1. The first type of fault point is also the location of the most faults in relays and contactors
For example, in the daily maintenance of the PLC control system of a production line, the largest consumption of electrical spare parts is all kinds of relays or air switches. In addition to the quality of the product itself, it is mainly due to the harsh on-site environment. For example, contactor contacts exposed to the production environment are susceptible to ignition or oxidation, and gradually heat up and deform until they can no longer be used. All the on-site control boxes of the production line are selected with better airtightness, and the service life of its internal components is significantly longer than that of other components in the open panel. Therefore, to avoid such failures, we should try to use high-performance relays and improve the use environment of components, so as to reduce the frequency of replacement and reduce the impact on system operation.
2. The second type of fault occurs on equipment such as valves or rams
3. The third type of failure point may occur in some components or equipment on switches, limit positions, safety protection and on-site operations
The reason for this may be due to long-term wear and tear, or it may be due to long-term rust and aging. For example, the cloth walking car on the kiln tail material ball storage of the production line moves back and forth frequently, and the dust on the site is large, so the contact of the proximity switch is deformed, oxidized, and the dust is blocked, which leads to poor contact contact or insensitive mechanism action. The handling of such equipment failures is mainly reflected in regular maintenance, so that the equipment is in good condition at all times. For limit switches, especially those on heavy equipment, in addition to regular maintenance, multiple protection measures should be added in the design process.
4. The fourth type of failure point may occur in the sub-equipment in the PLC system
Such equipment such as junction boxes, wire terminals, bolts and nuts, etc. The cause of this kind of failure is not only the manufacturing process of the equipment itself, but also related to the installation process, such as some people think that the wire and screw connection is pressed as tightly as possible, but it is easy to cause disassembly difficulties during the secondary maintenance, and it is easy to cause damage to the connecting parts and their nearby components when vigorously disassembled. Long-term ignition, rust, etc. are also the causes of failure. According to engineering experience, this type of fault is generally difficult to find and repair. Therefore, in the installation and maintenance of the equipment, it must be carried out in accordance with the installation process required by the installation, leaving no hidden dangers of the equipment.
5. The fifth type of failure point is sensors and meters
This kind of fault is generally reflected in the abnormal signal in the control system, and the shielding layer of the signal line should be reliably grounded at one end when this kind of equipment is installed, and be laid separately from the power cable as far as possible, especially the output cable of the inverter with high interference, and the software filtering should be carried out inside the PIC. The discovery and treatment of such faults are also related to daily point inspections, and problems should be dealt with in a timely manner.
6. The sixth type of fault is mainly the noise (interference) of the power supply, ground wire and signal line
The solution or improvement of the problem mainly lies in the experience of engineering design and the observation and analysis in daily maintenance.
To reduce the failure rate, it is very important to pay attention to the factory process and safety operation procedures, in the daily work to comply with the process and safety operation procedures, strict implementation of some relevant regulations, such as maintaining a centralized control room environment, etc., at the same time in the production should also strengthen the management of these aspects.
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