The electrical faults of CNC machine tools can be classified according to the nature, appearance, cause or consequence of the fault.
(1) It is divided into hardware faults and software faults in the parts where the fault occurs. Hardware failure refers to the abnormal state or even damage of electronic, electrical components, printed circuit boards, wires and cables, connectors, etc., which are faults that need to be repaired or even replaced. The software fault generally refers to the fault generated in the plc logic control program, which needs to input or modify some data or even modify the PLC program to eliminate the fault. A part program fault is also a software fault. The most serious software failure is the loss or even loss of the CNC system software, which is only solved by contacting the manufacturer or its service organization.
(2) In the presence or absence of an indication when the fault occurs, it is divided into a fault with a diagnostic indication and a fault with no diagnostic indication. Today's CNC systems are designed with a perfect self-diagnostic program that monitors the software and hardware performance of the entire system. Once a fault is discovered, it will immediately alert or display a brief text on the screen, combined with the diagnostic manual provided with the system. You can find the cause and location of the fault, and there are also troubleshooting tips. Machine tool builders also have relevant fault indications and diagnostic instructions for specific machine designs. The above two parts have diagnostic indication faults and various types of indicators on each electrical device make it easier to eliminate most electrical faults. Part of the fault without diagnostic indication is due to the incompleteness of the above two diagnostic procedures (such as the switch is not closed, the plug is loose, etc.). Such faults depend on the working process and fault phenomena and consequences before the fault occurs, and rely on the maintenance personnel to analyze and eliminate the familiarity and technical level of the machine tool.
(3) It is divided into destructive faults and non-destructive faults in the presence or absence of damage when faults occur. For destructive faults, damage to the workpiece or even the machine tool, replay is not allowed during maintenance. At this time, it can only be excluded according to the phenomenon of fault occurrence, and the technical difficulty is high and there is a certain risk. If the workpiece may be damaged, remove the workpiece and try to highlight the fault process, but be careful.
(4) According to the probability of failure, it is divided into systemic fault and random fault. Systematic faults are defined faults that must occur as long as certain conditions are met. Random faults are occasional faults under the same conditions. The analysis of such faults is difficult, usually with the mechanical structure of the machine tool. Local looseness misalignment, partial electrical workpiece drift or reliability degradation, and high internal temperature of the electrical device. The analysis of such failures may be eliminated after repeated trials and comprehensive judgments.
(5) Measured by the motion quality characteristics of the machine tool, it is a malfunction of the machine tool's motion characteristics. In this case, the machine tool can operate normally but does not produce a qualified workpiece. For example, the positioning accuracy of the machine tool is too poor, the reverse dead zone is too large, and the coordinate operation is not stable. Such faults must be diagnosed by the instrument to determine the error, the machine, the electrical link, and then through the optimization of the mechanical transmission system, CNC system and servo system to eliminate.
The classification of faults here is to facilitate the analysis and elimination of faults, and the generation of faults is often a mixture of multiple types, which requires maintenance personnel to analyze in detail, and take corresponding analysis and exclusion methods according to the above classification.
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