In early 1998, Shandong Hongcheng Group Company purchased 36 ZAX air jet looms produced by Tsudakoma. The machine has excellent performance and various technical indicators. Since its production, it has created good benefits for the company. However, since 2003, its E5 servo amplifiers on the board have begun to appear P6C failures, and more and more faulty machines have affected the company's production plan.
After careful comparison and measurement of the difference between the normal circuit board and the faulty circuit board, and consulted the technical staff of Tsudakoma, it was finally confirmed that the fault was caused by the failure of the trigger PC923 that sent the trigger signal to the inverter module. Once the cause of the failure is found, the fault can be eliminated by replacing the trigger. However, there are six triggers on each circuit board. There is no special test instrument. It is difficult to find the faulty trigger. It is necessary to weld each trigger very carefully to the normal circuit board. Run the test to confirm the failed trigger one by one. It takes at least 3 hours to repair a circuit board, and some even take more than a day.
Seriously compare the failed flip-flop with the normal flip-flop, and then carefully measure each pin with a multimeter and find that the middle two pins of the lower row of the flip-flop (the flip-flop is a double-row and eight-pin) and the circuit board. The control circuit is connected, and the two pins are measured by the diode of the digital multimeter. The resistance of the fault trigger is 1.01 Ω to 1.20 Ω, and the resistance of the normal trigger is 1.40 Ω or more. According to this rule, the trigger with abnormal measurement value is welded to the upper machine test, and the result is a P6C failure.
The improved method is very effective, and it takes only two hours to fix two boards. This method reduces the scope of maintenance, greatly saves maintenance time, and can be repaired at any time.
Up to now, there are more than 40 circuit boards for repairing such faults. As long as P6 appears (the fault can be repaired, the production plan is guaranteed to be completed smoothly, which has created good economic benefits for the company.
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