First, the handwheel fault

Reason:

1, poor contact of hand wheel shaft selector switch.

2. The handwheel ratio selector switch has poor contact.

3. The handwheel pulse disc is damaged.

4. The connecting wire of handwheel is broken.

Solution:

1. Enter the system diagnosis, observe the contact condition of the shaft selection switch (whether the connecting wire is intact), and replace the switch if it is damaged.

2. Enter the system to diagnose and observe the contact condition of the rate switch (the connecting wire is intact), and replace the switch if it is damaged.

3. Remove the pulse disk and measure whether the power supply is normal and whether the resistance between+and A,+and B is normal. If damaged, please replace it.

4. Enter the system to diagnose and observe the contact of each switch, and then measure whether the contact of the connecting line between the axis-selecting switch, the speed switch and the pulse disk is on or off or replaced with the corresponding point of the terminal entering the system.

Second, XYZ axis and spindle box fault

Reason:

1, YZ axis shield is deformed and damaged.

2. The 2.YZ shaft transmission bearing is damaged.

3, clothing parameters and mechanical properties do not match.

4. The connection between the servo motor and the screw head is deformed with different axes.

5. The upper and lower guide rails of the heavy hammer in the column are loose and deviated.

6. Wear and vibration of plunger hammer chain and guide wheel.

7. The shaft pulley is not parallel to the motor end pulley.

8. Damage and deformation of ingot belt.

Solution:

1. Sheet metal circuit of protective cover.

2. Check the main and negative positioning bearings of the shaft, judge that the bearing at this end is damaged and replace it.

3. Adjust the servo parameters to match the machine. Servo gain, resonance suppression, load inertia.

4. Recalibrate the connector position or replace the connection.

5. Correct the guide rail and lubricate it with butter.

6. Check the wear of the chain and guide wheel, correct the balance of the heavy hammer and lubricate it with butter.

7. Correct the parallelism of the two pulleys, and the dynamic balance instrument will correct it.

8. Check the belt deformation and replace it carefully, clean the belt and adjust the belt tightness.

Three, guide oil pump, cutting oil pump failure

Reason:

1, the oil level of the pilot oil pump is insufficient.

2. The oil pressure valve of the guide rail oil pump is damaged.

3. The oil circuit of the machine tool is damaged.

4. The filter screen of guide rail oil pump core is blocked.

5. The quality of guide rail oil purchased by customers exceeds the standard.

6. The oil pumping time of the guide oil pump is set incorrectly.

7, electric box cut oil pump overload circuit breaker jumped.

8, cutting oil pump joint leakage.

9. The check valve of the cutting oil pump is damaged.

10, cutting oil pump motor coil is short-circuited.

1 1, reverse oil pump motor.

Solution:

1, just inject the guide rail oil.

2. Check whether the pressure of the oil pressure valve is insufficient. If it is damaged, please replace it.

3. Check whether the oil path of each shaft of the machine tool is unobstructed, damaged or not, and whether the oil drain hole is damaged. If damaged, please replace it.

4. Clean the oil pump filter.

5. Replace the qualified guide rail oil that meets the requirements of the oil pump.

6. Reset the correct refueling time.

7. After detecting whether the oil guide pump is in good condition, reset the short circuit again.

8. Find the leaking connector and reconnect it.

9. Check whether the check valve is blocked or damaged. If it is damaged, please replace it.

10. Replace the detection motor coil with the cutting oil pump motor.

1 1. Correct the motor direction of the cutting oil pump.

Fourth, processing failure.

Reason:

1, XYZ axis reverse clearance compensation is incorrect.

2.XYZ is very relaxed about the main players.

3.XYZ bearing is damaged.

4, the fuselage mechanical geometric accuracy deviation.

5, the spindle axial and radial channeling.

6. Improper adjustment of system servo parameters and machining parameters.

7. Customer programming error.

8. The screw and nut of XYZ shaft are worn.

Solution:

1, the dial indicator corrects the correct reverse clearance.

2. Adjust the tightness of the main inserts of each shaft, and observe the system load to the best state.

3. Check the bearing and replace it if it is damaged.

4, marble square, club instrument to detect the geometric accuracy of each project, such as deviation correction.

