First, let's determine whether it is an issue with the hydraulic system, electrical system, or mechanical malfunction.
Then, let's handle the different phenomena accordingly.
Mechanical Issues:
Fault 1: Excessive clearance between the slide and the guide rail, resulting in abnormal noises.
This type of fault occurs when the guide rail has been worn over time, leading to increased clearance. It is necessary to check the degree of wear on the guide rail and determine whether to replace the guide rail and readjust it to the required clearance.
Fault 2: Failure of the back gauge transmission.
The failure of the back gauge transmission is caused by the disengagement of the key bar between the transmission shaft and the timing pulley or the slipping of the timing belt.
This type of fault requires reassembling the key bar and timing belt and checking the electrical components.
Fault 3: Excessive deviation in parallelism between the linear guide of the back gauge beam and the centerline of the mold.
This type of fault requires loosening the "X" axis timing belt and readjusting it to within the tolerance range of parallelism. Then, reinstall the timing belt.
Fault 4: Loose connection between the hydraulic cylinder and the slide, resulting in inaccurate bending angles or the machine's inability to find reference points.
This type of fault requires rechecking the tightening of the connection nut between the slide and the hydraulic cylinder.
Hydraulic Issues:
Fault 1: No pressure in the hydraulic system.
1. Check if the solenoid coil of the proportional relief valve is powered and if the voltage of the proportional solenoid coil meets the requirements. If not, check for related electrical issues.
2. Check if the cartridge valve is stuck or if the main spool is stuck, and if the damping orifice is blocked. If these are the reasons, disassemble the relief valve, clean it, and reinstall it.
3. Check if the three-phase power supply is phase-shifted, causing the motor to reverse.
Fault 2: Quick-to-slow motion of the slide with a long pause in between.
1. Check if the oil level in the tank is too low and if the fill port is not submerged. Insufficient filling may occur when the upper chamber of the cylinder is emptied during rapid advance. If this is the reason, add oil to the tank until it is at least 5mm above the fill port to fully submerge the fill hole.
2. Check if the rapid advance speed is too high, causing insufficient filling. If this is the reason, modify the system parameters to lower the rapid advance speed.
3. Check if the fill valve is fully open. If the valve core of the fill valve is not flexible due to oil contamination, causing insufficient filling, it needs to be cleaned and reinstalled to ensure smooth movement of the valve core.
Electrical System Issues: [Incomplete, please provide the remaining text.]
Fault 1: Low-pressure circuit breaker trips after oil pump starts.
The following checks are required for this type of fault:
1. Check for power phase loss in the power supply.
2. Check if the high-pressure filter is severely blocked, causing excessive current in the oil pump motor.
3. Check if the low-pressure circuit breaker is set too small.
Fault 2: Unable to find the reference point when returning to the reference point after startup.
1. Check if the connection of the read head of the grating ruler is loose, causing the machine to fail to align with the reference point of the grating ruler during the return stroke, while the stroke of the cylinder is used up and the oil pump is under load. If this is the reason, press the red stop button on the numerical control system to stop returning to the reference point, reconnect and calibrate the connection plate of the grating ruler, then enter manual mode and manually move the slide downward until it aligns with the lower mold. Then enter manual or semi-automatic mode and return to the reference point to eliminate the fault.
2. If, after the previous operation, the machine was not shut down strictly according to the operation procedure and the slide was left at the top dead center position before powering off, and during the next startup, the slide was not manually moved downward to the position where the upper and lower molds align before performing the reference point operation, it can cause the current operation to fail to find the reference point. If this is the reason, switch the system to manual mode, manually move the slide downward to the position where the upper and lower molds align, then switch to semi-automatic or automatic mode to find the reference point again.
Fault 3: No display on the DNC60 or DNC600 numerical control system screen, with the programming key indicator flashing in gray and white.
This type of fault mainly occurs when the operator of the system fails to timely and effectively clear the unused product program and directly modifies the previous working product program, resulting in repeated operations that fill up the buffer memory program in the system, making the system unable to run properly. First, disconnect the main power supply, simultaneously press the "++" and "--" keys on the system keyboard, and then turn on the power to put the system into the initialization state. The system screen will display the following:
Next, enter "1" to clear the desired project. After entering the password "817" and confirming with the confirm key, the screen will prompt "Executed", indicating that the required clearing has been completed.
Fault 4: Inaccurate counting of the grating ruler leading to bending angle errors.
This type of fault mainly reflects the cumulative increase in positioning accuracy errors of the "Y1" and "Y2" axes, resulting in larger bending angle errors, and the angle error accumulates on the basis of the previous one. The main cause is the missing pulse count in the feedback signal of the grating ruler. The grating ruler needs to be disassembled, cleaned, and protected from dust and vibration. The installation method should be redesigned to ensure proper installation. If the grating ruler is faulty, it needs to be sent back to the manufacturer for repair or replacement.
Fault 5: "X" axis and "R" axis safety distance alarm after product programming.
This type of fault mainly occurs when setting the safety distance between the upper and lower molds during mold preparation, and there is a contradiction between the system's settings of the limit positions of the "X" and "R" axes and the programmed positions of the current product. The system prompts an alarm, and for safety reasons, the system cannot operate normally. It is necessary to reprogram the product or modify the parameters of the product or mold to meet the requirements and remove the alarm before proceeding with the operation.
