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Causes and analysis of the bending machine failure

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Causes and analysis of the bending machine failure

作者: Release Date: 2016-07-27 Author: Click:

1. The main motor cannot start

the reason:

24V 控制电源等; 1. The main motor startup circuit is faulty, such as: the emergency stop button is not released, the cable wiring is loose, the 24V control power, etc .;

2. The related components of the starting part of the main motor are faulty, such as overload protection or damage to thermal relays, circuit breakers, AC contactors, etc .;

3. Power problems;

Measures:

、检查主电机启动电路是否有急停未释放、接线松动, 24V 控制电源; 1. Check if the start circuit of the main motor has an emergency stop that is not released, the wiring is loose, and the 24V control power supply;

2. Check whether the components of the starting circuit of the main motor have overload protection. If there is a need to analyze the reasons, check whether the components are damaged;

3. Check whether the three-phase power is normal;


2. The slider cannot go down quickly

the reason:

1. The slider guide is adjusted too tightly;

2. The back gauge shaft is not in place;

3 , the slider is no longer on the dead point;

4. The signal such as foot switch does not enter the module;

5. The proportional servo valve is faulty;

Measures:

1. Check if the slide guide is suitable;

X 实际位置处是否有光标,或在手动界面检查后挡料轴的编程值与实际值是否一致; 2. Check whether there is a cursor at the actual position of X on the system , or check whether the programmed value of the backgauge axis is consistent with the actual value in the manual interface;

Y 轴状态应该为 “1” ,如果为 “6”, 检查 Y 轴实际坐标,数值应小于 Y 轴与回程的差值; 3. The state of the Y axis on the system should be "1" . If it is "6", check the actual coordinates of the Y axis. The value should be less than the difference between the Y axis and the return;

4. According to the electrical diagram, check whether the input signals such as the foot switch are normal;

5 , check whether the proportional servo valve feedback is normal;


3. The slider cannot be bent or the bending speed is very slow

the reason:

1. The slider has not reached the speed conversion point;

Y 轴折弯部分参数设置不好; 2. The parameter setting of the system's Y- axis bending part is not good;

3. Insufficient pressure, such as: programming operation reasons, machine parameter setting reasons, hydraulic reasons, etc .;

Measures

Y 轴状态是否由 “2” 变为 “3” Y 轴实际值应大于速度转换点值,如果不是需调整快进部分参数; 1. Check whether the state of the Y axis changes from "2" to "3" . The actual value of the Y axis should be greater than the value of the speed conversion point. If it is not necessary to adjust the parameters of the fast forward;

Y 轴折弯部分参数; 2. Adjust the parameters of the Y- axis bending part;

3. Check whether it is the reason for programming operation, parameter setting reason, or hydraulic pressure; you can first check the signal of main pressure and proportional pressure valve with the help of pressure gauge, multimeter, etc., and then check whether the proportional pressure valve and main pressure reducing valve are stuck. Hold, then check the filter element and oil, and finally check the oil pump and its coupling;


4.Slider sometimes cannot return when bending

the reason:

1. It is not possible to return without load, which may be a parameter problem or a hydraulic failure;

2. The backhaul cannot be performed during processing, and the workpiece angle has not reached the set value;

3. It is not possible to return during processing, the workpiece angle has exceeded the set value;

Measures:

Y 轴折弯部分参数,折弯参数应根据实际调试,部分增益太小,滑块会折不动或折不到位,太大滑块会抖动,应该将参数调整为动作时滑块不抖动,增益尽量大一点;或者是诊断程序中左、右阀偏置设置不好,太小 Y 轴不能到位,太大 Y 轴不能卸荷;如果是液压故障,需要检查主压力,检查 PV S5 是否一直处于得电位置; 1. Debug some parameters of the Y- axis bending. The bending parameters should be adjusted according to the actual situation. Some gains are too small, the slider will not be able to move or not in place. Do not shake, the gain should be as large as possible; or the left and right valve offset settings are not good in the diagnostic program, too small Y axis cannot be in place, too large Y axis cannot be unloaded; if it is a hydraulic fault, you need to check the main pressure, check PV Whether valve S5 is always in the energized position;

