Common equipment failures and solutions -Production line equipment
Note: If the machine fails, do not deal with it manually. First observe the state of the machine (manual/automatic), then check the status of PLC (running/not running/fault), and then check the input points of PLC (whether there is a safety system not reset, such as emergency stop, safety photoelectric, grating, etc.). After confirmation, check the output state (mainly to determine the fault point of PLC and inverter), then check the external line, and finally confirm the mechanical problem (because the probability of mechanical failure is minimal).
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Categories of Failures |
Possible causes |
Solution way |
Remark |
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Press the automatic operation key when running the machine, the machine has no action |
1. The PLC is damaged 2. The machine is not fully reset |
Replace PLC(contact manufacturer) Check each origin signal |
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Frequency converter displays overload alarm |
1. The voltage is unstable 2. The cargo is overloaded 3. Frequency conversion parameters are not accurate |
Improve the quality of power supply. Lighten the cargo. Optimizing frequency conversion parameters |
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Film carriage does not send film |
1. The DC speed regulating box is damaged and has no output 2. The control system is faulty |
Replace it. Optimize the program |
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Failure of motor |
1. The motor is damaged 2. The program has no motor control output 3. Program control logic error 4. Signal interference and insufficient fault tolerance |
Replace it. Check the program and optimize the software Check the program and optimize the software Check the program and optimize the software |
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The membrane head is too long to wrap in |
1. Insufficient air volume 2. Short blowing time 3. The installation position is incorrect 4. Structural problems |
Improve air source Extend the time Optimize the location Improve the structure |
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Misoperation of cylinder |
1. Low air pressure 2. The solenoid valve is faulty 3. The air circuit is faulty 4. The magnetic switch has no signal |
Improve air source - Check wiring and replace body Optimize the program, check the air path, optimize, replace the gas pipe, cylinder Replace and check the wiring |
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Incorrect operation of the oil cylinder |
1. Insufficient oil pressure 2. The solenoid valve is faulty 3. The pipe is faulty 4. The limit is faulty |
Improve oil pressure Check the line Replacement of valve body Optimize the program Check the oil line. Optimize Replace tubing. Oil cylinder replace Check the line |
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Abnormal sound of the chain/plate cable |
1. Contact surface wear 2. Coaxiality of the transmission system. Poor flatness fit |
replace Reinstall |
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The sensor signals are incorrect |
1. Poor light (photoelectric) 2. Environmental interference 3. Program bugs |
Improve the environment. Optimize the installation location Improve and optimize the installation position. Eliminate Distractions Program error tolerance. Lack of error signal recognition ability. Need to optimize |
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The conveyor line does not stop |
1. Program bugs 2. The sensor has no signal or interference |
Lack of error action detection and judgment and safety instruction procedures Check photoelectric. Wiring. Improve the Environment |
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The action on the front and rear ends of the connected device is incorrect |
1. The interconnection signal transmission is unreliable 2. Communication problems 3. Programming software bugs |
Check the cable connection. No virtual connection. Missed connection. Wrong connection Check software for defects and fault tolerance Check whether the wiring of power line and signal line is compliant. Eliminate distractions Check communication lines and interfaces Check the communication Settings of the front and rear devices Check external factors. Avoid interference between power line and ambient magnetic field Check the hardware (device port. Communication module. Switch) Checking the Software Version Check program communication Settings. Test program functionality. Analyze program fault tolerance |
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Automatic film breaking fault |
1. The heating wire is not hot 2. The swing arm is not in position. The heating wire is not in contact with the film 3.PLC has no heating instruction output 4. Broken film cylinder has no action |
Check the wiring or replace the heating wire Check the adjustment stop bit Check program and PLC output for damage Check the cylinder or solenoid valve |
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Clip film fault |
1. The rubber cover of the film clamping device falls off. The clip film is not strong 2. Not enough air pressure 3.PLC no clip film instruction output 4. The solenoid valve is damaged 5. The cylinder is damaged |
Replace the rubber Check the air source Check whether the program and PLC output are damaged Replace the solenoid valve Replace the cylinder |
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The touch/text screen is faulty |
1. No communication with PLC 2. It is not displayed 3. Display alarm information |
Improve low-voltage power supply Replace the communication cable Replace the PLC Optimize the program Checking the low-voltage power Supply Replace the screen Optimize the program Replace the screen |
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Shandong Dyehome Intelligent Equipment Co.,LtdPhone：0086-17362172587
Email：machinedyehome@gmail.com
Add：Building 62, 3000 Meili East Road, DmiPark, Wujiapu Street, Huaiyin District, Jinan City,Shandong Province
Jinan Jiasen Packaging Equipment Co., LtdPhone：0086-15665802370
Add：High-end Equipment Manufacturing Industrial Park, East Industrial New Town, Ancheng Town, Pingyin County, Jinan City, Shandong Province
Shandong Golden Pack Intelligent Equipment Co.,LtdPhone：0086-15662690213
Add：High-end Equipment Manufacturing Industrial Park, East Industrial New Town, Ancheng Town, Pingyin County, Jinan City, Shandong Province
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