In modern manufacturing, fully automatic hydraulic lathes have become the main production force with their efficient and precise machining capabilities. However, its complex electrical system is prone to malfunctions during long-term operation, which can affect production efficiency and product quality. Mastering common electrical fault handling methods is the key to ensuring stable operation of the lathe.
1. Power failure and handling
Power failure is one of the most common issues. When the lathe cannot be started, the first step is to check the external power supply line to see if there are any power outages, damaged lines, or short circuits. A multimeter can be used to detect the power supply voltage. If the voltage is abnormal, contact the power department or electrician for maintenance. If the external power supply is normal, it is necessary to check the power switch, fuse and other components inside the lathe. When a fuse is blown, it cannot be directly replaced with a fuse of the same specification. Instead, the circuit should be checked for a short circuit, such as checking whether the motor, transformer, control circuit, etc. have insulation damage, identifying the fault point and repairing it before replacing the fuse to ensure that the new fuse will not melt again.
2. Control system faults and their handling
The control system of the lathe is the core part, and faults in the PLC (Programmable Logic Controller) or CNC system can cause abnormal operation of the lathe. When the control system reports an error, carefully check the fault code on the operation panel and understand the corresponding cause of the fault by referring to the equipment manual. For example, if a servo alarm occurs, it may be due to servo motor overload, driver failure, or encoder feedback abnormality. At this point, diagnostic tools can be used to check whether the operating current of the servo motor, the output voltage of the driver, and the signal of the encoder are normal. If the current of the servo motor is too high, it is necessary to check whether the motor load is too heavy and whether the mechanical transmission components are stuck; If the drive fails, the faulty drive can be determined through replacement method and repaired or replaced; If the encoder feedback is abnormal, it is necessary to check whether the encoder connection wire is loose, whether the encoder is damaged, and replace it if necessary.
3. Sensor malfunction and handling
The fully automatic hydraulic lathe relies on multiple sensors to monitor the operating status of the equipment, such as position sensors, pressure sensors, etc. When the sensor malfunctions, the lathe may not be able to accurately control the machining dimensions or experience abnormal movements. If the position sensor fails, the positioning accuracy of the lathe will be affected, leading to an increase in machining errors. At this point, an oscilloscope can be used to detect the output signal of the sensor and determine whether the sensor is working properly. If the sensor has no signal output, it is necessary to check whether the power supply and connection wires of the sensor are normal. If there is no hardware problem, it may be due to damage to the internal circuit of the sensor and replacement is needed. For hydraulic system pressure abnormalities caused by pressure sensor failures, it is necessary to check whether the sensor installation is loose or blocked by impurities. After cleaning or reinstalling, if the problem is still not solved, the sensor also needs to be replaced.
In the face of electrical faults in fully automatic hydraulic lathes, by using systematic troubleshooting methods to accurately locate the fault point and taking appropriate measures, it is possible to quickly restore the normal operation of the lathe and ensure smooth production.