as the content of the alarm information, you can eliminate the numerical control equipment failures.
For example, a CNC channel grinder using the German SIEMENS 810 system will generate an alarm number “BATTERY ALARM POWER SUPPLY†after powering on. It clearly indicates that the power failure protection battery of the CNC system is dead and a new battery has been replaced (Note: Always replace the battery while the system is live. Reset the fault and return the machine to service. Another CNC grinding machine adopting SIEMENS 3 system is not displayed on the screen after power on. Check the numerical control device and find that a light emitting diode on the CPU board flickers. According to the instructions, analyze the flicker frequency and confirm that the power supply is low. After the battery is replaced, the battery voltage is low. , restart the system failure disappears.
For example, a numerical control lathe adopting Japan's FANUC 0TC system has alarm No. 2043 indicating “HYD. PRESSURE DOWN†indicating that the hydraulic system pressure is low. According to the alarm information, the hydraulic system was inspected and it was found that the hydraulic pressure was indeed very low. The hydraulic pressure was adjusted so that the machine tool returned to normal use.
Other fault alarm information does not reflect the root cause of the fault, but reflects the result of the fault or other problems arising therefrom. At this time, careful analysis and inspection are required to determine the cause of the fault. The following methods are applicable to such faults. The detection of some faults without alarm is effective.
To find out the fault phenomenon
When the numerical control equipment fails, first of all to find out the fault phenomenon, to the operator to understand the first time the fault occurred, observe the process of the fault when possible, observe the fault is under what circumstances, how to happen , what caused the consequences. Only knowing the first-hand situation will help to eliminate the fault and clarify the fault process. The problem will be solved by half. Clearly understand the fault phenomenon, and then according to the working principle of the machine tool and numerical control system, you can quickly diagnose the problem and troubleshooting, so that the device back to normal use.
For example, when a CNC cylindrical grinder using the American Bryant company TEACHABLE III system is used for automatic machining, the grinding wheel wears off one piece of the dresser. In order to observe the phenomenon of failure and prevent accidental recurrence, the grinding wheel was removed to run the machine tool. At this time, the failure phenomenon was observed. It was found that during the automatic grinding process, there was no problem with grinding. After the grinding of the workpiece was completed, the grinding wheel was normal when dressing the grinding wheel. The feed, while the dresser rotates very quickly, quickly presses the upper limit switch. If the grinding wheel is not removed at this time, the grinding wheel must hit the dresser. According to the working principle of the machine tool, the wheel dresser is driven by the E-axis servo motor and the rotary encoder is used as a position feedback element. Normally, when the dresser trims the grinding wheel, the Z-axis slide moves the E-axis dresser to the dressing position, and the dresser makes a 30° to 120° swing to dress the grinding wheel. We observed the failure phenomenon several times and found that when the E axis is at the pressure upper limit switch, the coordinate value of the E axis on the screen is only about 60°, and the actual position is about 180°. Obviously, the position feedback has a problem, but the position is changed. Both the control board and the encoder did not solve the problem. After repeated observations and experiments, we found that: When the E-axis dresser is at the edge of the Z-axis, there is no problem with the reference point and rotary swing. Use the system's alarm information.
Now the self-diagnosis ability of the numerical control system is getting stronger and stronger. Most of the faulty numerical control systems of the equipment can be diagnosed and take corresponding measures, such as shutdown, etc., and generally can generate an alarm display. When the numerical control device fails, sometimes the alarm information is displayed on the display, and sometimes there are alarm indications on the numerical control device, the PLC device and the drive device. At this time according to the manual analysis of these alarm information, some according to the alarm information can directly confirm the cause of the fault, as long as the content of the alarm information, you can eliminate the numerical control equipment failures.
For example, a CNC channel grinder using the German SIEMENS 810 system will generate an alarm number “BATTERY ALARM POWER SUPPLY†after powering on. It clearly indicates that the power failure protection battery of the CNC system is dead and a new battery has been replaced (Note: Always replace the battery while the system is live. Reset the fault and return the machine to service. Another CNC grinding machine adopting SIEMENS 3 system is not displayed on the screen after power on. Check the numerical control device and find that a light emitting diode on the CPU board flickers. According to the instructions, analyze the flicker frequency and confirm that the power supply is low. After the battery is replaced, the battery voltage is low. , restart the system failure disappears.
For example, a numerical control lathe adopting Japan's FANUC 0TC system has alarm No. 2043 indicating “HYD. PRESSURE DOWN†indicating that the hydraulic system pressure is low. According to the alarm information, the hydraulic system was inspected and it was found that the hydraulic pressure was indeed very low. The hydraulic pressure was adjusted so that the machine tool returned to normal use.
Other fault alarm information does not reflect the root cause of the fault, but reflects the result of the fault or other problems arising therefrom. At this time, careful analysis and inspection are required to determine the cause of the fault. The following methods are applicable to such faults. The detection of some faults without alarm is effective.
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