Introduction:

In the conveyor system of PCB production equipment, ensuring the normal operation of equipment is the key to improve production efficiency and product quality. The common fault types of conveyor system include conveyor roller offset, conveyor system failure, sensor failure, motor overload, etc., which affect the stability of production. The following is an introduction to the common problems in the conveyor system of PCB machine and solutions.

Key Words:

• Conveyor System,
• PCB Machine
• Conveyor Roller
• Bearing
• Drive Shaft
• Gear
• Bolt
• Nut

Main Content:

1- Conveyor roller offset problem

Problem description:

The conveyor roller offset is one of the common faults in the conveyor system equipment. The conveyor roller may shift to one side due to various factors, which affects the normal conveyor and may even cause the conveyor roller to wear or fall off.

Reason analysis:

• Uneven tension: Uneven tension on both sides of the conveyor roller, resulting in one side of the force greater than the other side, resulting in deviation.
• Roller bearing damage: Conveyor roller bearing wear or aging, resulting in uneven rotation of the roller, so that the conveyor roller offset.
• Uneven material force: Uneven material placed on the conveyor roller, resulting in a large force on one side, resulting in deviation.
• Improper installation of the conveyor roller: Conveyor roller is not aligned to the center during installation, resulting in gradual deviation of the conveyor roller during operation.

Solution:

• Adjust the tension: Use the tension device to adjust the tension on both sides of the conveyor roller to ensure uniform force, check and calibrate regularly.
• Replace the damaged bearing: If the bearing is found to be seriously worn, it is necessary to replace the new bearing in time and ensure that the conveyor roller rotates smoothly.
• Adjust the material placement: Try to distribute the material evenly on the conveyor roller to avoid overload and partial load.
• Reinstall the conveyor roller: Ensure that the conveyor roller is aligned with the center when installed, and the forces on both sides are consistent.

2- Conveyor system failure

Problem description:

The conveyor system includes motor, reducer, gear, roller and other components. The failure of the conveyor system will cause the conveyor roller to fail to operate normally or the speed is unstable.

Reason analysis:

• Motor failure: The motor may have problems such as overload, short circuit or loose wiring, resulting in the conveyor system can not work normally.
• Reducer wear: Gear wear or oil seal aging oil leakage may occur after long-term use of the reducer, affecting the stability of the reduction ratio.
• Gear wear: Serious gear wear may cause the conveyor to be out of sync, and even the circuit board may fall or get stuck.
• Insufficient lubrication: Lack of lubrication between conveyor components will increase frictional resistance, resulting in poor conveyor or overheating equipment.

Solution:

• Check the motor: Check the motor regularly to ensure that the line is firmly connected, no abnormal heating or noise, and clean and maintain the motor if necessary.
• Maintain the reducer: Regularly check the wear of the gear of the reducer, add lubricating oil or replace the oil seal in time, and extend the life of the reducer.
• Timely replacement of plastic gears: Check the wear of plastic gear regularly and replace them if necessary.
• Lubrication maintenance: Regularly add lubricants to each part of the conveyor system to reduce wear and energy loss and extend the service life of the equipment.

3- The sensor is faulty

Problem description:

The conveying system is usually equipped with photoelectric sensors, proximity sensors, etc., for detecting the position, speed and other parameters of the circuit board. Failure of the sensor will lead to failure to detect the plate or misjudgment, affecting the accuracy of automated production.

Reason analysis:

• Sensor surface pollution: Dust and oil are attached to the surface of the sensor, which will affect the detection accuracy of the sensor.
• Connection fault: The sensor circuit is not securely connected, loose or short circuit occurs.
• Sensor aging: After a long time of use, the sensitivity of the sensor decreases and the detection accuracy decreases.
• External interference: External factors such as electromagnetic interference and static electricity may affect the accurate conveyor of sensor signals.

Solution:

• Clean the sensor: Clean the surface of the sensor regularly to ensure that the detection area of the photoelectric or near the sensor is pollution-free.
• Check the circuit connection: Check the connection line of the sensor regularly to ensure that there is no loosening or short circuit, and re-fix or replace the connector if necessary.
• Replace the aging sensor: Replace the sensor that has been used for a long time and has low detection accuracy to ensure detection stability.
• Reduce external interference: When installing and arranging sensors, try to stay away from high-voltage cables or other interference sources, or increase shielding measures.