Then, let's handle the different phenomena accordingly.
Mechanical Issues:
Fault 1: Excessive clearance between the slide and the guide rail, resulting in abnormal noises.
This type of fault occurs when the guide rail has been worn over time, leading to increased clearance. It is necessary to check the degree of wear on the guide rail and determine whether to replace the guide rail and readjust it to the required clearance.
Fault 2: Failure of the back gauge transmission.
The failure of the back gauge transmission is caused by the disengagement of the key bar between the transmission shaft and the timing pulley or the slipping of the timing belt.
This type of fault requires reassembling the key bar and timing belt and checking the electrical components.
Fault 3: Excessive deviation in parallelism between the linear guide of the back gauge beam and the centerline of the mold.
This type of fault requires loosening the "X" axis timing belt and readjusting it to within the tolerance range of parallelism. Then, reinstall the timing belt.
Fault 4: Loose connection between the hydraulic cylinder and the slide, resulting in inaccurate bending angles or the machine's inability to find reference points.
This type of fault requires rechecking the tightening of the connection nut between the slide and the hydraulic cylinder.
Hydraulic Issues:
Fault 1: No pressure in the hydraulic system.
1. Check if the solenoid coil of the proportional relief valve is powered and if the voltage of the proportional solenoid coil meets the requirements. If not, check for related electrical issues.
2. Check if the cartridge valve is stuck or if the main spool is stuck, and if the damping orifice is blocked. If these are the reasons, disassemble the relief valve, clean it, and reinstall it.
3. Check if the three-phase power supply is phase-shifted, causing the motor to reverse.
Fault 2: Quick-to-slow motion of the slide with a long pause in between.
1. Check if the oil level in the tank is too low and if the fill port is not submerged. Insufficient filling may occur when the upper chamber of the cylinder is emptied during rapid advance. If this is the reason, add oil to the tank until it is at least 5mm above the fill port to fully submerge the fill hole.
2. Check if the rapid advance speed is too high, causing insufficient filling. If this is the reason, modify the system parameters to lower the rapid advance speed.
3. Check if the fill valve is fully open. If the valve core of the fill valve is not flexible due to oil contamination, causing insufficient filling, it needs to be cleaned and reinstalled to ensure smooth movement of the valve core.
Electrical System Issues: [Incomplete, please provide the remaining text.]
Fault 1: Low-pressure circuit breaker trips after oil pump starts.
The following checks are required for this type of fault:
1. Check for power phase loss in the power supply.
2. Check if the high-pressure filter is severely blocked, causing excessive current in the oil pump motor.
3. Check if the low-pressure circuit breaker is set too small.
Fault 2: Unable to find the reference point when returning to the reference point after startup.
1. Check if the connection of the read head of the grating ruler is loose, causing the machine to fail to align with the reference point of the grating ruler during the return stroke, while the stroke of the cylinder is used up and the oil pump is under load. If this is the reason, press the red stop button on the numerical control system to stop returning to the reference point, reconnect and calibrate the connection plate of the grating ruler, then enter manual mode and manually move the slide downward until it aligns with the lower mold. Then enter manual or semi-automatic mode and return to the reference point to eliminate the fault.
2. If, after the previous operation, the machine was not shut down strictly according to the operation procedure and the slide was left at the top dead center position before powering off, and during the next startup, the slide was not manually moved downward to the position where the upper and lower molds align before performing the reference point operation, it can cause the current operation to fail to find the reference point. If this is the reason, switch the system to manual mode, manually move the slide downward to the position where the upper and lower molds align, then switch to semi-automatic or automatic mode to find the reference point again.
Fault 3: No display on the DNC60 or DNC600 numerical control system screen, with the programming key indicator flashing in gray and white.
This type of fault mainly occurs when the operator of the system fails to timely and effectively clear the unused product program and directly modifies the previous working product program, resulting in repeated operations that fill up the buffer memory program in the system, making the system unable to run properly. First, disconnect the main power supply, simultaneously press the "++" and "--" keys on the system keyboard, and then turn on the power to put the system into the initialization state. The system screen will display the following:
Next, enter "1" to clear the desired project. After entering the password "817" and confirming with the confirm key, the screen will prompt "Executed", indicating that the required clearing has been completed.
Fault 4: Inaccurate counting of the grating ruler leading to bending angle errors.
This type of fault mainly reflects the cumulative increase in positioning accuracy errors of the "Y1" and "Y2" axes, resulting in larger bending angle errors, and the angle error accumulates on the basis of the previous one. The main cause is the missing pulse count in the feedback signal of the grating ruler. The grating ruler needs to be disassembled, cleaned, and protected from dust and vibration. The installation method should be redesigned to ensure proper installation. If the grating ruler is faulty, it needs to be sent back to the manufacturer for repair or replacement.
Fault 5: "X" axis and "R" axis safety distance alarm after product programming.
This type of fault mainly occurs when setting the safety distance between the upper and lower molds during mold preparation, and there is a contradiction between the system's settings of the limit positions of the "X" and "R" axes and the programmed positions of the current product. The system prompts an alarm, and for safety reasons, the system cannot operate normally. It is necessary to reprogram the product or modify the parameters of the product or mold to meet the requirements and remove the alarm before proceeding with the operation.