5, repair the spindle hole accuracy, spindle bearing clearance, such as can't repair the replacement.

6. Adjust servo position loop, speed loop gain, load inertia ratio, machining accuracy coefficient and acceleration and deceleration time constant.

7. Optimize and adjust the programming process.

8. Screw clearance compensation with laser interferometer.

Five, loose knife fault

Reason for failure:

1. The solenoid valve for loosening the cutter is damaged.

2. The spindle cylinder is damaged.

3. The shrapnel of the spindle is damaged.

4. The spindle claw is damaged.

5. The customer's air supply is insufficient.

6, loose knife button contact is poor.

7. The line is broken.

8. The oil cup of the knife cylinder is short of oil.

9. The customer's Latin handle does not meet the requirements and specifications.

Solution:

1. Check the action of the solenoid valve and replace it if it is damaged.

2. Check the action of the knife cylinder. If it is damaged, please replace it.

3. Detect the damage degree of shrapnel and replace shrapnel.

4. Check whether the spindle claw is in good condition. If it is damaged or worn, please replace it.

5. Check the damage degree of the button. If it is damaged, please replace it.

6. Check whether the line is disconnected.

7. Oil cup of knife cylinder.

8. Installation conforms to standard Latin.

Six, the machine tool can't return to zero.

Reason:

The contact of the 1. origin switch is stuck and cannot be moved.

2. The origin stop cannot keep the origin switch in the switch action position.

3. Due to the water inflow of the origin switch, the contact of the switch is poor.

4. The origin switch circuit is disconnected or the input signal source is faulty.

5. The input point of 5.PLC is burnt out.

Method:

1. Clean the stuck parts to make the moving parts move smoothly, or replace the travel switch.

2. Adjust the installation position of the travel switch, so that the contact of the zero switch can be stably pressed to the switch action position by the stopper.

3. Replace the travel switch and take waterproof measures.

4. Check the switch circuit for open circuit, short circuit and signal source (+24V DC power supply).

5. Replace the input points on the I/O board, set the parameters and modify the PLC program.

Seven, machine tool positive and negative hard limit alarm

Under normal circumstances, the alarm will not appear, but it may appear when the machine tool is operated before returning to zero. Because the system has no fixed mechanical coordinate system before returning to zero, the soft limit is invalid, and the machine tool can only be operated after returning to zero.

Reason:

1. The contact of the travel switch is pressed and stuck (overtravel).

2. The travel switch is damaged.

3. There are open circuit, short circuit and no signal source in the travel switch circuit.

4. The limit stop cannot press the switch contact to the action position.

5. The input point of 5.PLC is burnt out.

Method:

1, manually or by handwheel, or clean the switch contacts.

2. Replace the travel switch.

3, check whether there is a short circuit on the travel switch circuit, if there is a short circuit, re-processing. Check the signal source (+24V DC power supply).

4. Adjust the installation position of the travel switch so that it can normally press on the switch contact to the action position.

5. Replace the input points on the I/O board, set the parameters and modify the PLC program.

Eight, tool change fault

Reason:

1, insufficient air pressure.

2. The button for releasing the knife has poor contact or the line is open.

3. The PLC input address point of the tool release button is burnt out or there is no signal source (+24V).

4, loose knife relay does not act.

5. The solenoid valve for loosening the cutter is damaged.

6, the amount of knives is insufficient.

7. The oil cup of the knife cylinder is short of oil.

8, knife cylinder failure.

Method:

1, check the air pressure until it reaches 6 kg1kg.

2. Replace the switch or check the circuit.

3. Replace the PLC input port on the I/O board or check the PLC input signal source, and modify the PLC program.

4, check the PLC output signal/no, PLC output port burned out, modify the PLC program.

5. If the solenoid valve coil is burnt out, replace it. If the solenoid valve body leaks and the piston does not move, replace the valve body.

