(1) Measure the clock signal and data signal of the displacement sensor of 4 hydraulic cylinders, the clock signal is about 2.8V DC and 0.123V AC; The data signals are all about 2.8V DC and 0.245V AC. From this, it can be judged that the PLC clock and MTS data bit transmission and reception pulse loops are normal.
(2) Check the mounting screws of the outlet sensor on the operating side and all are in good condition. Explain that there is no problem with the installation of the sensor.
(3) Check the external cable of the sensor, there is no short circuit, and the ground insulation is excellent. Check the wiring in the junction box of the hydraulic cylinder and the terminal box at the top of the archway, the wiring situation is good, and the shielding layer of all signal lines is reliably grounded, and the phenomenon is still there.
(4) Replace the outlet displacement sensor on the operating side, and the reading of the new displacement sensor still shows random jumps.
(5) The wiring of the inlet and outlet displacement sensor on the operation side is reversed in the junction box, and it is found that the outlet MTS still has random jumps. Explain that there is no problem with the cable between the terminal box at the top of the torii and the junction box of the hydraulic cylinder.
(6) Adjust the outlet displacement sensor on the operating side with the inlet displacement sensor on the transmission side, and find that the MTS at the outlet of the operating side still has random jumps, and the inlet sensor is normal. The transmission side sensor is also normal. Explain that the MTS displacement sensor is good.
(7) In the PLC cabinet, the channel connected to the two-digit shift sensor on the operation side is reversed, and it is found that the outlet MTS still has random jumps, and the entrance sensor is normal. There is no problem with the template channel.
(8) Replace the special wire between the top of the archway and the junction box of the hydraulic cylinder on the outlet of the operation side, and find that the MTS at the outlet of the operation side still has random jumps, and the inlet sensor is normal. Again, there is no problem with this section of cable.
(9) In the PLC cabinet, the channel connected to the displacement sensor on the operating side and the transmission side is adjusted as a whole, and it is found that the MTS at the outlet of the hydraulic cylinder on the operating side still has random jumping, and the other sensors are normal. Explain that there is no problem with the template.
(10) We carefully analyzed each test process and the location of the sensor, and found that the ambient temperature of the displacement sensor at the outlet of the hydraulic cylinder on the operating side was the worst. Therefore, the operation side outlet sensor is connected with cooling water, and the phenomenon of violent jumping disappears immediately, and the hydraulic system continues to be used, but after four or five days, the operating side outlet sensor begins to jump again.
(11) Replace all FM458 and EXM438 templates with new templates, and the MTS at the outlet of the operation side still has random jumps, which further indicates that there is no problem with the PLC template.
(12) Take out a new MTS displacement sensor to fix its position, directly connected to the terminal junction box at the top of the rolling mill archway, after the system is powered on, after observation, we find that the position of the sensor is fixed, its reading should remain unchanged, but with the process of rolling random jumps. So we took the sensor to the back of the PLC electrical cabinet and directly connected to the PLC template channel, after continuous tracking and observation, we found that the reading of the sensor did not move at all, very stable, so we came to the conclusion that only the cable from the PLC electrical cabinet to the terminal junction box at the top of the rolling mill archway does have unmeasurable interference.
Solution: Re-lay a separate tray for all the connecting cables of the MTS displacement sensor, replace all the cables, cover the bridge cover, and reliably ground all shielding layers to completely eliminate interference signals. It turns out that after the improvement measures were completed, a similar phenomenon never happened again.
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