Y 轴折弯部分参数增益设的偏小,可适当增加;或者压力不够,分析压力不够原因,是编程原因还是信号、液压部分原因;编程原因主要有模具选择、板厚、材质、工件长度、折弯方式等,液压原因主要有油泵是否内泄漏,比例压力阀是否污染或损坏,滤芯是否被堵住,油液是否已经污染等; 2. The parameter gain of the Y- axis bending part may be set too small and can be appropriately increased; or the pressure is not enough to analyze the cause of the insufficient pressure. It is the programming reason or the signal and hydraulic part. The programming reasons mainly include die selection, plate thickness, material, Workpiece length, bending method, etc. The main reasons for hydraulic pressure are whether the oil pump is leaking inside, whether the proportional pressure valve is contaminated or damaged, whether the filter element is blocked, whether the oil has been contaminated, etc .;

3. Mainly for programming and operation reasons, check the programmed programs and processed workpieces;


5. The slider does not move well

the reason;

1. The slider rail is not tight tightly;

2. The slider lock nut is loose;

3. Machine parameters need to be adjusted;

4. The gain and zero position on the proportional servo valve amplifier need to be adjusted;

5. The pressure setting of the back pressure valve is incorrect or the two sides are unbalanced. The back pressure setting is too small, the slider will slowly slide down, and it will shake during the process; the two sides of the back pressure are unbalanced, and the slider will twist when running;

Measures:

1. Re-adjust the gap of the guide rail;

2. Retighten, if the lock nut and the screw are too loose, it needs to be replaced;

3. If there is a reference curve, it should be adjusted according to the reference curve;

BOSCH REXROTH 阀可调,但需谨慎; 4. Only BOSCH and REXROTH valves can be adjusted, but be careful;

5. Use the pressure gauge to adjust the pressure of the back pressure valve and make both sides consistent;


6. Sometimes the main motor stops automatically, thermal relay, circuit breaker protection

the reason:

、比例压力阀、主减压阀被卡住,机床一直在加压状态; 1. The proportional pressure valve and main pressure reducing valve are stuck, and the machine tool is always under pressure;

2. The filter element is clogged, the oil output is not smooth, and the oil pump pressure is always high;

3. The oil has been used for too long and has been polluted;

4. Poor oil quality;

5 , circuit breakers, thermal relay problems, the operation can not reach the rated current;

6. The system control pressure output part is faulty and sends out wrong signals to make the proportional pressure valve work all the time;

Measures:

1. Cleaning proportional pressure valve and main pressure reducing valve;

2. Replace the filter element and check the degree of oil pollution;

3. Immediately replace the oil filter element;

4. Replace with recommended oil;

5. Replace circuit breaker and thermal relay;

6 , check the system output;


7. Any valve is stuck

the reason:

1. The oil has been used for too long and has been polluted;

2. Poor oil quality;

3. Whether the rubber skin of the oil inlet in the fuel tank is aging;

Measures:

1. It is recommended that customers change the oil on time;

2. Replace the recommended oil;

3. Replace oil-resistant rubber sheet;


8.Cylinder down

the reason:

1. Back pressure valve and poppet valve are dirty or damaged;

2. Low back pressure;

3. Gray ring strain and wear;

4. The internal wall of the oil tank is strained;

5 分钟下滑小于 0.50mm ,则为正常,此现象主要由于液压油特性引起; 5. If the slider stops at any position and slides slowly, and the 5- minute slide is less than 0.50mm , it is normal. This phenomenon is mainly caused by the characteristics of hydraulic oil

Measures:

1. Clean back pressure valve and poppet valve, and replace if damaged;

2. Readjust the back pressure valve pressure according to the standard;

3. Replace the Gray ring, and check the cause of the strain and wear of the Gley ring;

4 , generally due to oil pollution, replace the cylinder, seal;

5. No processing required;


9. When pressing the mold, the height of the two sides is not consistent

the reason:

1. The two sides of the back pressure are not consistent, and the back pressure setting may be too high;

Measures:

1. Adjust the back pressure on both sides to the specified value and keep the same;


10. The slider waits too long at the speed transition point

the reason:

1. Air leakage in the oil suction port in the fuel tank;

2. The filling valve is faulty, such as the valve core is stuck due to improper installation, or the spring tension is insufficient;

Y 轴工进参数设置不好; 3 , Y axis industrial feed parameter setting is not good;

Measures:

1. Check the seal of the rubber sheet and reinstall the cover here;

2. Check the installation of the filling valve, check the action of the spool, and check the spring tension;

Y 轴工进参数 3.Adjust the Y- axis working parameters


11. The angle of the workpiece changes too much when bending

the reason:

1. The inertia parameter setting of the machine tool is inappropriate;

2. The material of the processed plate;

Measures:

1. Re-adjust the inertia parameters of the machine tool;

2. Check the material of the board;


12. When the workpiece has multiple bends, the size error of the accumulated error is too large

the reason:

1. There are many bends in the workpiece, leading to a large cumulative error;

2. The bending sequence is unreasonable;

Measures:

精调每道折弯的精度,使角度尽量在负差,尺寸尽可能准确; 1. Finely adjust the accuracy of each bend to make the angle as negative as possible and the size as accurate as possible;

在可能的情况下调整折弯顺序; 2. Adjust the bending sequence if possible;


13. The pressure automatically calculated by the system is greater than the mold impedance

the reason:

1. The die selection is unreasonable during programming;

2. The impedance setting of the mold is incorrect;

3. The bending method is incorrectly selected during programming;

4. The parameters of machine constants are modified, such as material parameters, unit selection and other parameters;

Measures:

1. The mold should be selected according to the relationship between the thickness of the plate and the opening of the lower mold;

2. Set the mold impedance correctly;

3. Check the program;

4 , check the machine constant parameters;


14. When programming a large arc bend, the system calculation is slow or freezes

the reason:

X 值超过参数中 X 轴的最大值; 1. The X value set during programming exceeds the maximum value of the X axis in the parameter ;

Measures:

1. Check the programmed procedures;


15. Oil temperature is too high

the reason:

1. Failure of the hydraulic part, such as blocked filter element, oil pollution, deterioration, etc .;

2. Work under high pressure for a long time;

Measures:

1. Check the filter element and oil, and replace if necessary;

2. Check whether the reason for long-term high-voltage work is actual need or other reasons;


16.Inaccurate machining workpiece angle

the reason:

1. If the error is very large, it may be a programming error, a loose slider connection, a failure of the encoder, etc .;

2. Normally, there is a little error, which can be corrected on the system. After the correction, it can work stably, which is normal.

3. The angle is unstable and often changes, which may be related to the loose connection of the slider, the failure of the grating ruler, the material and so on;

Measures:

、检查所运行程序,重点检查程序中的模具、材料、板厚、工件长度、折弯方式是否与实际操作一致,滑块连接是否松动,光栅尺连接是否牢固; 1. Check the running program, and focus on checking whether the mold, material, plate thickness, workpiece length, bending method in the program are consistent with the actual operation, whether the slider connection is loose, and the scale is connected firmly;

、正常有一点误差,可有多方面原因引起,例如:编程的材料厚度与实际使用的厚度之间误差;材质的均匀度、模具的磨损、操作等原因; 2. There is a little error in normal, which can be caused by many reasons, for example: the error between the thickness of the programmed material and the thickness actually used; the uniformity of the material, the wear of the mold, the operation and other reasons;

、检查Y 轴重复定位精度,检查滑块连接、光栅尺连接是否正常,如果正常,则很可能与材料材质有关; 3. Check the repeated positioning accuracy of the Y axis, check whether the slider connection and the scale connection are normal. If normal, it is likely to be related to the material;


17. Inaccurate workpiece size

the reason:

1. The size is unstable and often changes, which may be related to factors such as machine tool power, servo drive, servo motor encoder and related cables, systems, mechanical connection of lead screw, timing belt (wheel) and other factors;

2. The size is biased but stable, and it is mostly related to the parallelism, straightness, parallelism, and verticality of the back gauge crossbeam;

90° ,导致尺寸偏小; 3. When positioning with bent edges, the bend angle of this road is greater than 90 ° , resulting in a small size;

Measures:

0.02mm ,如相差较大,需对可能的因素逐一检查,如是由伺服驱动、伺服电机编码器、系统等原因引起,最好由制造商处理; 1. The repeated positioning accuracy of the blanking shaft after inspection is generally less than 0.02mm . If the difference is large, it is necessary to check the possible factors one by one. If it is caused by servo drive, servo motor encoder, system, etc., it is best to be produced by the manufacturer. deal with;

2. First check the parallelism and straightness of the beam, then check the parallelism and verticality of the stop fingers;

90° 3. If using bending edges for positioning, try to make the curve not more than 90 ° ;



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