Replacement comparison method
When it is difficult to determine what kind of fault occurs in the machine tool, the displacement comparison method can be used to determine. It is possible to compare a faulty machine tool with a normal machine tool. In general, the difference is the machine fault. When it is difficult to determine whether the technical condition of a component is normal, it can be tested with a good component replacement. If the working condition of the machine tool does not change significantly, the original part is qualified, and the machine fault is not related to the part, otherwise there is a problem with the part.
2. Partial stop method
This method is suitable for diagnosing machine tool rotation system failures. During diagnosis, you can intermittently stop or isolate the work of a certain part or a certain part to observe the fault phenomenon, and then confirm the fault. For example, the C630 bedhead made a loud bang, but I don't know which axis failed. The axes of the headstock can be turned on in turn, and when the sound is similar to the abnormal sound, it is possible to determine which axis is the problem. This method diagnoses faults in parts such as shafts, gears, and clutches.
3. Conditional change method
This method is often used when the symptoms of machine failure are not obvious, inadequate or irregular. Such as changing the force on the machine tool, changing the machine operating conditions, environmental conditions, and so on. Sometimes additional conditions are required for mandatory testing to expose the symptoms of the malfunction more fully. For example, when machining parts on a lathe, the workpiece vibrates. You can change the three elements of turning and observe the vibration. If the cutting test is performed with a cutting knife, if the vibration is intensified, the radial clearance of the front bearing of the main shaft is large and should be adjusted.
4. Exploring the counter-evidence method
Try to change the working conditions or working conditions of a certain part, and observe the change of the phenomenon of the fault to counter the location of the fault. For example, the phenomenon of the knife on the ordinary lathe, the failure of the carriage and the tool holder system can cause the knife. First, we must choose the reason for the greater possibility and conduct a tentative investigation. For example, if the positioning mechanism on the tool holder fails or the fastening device fails, if there is no problem, choose another situation that is prone to the knife phenomenon until the cause is found.
5. Trial test method
When the machining accuracy of the part does not reach the specified accuracy of the machine, the parts that have been cut out by the machine can be measured to diagnose the malfunction of the machine. For example, the vibration of the machine tool is diagnosed according to the direction and frequency of the surface vibration of the part; the geometrical accuracy of the machine tool is diagnosed by the shape and position error of the part. For thread processing machines and gear processing machines, the adjacent difference, cumulative error and tooth profile error of the test parts are mainly determined by the accuracy of the machine tool rotation chain. The tooth direction error determines the geometric accuracy of the machine tool. The roughness determines the vibration of the process system. Therefore, the accuracy of the workpiece can be measured to roughly determine the location and cause of the fault. However, when using this method, it is necessary to consider the influence of tools, fixtures and processes on the machining accuracy of the parts.
6. Monitoring, measurement method
Use tools, gauges, instruments and meters to monitor or measure the technical parameters of the machine to diagnose machine faults. If you observe the pressure gauge to monitor the pressure of the hydraulic system of the machine tool, if the pointer of the pressure gauge is unstable or the pressure is not reached, it indicates that there is a leak in the oil circuit or there is gas in the pipeline, which needs to be repaired or replaced.
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Tag: Diagnostics Gear processing machine Rotating system Radial clearance Fastening device
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