Common Troubleshooting Methods for Automated Equipment

With the continuous introduction of automated equipment by manufacturers, it has become a powerful tool for production companies to enhance efficiency and reduce costs. Any automated machine is composed of three main parts: the actuator, the sensor section, and the control unit. When an automated machine suddenly fails to operate or experiences a program malfunction, it is imperative to perform a fault detection.

Let's familiarize ourselves with the methods of diagnosing automated mechanical failures by looking at the three components that make up machinery. Inspect the entire power supply, air source, and hydraulic source for mechanical automation. Issues with the power supply, air source, or hydraulic source often lead to automated mechanical failures. For example, problems with the power supply system, including failures in the entire production workshop's power supply system, such as low power supply, blown fuses, and poor contact of power cord plugs; failure to turn on air or hydraulic pumps, failure to open the pneumatic or dual-valve components, or failure to open load relief valves or some pressure valves in the hydraulic transmission system.

When inspecting automated machinery, the following aspects should be included:

1. Inspect power sources, including the power supply systems for each piece of machinery and equipment as well as the power source for the production workshop. Check gas sources, including the pressure sources required for pneumatic equipment. Verify hydraulic sources, including the operational status of the hydraulic pumps necessary for the automated mechanical hydraulic units.

2. Verify the specific location of the sensors on the automated machinery to ensure there is no misalignment. Due to the negligence of equipment maintenance and management staff, some sensors may be misplaced, such as not being properly installed, common sensor failures, and sensitivity issues. Regularly check the specific location and sensitivity of the sensors, make timely adjustments for errors, and immediately replace any damaged sensors. Additionally, due to the vibration of automated machinery, most sensors will eventually become loose in their position after long-term use. Therefore, during routine maintenance, it is important to frequently check whether the sensors are correctly positioned and securely placed.

3. Relay inspections of automated machinery include checking for relay, flow control valves, pressure control valves, and magnetic inductive sensors. Over time, these components can experience sticking, which can prevent the normal operation of electrical control circuits and necessitate replacement. In pneumatic or hydraulic transmission systems, the throttle valve openings and pressure valve spring adjustments can also become loose or drag due to equipment vibration. Like sensors, these components are all critical parts of automated machinery that require regular maintenance.

4. Inspect Electrical, Pneumatic, and Hydraulic Circuit Connections - If no other issues arise from the first three steps, then inspect all control circuits. Check for any broken wires in the power circuit, particularly those within conduits, which may have been damaged due to pulling or scraping. Inspect the气管 for any damaging kinks. Verify that the hydraulic oil lines are not blocked. If the气管 shows significant kinks, replace it immediately. The hydraulic oil lines also require replacement.