Electrical fault in the control cabinet
1. Computer operating system and cutting software failure
(1) Computer system failure
Main manifestation: When opening the software, it shows that the file is missing, or the operation is very slow after opening the software; in some serious cases, the computer freezes directly.
Solution: Restore or reinstall the computer operating system. After restoring or reinstalling, install the restore wizard for the customer and ask them not to install any other software except the cutting software on the local computer.
2. Computer host and display failure
(1) Computer host failure
Main manifestation: Unable to start up and intermittent restart, freeze
Solution: Clean the dust inside the computer, check the computer host power supply, motherboard and hard disk to see if they are burned out.
(2) Computer monitor failure:
Main symptoms: Display is distorted or black
Solution: This phenomenon is caused by interference in the WGA video output signal line. The WGA line can be replaced separately. At the same time, the monitor itself may also fail.
Main symptoms: The main power input is normal but the machine cannot start up
Solution: Replace the power supply
3. Servo drive and control line faults
(1) Driver alarm
Main manifestations: 1 Alarm motor overload overcurrent: (Inovance: ER.201:210 Fuji: OC/OL)
Solution: Check the circuit, which is often caused by broken brake wires, poor contact or virtual connection of U/V/W wires. At the same time, after the disconnection, the machine tool will also experience vibration and abnormal noise, and sometimes there will be an alarm for excessive deviation of the dual drive axis in the software.
(2) Control line fault
Main manifestations: Communication interruption of alarm encoder (Inovance: ER740/800 Fuji: EC/ET/OF)
Solution: If the encoding cable plug is loose, the contact is poor, the encoder cable is broken, there is magnetic field interference, etc., check or replace the encoder cable.
4. Fault in servo motor and power cord
(1) Servo motor fault
Main manifestations: motor burnout/encoder failure or poor contact of motor main power supply
Solution: Check if the main power plug is securely plugged in. If it still cannot be used after inspection, replace the motor with a new one
5. Height controller and capacitor amplifier failure
(1) Height controller failure
Main manifestations: limit enable alarm/encoder no response, etc.
Solution: First use a multimeter to check whether the limit line from the height controller to the machine tool is broken. To eliminate the line fault, replace the limit switch.
Main manifestations: encoder no response
Solution: Check the height controller to servo drive pin line to see if the soft limit is effective
(2) Capacitor alarm
Main manifestations: Generally, the capacitance increases/decreases/becomes 0
Solution: When this phenomenon occurs, first check the capacitor sensing line and signal transmission line, whether the ceramic plate is short-circuited and dusty, and whether the machine is grounded and connected. If these problems are eliminated, it is most likely a capacitor amplifier failure and needs to be replaced.
6.Electromagnetic valve fault
Main manifestations: The solenoid valve cannot close the gas or open the gas
Solution: There are impurities inside the solenoid valve that prevent it from shutting off, the circuit board's out port is faulty, and the solenoid valve coil is burnt out
Motion limit fault
1. Machine limit failure
Main manifestation: Servo overload alarm, hard limit alarm and soft limit alarm when returning to the machine origin
Solution: Hard limit failure is mostly caused by limit switch damage or insufficient sensing distance. The switch needs to be replaced or the distance needs to be adjusted (the platform configuration cannot be changed to handle the alarm). Soft limit failure is caused by the loss of the machine return origin sampling signal, resulting in the soft limit and the machine tool's motion range not coinciding. It is necessary to check whether the return origin contact and the limit polarity in the platform setting are correct.
2. Drive motor reducer failure
(1) Reducer failure
Main manifestation: Wavy lines appear during cutting, which is caused by internal wear and jamming of the reducer/loosening and slipping of the motor reducer shaft sleeve/excessive gear rack matching difference.
Solution: Tighten the servo motor base. If the reducer is damaged, the reducer needs to be replaced. Adjust the gear rack clearance and perform gantry initialization.
3. Slider Failure
Main manifestation: Wavy lines appear during cutting and shake during operation. This is primarily due to poor lubrication or foreign matter stuck in the slider.
Solution: Purchase a suitable slider model, check for proper lubrication and cracks in the oil pipes, regularly clean the guide rails, and remove foreign matter from both sides of the rack.
4. Unable to Interchange the Table
Solution: Ensure the limit and run command signals are normal, then check the chain for breaks.
Chiller Failure
Main manifestation: Water flow or high temperature alarms. Use the alarm code table to identify the cause of the malfunction. Solution:
（1）Regular Inspection and Maintenance
To ensure proper operation of the water chiller, check the water tank level every two weeks to ensure it meets operating requirements. Check the water quality monthly, observing any abnormalities in color, odor, and impurities. Additionally, equipment maintenance should be performed according to a specific replacement and cleaning schedule.
（2）Filter Inspection and Cleaning
Filters are crucial components for maintaining the cleanliness of the water chiller and should be inspected weekly for blockage. This includes the filter at the laser water inlet and the filter within the water chiller itself. The laser filter is located at the Y-shaped connector on the water inlet, while the location of the water chiller filter varies depending on the model, typically near the water outlet pipe.
（3） Dust Screen Maintenance and Cleaning
The dust screens are located on both sides of the water chiller and are easily removable. Clean them more frequently in dusty environments. When cleaning, use an air gun to blow away dust. If you encounter oily dirt, it is recommended to use a neutral detergent. Before reinstalling, make sure the dust filter is thoroughly rinsed and dried.
Collimating lens, focusing lens, and protective lens failures
When cutting products, if you experience problems such as unclear cuts, large burrs, or chipped or burned edges, in addition to workmanship, impure gas, and plate rust, you should inspect the optical lenses. Use photographic paper to illuminate the film. If black spots are found, inspect from bottom to top, first checking the copper nozzle, then the protective lens, focusing lens, collimating lens, and fiber optic head.