4- Motor overload problem

Problem description:

The overload of the motor in the conveyor system will cause the temperature to rise, the operation to be abnormal, and even trigger the overload protection device, so that the equipment will stop.

Reason analysis:

• The load is too large: Too much material is carried on the conveying system, exceeding the rated power of the motor.
• Insufficient lubrication: Insufficient lubrication of conveyor components increases friction resistance, and the motor load increases.
• Poor heat dissipation of the motor: The heat dissipation system is not smooth, resulting in excessive motor temperature, resulting in overload.
• Unstable power supply voltage: Too high or too low power supply voltage will affect the normal operation of the motor.

Solution:

• Reasonable control of load: According to the rated power of the motor, control the load of the conveying system to avoid overload operation.
• Regular lubrication maintenance: Regularly lubricate the motor and related conveyor components to reduce friction resistance and ensure easy operation of the motor.
• Check the heat dissipation system: Ensure that there are no obstacles around the motor, the heat sink or fan is working properly, and clean the dust on the heat sink if necessary.
• Ensure the stability of the power supply: Check the power supply to ensure that the voltage meets the requirements, and install a regulator if necessary.

5- The conveyor system abnormal sound problem

Problem description:

Abnormal noise during operation of the conveying system equipment is usually a sign of equipment wear, loosening or lack of lubrication.

Reason analysis:

• Bearing wear: The bearing on the drum or Stainless steel rod is worn or aging, resulting in abnormal sound when the operation is not smooth.
• Loose parts: Bolts, Grub Screw and other connectors are loose, equipment vibration intensifies, and noise is generated.
• Insufficient lubrication: Long-term lack of lubrication will increase friction, resulting in increased friction between components.
• Conveying shaft wear: The Stainless steel rod is worn, so that the entire conveying surface is not on the horizontal line, and it is easy to produce friction noise during operation.

Solution:

• Replace the bearing: Check the bearing wear regularly and replace the new bearing if necessary to ensure the smooth operation of the equipment.
• Fastening parts: Tighten all the connected parts on the equipment to reduce vibration and noise.
• Add lubricant: Regularly add lubricating oil to the parts that need lubrication to reduce friction noise.
• Replace the conveying shaft: If the shaft is seriously worn, it should be replaced in time to ensure the smoothness and quietness of operation.

6- Plate stuck

Problem description:

The plate is stuck in the conveying system or cannot pass smoothly.

Reason analysis:

• Aging or loosening of conveyor roller: the conveyor roller is worn or stretched, affecting normal operation.
• Roller or chain wear: the surface of the roller is worn or the chain is loose, resulting in poor delivery.
• Foreign body blockage: Foreign body (such as debris, dust) accumulation in the delivery system, resulting in the plate stuck.

Solution:

• Replace the conveyor roller: check the tension and wear of the conveyor roller regularly, and replace or adjust it in time.
• Clean the delivery area: Clean the foreign matter in the delivery system regularly to prevent debris accumulation.
• Lubrication maintenance: Add lubricant to the roller and chain regularly to ensure smooth operation.

7- Fault diagnosis and preventive maintenance suggestions

In order to reduce the frequency of board equipment delivery system failures, the following are some preventive maintenance recommendations:

• Develop regular inspection system: Develop regular inspection and maintenance plan of equipment, including inspection content of conveyor system, bearing, conveyor roller, sensor, etc., to ensure that equipment is always in good condition.
• Establish a lubrication system: According to the operation time and load of the equipment, formulate a reasonable lubrication cycle to provide sufficient lubrication for each conveyor component and extend the service life of the equipment.
• Operator training: Strengthen operator training, improve the ability to identify and handle common faults, and ensure the standardization of equipment operation.
• The introduction of monitoring equipment: Temperature, vibration and other monitoring equipment can be considered to conduct real-time monitoring of key components, timely detection of anomalies and processing.
• Through the above troubleshooting and preventive measures, the stability and use of the circuit board equipment conveying system can be effectively improved.