Electrical faults may occur during the operation of busbar processing machines. Fault analysis is equivalent to troubleshooting process. Here are common solutions for typical electrical faults.

1. Power Supply Faults

Power supply provides energy for the control system and the whole machine. Minor failures may lead to data loss and shutdown, while severe faults can cause partial or total system damage.

Power grid design in western countries seldom considers voltage fluctuation and harmonic interference thanks to stable power quality. Such design cannot fully adapt to domestic power conditions with frequent fluctuations and harmonics. Combined with improper manual operation, power-related faults tend to happen.

2. Position Loop Faults of CNC System

Position loop alarm

Possible causes include open circuit of position measuring loop, damaged measuring components and missing interface signals for position control.

Axis moves without operation commands

It may result from excessive drift, positive feedback connection of position or speed loop, broken feedback wiring and defective measuring elements.

3. Failure to Return to Mechanical Zero Point

Potential reasons: the moving direction deviates from the zero position, encoder damage or disconnected wiring, offset grating zero mark and faulty homing deceleration switch.

4. Degraded Dynamic Performance and Poor Machining Quality

Machine vibration may occur at certain running speed.

Major mechanical reasons include excessive transmission clearance, severe part wear and insufficient guide rail lubrication.

From the electrical control perspective, mismatched parameters of speed loop and position loop will also trigger the problem. Relevant parameters shall be readjusted after mechanical faults are eliminated.

5. Occasional Shutdown Failure

Two common causes are concluded:

First, inherent software defects lead to shutdown under specific operation combinations. The fault can be eliminated by power restart.

Second, adverse environmental impact, such as strong electromagnetic interference from power grid and surrounding equipment, overhigh temperature and humidity. These factors are often ignored. For instance, machines placed near open doors, long-term open electric cabinet doors, and nearby equipment generating dust, metal scraps and water mist will easily induce intermittent faults.

Above are the conventional troubleshooting methods. Feel free to contact us if you have any questions.