6. Adjust the punching amount to loosen the knife smoothly.

7. Add hydraulic oil into the oil cup of the drilling cylinder.

8. If the internal thread of the drilling cylinder is loose and leaks, tighten the screw again and replace the sealing ring in the cylinder. If it cannot be repaired, replace the drill string.

9. Abnormal sound during triaxial operation

Reason:

1, bearing failure.

2. The lead screw sleeve and the guide rail are unbalanced.

3. Due to the serious wear of the wear-resistant sheet, the guide rail is seriously scratched.

4. The servo motor gain does not match.

Method:

1. Replace bearing.

2. Correct the lead screw bus.

3. Re-attach the wear-resistant sheet, and rework the guide rail when the scratch is too serious.

4. Adjust the servo gain parameters to match the machine.

Lubrication failure

Reason:

1, lubricating pump tank is short of oil.

2, lubricating pump oil time is too short.

3. The pressure relief mechanism of lubricating pump releases pressure too fast.

4. Oil leakage from the oil pipeline.

5. The check valve in the oil circuit doesn't work.

6. The oil pump motor is damaged.

7. The control circuit board of lubricating pump is damaged.

Method:

1. Add lubricating oil to the upper limit line.

2. The refueling time is adjusted to 32 minutes refueling 16 seconds.

3. Adjustable pressure relief speed can be adjusted, but it can't be adjusted.

4, check the tubing interface and handle.

5. Replace the check valve.

6. Replace the lubricating pump.

7. Replace the control circuit board.

8. In case of emergency, in I/F diagnosis, it is mandatory that M64S is 1A and E60 is 32, so the machine tool can work temporarily.

XI。 The program cannot be transmitted, and P460, P46 1 and P462 alarms appear.

Method:

1. Check the transmission line for open circuit, virtual welding and plug connection.

2, computer transmission software parameters should be consistent with the machine.

3. Replace the computer and try to transmit.

4. Whether the grounding is stable.

Twelve. Tool library problem

Reason:

1, tool change suddenly stopped, and tool change cannot be continued.

2. The bucket knife magazine won't come out.

3, can't loosen the knife in the process of changing the knife.

4. The cutter head cannot rotate.

5. The time difference of sudden reversal of the cutter head is half a cutter position.

6. When changing knives, an alarm of loosening and tightening knives will be issued.

7. When the tool is retracted during tool changing, the spindle side makes a loud noise.

8. After replacement, the spindle cannot be loaded with the cutter (the cutter is abnormally loose).

Method:

1, whether the air pressure is enough (6 kg).

2. Check whether the tool withdrawing signal of the tool magazine is in place, and whether the solenoid valve circuit and PLC are output in and out of the tool magazine.

3. Adjust the punching amount and check whether there is water in the punching cylinder.

4. After the cutter head comes out, it reverses, the power cord of the motor in the tool magazine is open, and the contacts and relays are damaged.

5. The motor braking mechanism of the tool magazine is loose and can't be braked normally.

6. Check the air pressure, whether the cylinder is fully running (whether there is water) and whether the knife loosening switch is pressed in place, but not too much (as long as there is signal input).

7. Adjust the punching amount.

8. Modify the tool changing program (macro program O9999).

Thirteen, the machine can't be electrified.

Reason:

1. The three-phase contact of the main switch of power supply is poor or the switch is damaged.

2. The operation panel cannot be powered on.

Method:

1. Replace the main power switch.

Step 2 check.

A whether the switching power supply has voltage output (+24V).

B, the system power switch has poor contact and the power switch is open.

C, the system power relay contact is not good, can't self-locking.

D, the line is open.

E, drive the power-on AC contact, and the power-on relay of the system fails.

F, whether the circuit breaker trips g, whether the system is ready for normal work or whether the Z-axis driver is damaged, and whether there is automatic power-on signal output.

Fourteen, cooling water pump failure

1, check whether the water pump is burnt out.

2. Whether the power phase sequence is reversed.

3. AC contacts and relays are burnt out.

4, the panel button switch with or without input signal.

Fifteen. Blowing failure

1, check whether the solenoid valve operates.

2, check whether there is any action on the blowing relay.

3. There is no signal on the panel button and PLC output interface.