1、 Reason for handwheel malfunction:

1. Poor contact of handwheel shaft selection switch

2. Poor contact of handwheel magnification selection switch

3. Hand wheel pulse occurs and the disc is damaged

4. The handwheel connecting wire is broken

Solution:

1. Enter the system diagnosis and observe the corresponding contact condition of the axis selection switch (the condition of the connecting wire is intact). If it is damaged, replace it

The switch can solve the problem

2. Enter the system for diagnosis and observe the corresponding contact condition of the magnification switch (the condition of the connecting wire is intact). If it is damaged, replace it

The switch can solve the problem

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

replace

4. Enter the system diagnosis and observe the corresponding contact conditions of each switch. Furthermore, measure the axis selection switch, magnification switch, and pulse

Are the contacts of the connecting wires between the punch plates connected to the corresponding points of the input system terminals open or closed? If they are broken, they can be replaced.

2、 Causes of faults in X, Y, Z axes and spindle housing:

1. The Y-axis protective cover is deformed and damaged

2. The Y-axis and Z-axis transmission bearings are damaged

3. The server parameters do not match the mechanical characteristics.

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

5. The upper and lower guide rails of the heavy hammer inside the column are loose and offset

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

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

8. The spindle belt is damaged and deformed

Solution:

1. Protective cover sheet metal return

2. Check the shaft main and negative positioning bearings, determine which end of the bearing is damaged, and replace it

3. Adjust the servo parameters to match the machinery. (Servo gain, resonance suppression, load inertia)

4. Re calibrate the position of the connector 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 between the two pulleys and calibrate the dynamic balance instrument

8. Check the deformation and severe damage of the belt, replace it, clean the belt, and adjust the tightness of the belt.

3、 Reason for malfunction of guide rail oil pump and cutting oil pump:

1. Insufficient oil level in the guide rail oil pump

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 the guide rail oil pump core is blocked

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

6. Incorrect oil injection time setting for guide rail oil pump

7. The circuit breaker in the overload electrical box of the cutting oil pump has tripped

8. Air leakage at the cutting oil pump joint

9. The one-way valve of the cutting oil pump is damaged

10. Short circuit of cutting oil pump motor coil

11. Cutting oil pump motor in opposite direction

Solution:

1. Inject guide rail oil

2. Check if the oil pressure valve has insufficient pressure, and replace it if it is damaged

3. Check whether the oil circuits of each axis of the machine tool are unobstructed, broken, and whether the oil discharge is damaged. Replace if damaged

4. Clean the oil pump filter screen

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

6. Reset the correct oiling time

7. After checking whether the guide rail oil pump is intact, reset the short circuit again

8. Find the leaking joint and reconnect it

9. Check whether the one-way valve is blocked or damaged, and replace it if it is damaged

10. Replace the cutting oil pump motor by testing the motor coil

11. Correct the direction of the cutting oil pump motor

4、 Reason for processing failure:

1. Incorrect compensation for the reverse clearance of X, Y, and Z axes

2. The main insert strip in X, Y, and Z directions is loose

3. The X Y Z bearings are damaged

4. Mechanical geometric accuracy deviation of the aircraft body

5. Axial and radial movement of the main shaft

6. Improper adjustment of system servo parameters and processing parameters

7. Customer programming error

8. Wear of X, Y, and Z axis screws and nuts

Solution:

1. Correct calibration of dial gauge with reverse clearance

2. Adjust the tightness of each axis main strip and observe the system load to adjust it to the optimal state

3. Check the condition of the bearings and replace them if damaged

4. Use a marble angle ruler and a golf club to measure the geometric accuracy of each item, such as deviation correction

5. Repair the accuracy of the spindle inner hole and the clearance of the spindle bearing movement. If it cannot be repaired, replace it

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

7. Optimize and adjust programming processes

8. Use a laser interferometer to compensate for the gap between the lead screws

5、 Reason for loose blade malfunction:

1. The loosening knife solenoid valve is damaged

2. The spindle cutting cylinder is damaged

3. Damaged spindle spring plate

4. The spindle claw is damaged

5. Insufficient customer gas supply

6. Poor contact of the loosening knife button

7. Line breakage

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

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

Solution:

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

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

3. Check the degree of damage to the spring plate and replace it

4. Check if the spindle claw is intact, damaged or worn, and replace it

5. Check the degree of damage to the button and replace it if it is damaged

6. Check if the circuit is broken

7. Fill the oil cup of the knife cylinder with oil

8. Install in accordance with standard Latin

6、 Reason why the machine tool cannot return to zero:

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

2. The origin block cannot press the origin switch to the switch action position

3. Water ingress into the origin switch causes poor contact between the switch contacts

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

5. PLC input point burned out

Countermeasure:

1. Clean the stuck area to ensure smooth movement of its moving parts, or replace the travel switch

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

3. Replace the travel switch and take waterproof measures

4. Check if there are any open or short circuits in the switch circuit, and if there is a signal source (+24V DC power supply)

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

7、 Under normal circumstances, the positive and negative hard limit alarm of the machine tool does not occur. It may occur when operating the machine tool before returning to zero, as the system does not return to zero

There is no fixed mechanical coordinate system but arbitrary positioning, and the soft limit is invalid, so it is necessary to return to zero before operating the machine tool

reason:

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

2. The travel switch is damaged

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

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

5. PLC input point burned out

Countermeasure:

