Common Busbar Processing Machine Faults and Solutions
1. Mechanical Jam or Abnormal Operation
- Symptom: The punching or bending unit moves sluggishly or cannot reset.
- Cause Analysis:
- Insufficient lubrication leading to wear of the guide rails or slides (lubrication is recommended to be checked every 8 hours);
- Insufficient hydraulic system pressure (the standard pressure range is typically 5-7 MPa; refer to the equipment manual for adjustment);
- Foreign objects stuck in the mold or transmission components.
- Solution:
- Clean the guide rails and add special grease;
- Check the hydraulic oil level and filter element, and replace if necessary;
- Disassemble the mold, clean out debris, and ensure there are no hard objects blocking the machine.
2. Electrical System Fault
- Symptom: The machine fails to start, the display shows an error, or the motor overheats.
- Cause Analysis:
- Unstable power supply voltage (allowable fluctuation range ±10%);
- Poor control circuit contact or PLC module failure;
- Motor overload (continuous operation exceeding the rated time).
- Solution:
- Use a multimeter to check the input voltage and install a voltage regulator;
- Reconnect the wiring terminals and replace damaged components if necessary;
- Adjust the processing rhythm to avoid running the motor at full load for extended periods.
3. Processing Accuracy Deviation
- Symptom: Punch position deviation or bending angle error > 1°.
- Cause Analysis:
- The mold is loose or worn (usually has a service life of 100,000 punches);
- The servo motor encoder signal is abnormal;
- The material thickness exceeds the equipment's range (for example, the standard machine only supports 3-12mm copper busbars).
- Solution:
- Tighten the mold bolts or replace the mold;
- Calibrate the servo system parameters and check the encoder cable;
- Confirm that the material specifications meet the equipment requirements.
II. Preventive Maintenance and Operational Recommendations
1. Regular Maintenance Plan
- Daily: Clean the waste bin and check for leaks in the air/hydraulic lines;
- Monthly: Lubricate all moving parts and test the emergency stop function;
- Annual: Replace the hydraulic oil and filter, and fully calibrate the accuracy.
2. Operating Precautions
- Avoid overloading. The recommended single-process copper busbar length should not exceed 6 meters;
- Turn off the power when changing molds to prevent accidental triggering;
- Maintain an ambient temperature of 5-40°C and humidity below 80%.
Systematic troubleshooting and standardized maintenance can reduce unexpected failures by over 80%. If the problem persists, contact a professional technician for further diagnosis.
