I. Mechanical Structure Failures
1. Jerky Movement or Abnormal Noise
- Causes: Lack of lubrication in friction-prone areas like guides and bearings; welding slag or dust trapped in gear/chain drives; loose connections causing part misalignment.
- Symptoms: Uneven rotation or tilting, accompanied by metal grinding or impact noises.
2. Positioning Accuracy Deviation
- Causes: Malfunctioning limit devices (e.g., limit switches); excessive backlash due to gear/worm wear; guide rail misalignment.
- Symptoms: The worktable fails to stop precisely at preset positions, affecting welding alignment accuracy.
3. Structural Deformation or Fracture
- Causes: Long-term overload operation; uneven local heating during welding; bolt loosening leading to vibration fatigue.
- Symptoms: Worktable tilting, frame cracking, or even safety hazards in severe cases.
II. Drive System Failures
1. Motor Failure
- Common Issues: Overheating (overload, poor cooling), bearing noise (lack of lubrication or wear), failure to start (loose wiring, burnt windings).
- Inspection: Measure winding resistance with a multimeter—short circuits or open circuits require repair or replacement.
2. Reducer Failure
- Common Issues: Oil leakage (seal aging), transmission noise (gear wear or lack of lubrication), abnormal output speed (internal jamming).
- Solution: Regularly check oil levels and replace damaged seals or worn gears.
III. Electrical System Failures
1. Control Failure
- Causes: PLC program errors, burnt contactor/relay contacts, interrupted sensor signals (e.g., photoelectric switches blocked by welding slag).
- Symptoms: Unresponsive control panel buttons or incorrect machine movements.
2. Circuit Faults
- Common Issues: Short circuits/leakage due to damaged cables, loose or oxidized terminals, blown fuses (overload or short circuit).
- Troubleshooting: Check circuit continuity with a multimeter, replace damaged parts, and secure connections.
IV. Hydraulic/Pneumatic System Failures (For Relevant Positioner Types)
1. Hydraulic System Failure
- Common Issues: Slow or weak cylinder movement (low oil level, clogged lines, hydraulic pump failure); oil leaks (cracked hoses, damaged seals).
- Solution: Check oil levels and filters, replace damaged hoses/seals, and repair the hydraulic pump if necessary.
2. Pneumatic System Failure
- Common Issues: Insufficient air pressure (faulty regulator, leaks); jerky cylinder movement (condensation buildup, clogged components).
- Solution: Regularly drain water, clean pneumatic components, and replace faulty regulators or solenoid valves.
V. Fault Handling Principles
- Immediate Shutdown: Stop operation upon detecting abnormalities to prevent secondary damage.
- Simple vs. Complex Faults: Minor issues (e.g., lack of lubrication, loose parts) can be addressed per the manual; major faults (e.g., motor burnout, control system failure) require professional repair.
- Safety First: Always disconnect power and air supply before maintenance, and use safety measures (e.g., warning signs).
Regular maintenance significantly reduces these failures. Strictly follow the equipment manual for daily checks and scheduled servicing.