1. Manually or manually shake the handwheel away from the safe position, or clean the switch contacts

2. Replace the travel switch

3. Check if there is a short circuit in the travel switch circuit. If there is a short circuit, reprocess it. Check the signal source (+24V DC power supply)

4. Adjust the installation position of the travel switch so that it can be pressed onto the switch contact normally to the action position

5. Replace the input points on the I/O board and make parameter settings, modify the PLC program

8、 Reason for tool change malfunction:

1. Insufficient air pressure

2. Poor contact or open circuit of the loose knife button

3. Loose knife button PLC input address point burned out or no signal source (+24V)

4. The loose knife relay does not operate

5. The loosening knife solenoid valve is damaged

6. Insufficient cutting amount

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

8. Knife cylinder malfunction

Countermeasure:

1. Check the air pressure until it reaches 6 kilograms plus or minus 1 kilogram

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, modify the PLC program

4. Check the presence/absence of PLC output signals, whether the PLC output port is burnt out, and modify the PLC program

5. If the solenoid valve coil is burned out and replaced, and the solenoid valve body leaks air or the piston does not move, then replace the valve body

6. Adjust the cutting amount to ensure smooth loosening of the blade

7. Add hydraulic oil to the cutting cylinder oil cup

If the screws inside the knife cylinder are loose or leaking, the screws need to be tightened again and the sealing ring in the cylinder body needs to be replaced,

If it cannot be repaired, replace the knife cylinder

9、 Reason for abnormal sound during three-axis operation:

1. Bearing malfunction

2. The screw busbar and guide rail are unbalanced

3. Severe wear of the wear-resistant plate leads to severe scratches on the guide rail

4. Mismatched servo motor gain

Countermeasure:

1. Replace the bearing

2. Correct the lead screw busbar

3. Re attach the wear-resistant plate, and if the rail is severely scratched, it needs to be reprocessed

4. Adjust the servo gain parameters to match the mechanical specifications

10、 Reason for lubrication failure:

1. The lubrication pump oil tank is short of oil

2. The lubrication pump has a short oiling time

3. The pressure relief mechanism of the lubrication pump releases pressure too quickly

4. There is oil leakage in the oil pipe and oil circuit

5. The one-way valve in the oil circuit does not operate

6. Damaged oil pump motor

7. The control circuit board of the lubrication pump is damaged

Countermeasure:

1. Add lubricating oil to the upper limit line position

2. Adjust the oiling time to 32 minutes and oiling for 16 seconds

If the adjustable pressure relief speed can be adjusted, it needs to be replaced if it cannot be adjusted

4. Check the oil pipe and oil circuit interface and handle it properly

5. Replace the one-way valve

6. Replace the lubrication pump

7. Replace the control circuit board

If in an emergency situation, force M64S to 1A and E60 to 32 in the I/F diagnosis, and the machine tool can temporarily work

11、 The program cannot be transmitted, resulting in alarms P460, P461, and P462. Countermeasures:

1. Check for any open circuits or virtual soldering in the transmission line, and ensure that the plug is properly inserted

2. The parameters on the computer transmission software side should be consistent with those on the machine tool side

3. Replace the computer and try transferring

4. Is the grounding stable

12、 Reason for knife magazine problem:

1. Sudden stop during tool change process, unable to continue tool change

2. The conical hat style knife magazine cannot come out

3. Do not loosen the knife during the tool change process

4. The cutterhead cannot rotate

5. The sudden reverse rotation of the cutterhead causes a difference of half a knife position

6. When changing the knife, there is an alarm for loose or tight knife errors

When returning the tool during the replacement process, there is a loud noise on the spindle side

8. After replacement, the spindle cannot be used for tool installation (abnormal loosening of the tool)

Countermeasure:

1. Is the air pressure sufficient (6 kilograms)

2. Check if the reverse signal of the tool magazine is in place, and if there is any output from the electromagnetic valve circuit and PLC for the entry and exit of the tool magazine

3. Adjust the cutting amount and check if there is water accumulation in the cutting cylinder body

4. When the cutterhead rotates after coming out, check for any open circuit in the power cord of the magazine motor, and any damage to the contacts or relays

5. The brake mechanism of the knife magazine motor is loose and cannot brake normally

6. Check the air pressure, whether the cylinder is fully activated (whether there is water accumulation), and whether the loosening switch is pressed in place, but not too much (assuming there is just a signal input)

7. Adjust the cutting amount;

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

13、 Reason for machine tool not being able to power on:

1. Poor three-phase contact or damaged switch of the main power switch

2. The operation panel cannot be powered on

Countermeasure:

1. Replace the main power switch

2. Check

A. Does the switch power supply have voltage output (+24V)

B. The power on switch of the system has poor contact, and the power-off switch is disconnected

C. The system's power on relay has poor contact and cannot self lock

D. Line break

E. Drive power on AC contact, system power on relay faulty

F. Is the circuit breaker tripping

G. Is the system working properly? Is the preparation completed or is the Z-axis driver damaged? Is there no automatic power on signal output

14、 Cooling water pump malfunction 1. Check if the water pump is burnt out

2. Is the power phase sequence reversed

3. Check for burnt communication contacts and relays

4. Is there an input signal for the panel button switch

15、 Blowing fault 1. Check if the solenoid valve is operating

2. Check if the blowing relay is activated

3. Are there any signals from the panel buttons and PLC output interface