What are the common faults of five-axis gantry machining centers

The common faults of five-axis gantry machining centers mainly focus on five aspects: mechanical structure, electrical system, tool magazine system, lubrication system and control system. The specific manifestations and solutions are as follows:

I. Mechanical Structure failure

The positioning of the ‌ rotating shaft is inaccurate ‌

Cause ‌ : Wear of the supporting bearing, loose coupling, insufficient lubrication of the guide rail.

Solution ‌ : Replace the bearing, adjust the preload, clean the guide rail and replenish the grease.

Spindle orientation Angle deviation ‌

Cause ‌ : The main shaft synchronous toothed belt is damaged or impacted, resulting in orientation errors.

Solution ‌ : Inspect and replace the synchronous toothed belt, and recalibrate the spindle orientation Angle.

Abnormal tool change origin ‌

Cause ‌ : the collision accident caused the tool change origin to shift.

Solution ‌ : Manually adjust the position of the tool arm to ensure that the brake device of the tool arm motor is reset.

Ⅱ. Electrical System Faults

Servo motor encoder signal interference ‌

Cause ‌ : encoder signal drift or incorrect parameter Settings.

Solution ‌ : Check the encoder connection lines and recalibrate the servo parameters.

The position compensation parameter of the ‌ numerical control system is lost ‌

Cause ‌ : incorrect parameter Settings or system failure.

Solution ‌ : Restore the backup parameters of the numerical control system and reset the position compensation.

Ⅲ. Tool Magazine System Failure

Tool jam fault ‌

Cause ‌ : incorrect spindle orientation Angle, abnormal tool change origin.

Solution ‌ : Loosen the motor braking device, manually adjust the position of the knife arm, and ensure that the motor braking device of the knife arm is reset.

Insufficient air pressure ‌

Cause ‌ : Malfunction of the air pressure system or improper air pressure setting.

Solution ‌ : Check the air pressure system to ensure that the air pressure reaches 6 kilograms plus or minus 1 kilogram.

Iv. Lubrication System failure

The oil tank of the ‌ lubrication pump is short of oil ‌

Cause ‌ : the lubricating oil is consumed too quickly or the oil tank is leaking oil.

Solution ‌ : Add lubricating oil to the upper limit line position and check the sealing of the oil tank.

The oil circuit is clogged ‌

Cause ‌ : The check valve in the oil circuit does not operate or the oil pump motor is damaged.

Solution ‌ : Replace the check valve or oil pump motor, and check the oil circuit interface.

V. Control System Failure

Program transfer failed ‌

Cause ‌ : transmission line open circuit, software parameter mismatch or unstable grounding.

Solution ‌ : Check the connection of the transmission line to ensure that the software parameters are consistent with those of the machine tool, and check the stability of the grounding.

PLC input point burned out ‌

Cause ‌ : The limit switch contacts are pressed or there is a short circuit in the circuit.

Solution to ‌ : replace the input points on the I/O board and modify the PLC program.

Ⅵ. Other Common Faults

The cutting tool is broken or damaged ‌

Cause ‌ : Poor tool quality, unreasonable cutting conditions or excessive tool wear.

Solution ‌ : Inspect and replace the damaged tool to ensure that the cutting parameters are reasonable.

The machining accuracy of ‌ does not meet the standard ‌

Cause ‌ : incorrect processing program, improper machine tool adjustment or vibration during the processing.

Solution to ‌ : Carefully inspect the processing program and make necessary adjustments to ensure the accuracy and stability of the machine tool, and take effective vibration reduction measures.

Ⅶ. Troubleshooting and Maintenance Suggestions

regularly check ‌

The backlash of the feed drive chain and the pitch error of the lead screw should be inspected regularly every year, and timely compensation should be made.

Lubrication system maintenance ‌

Regularly check the oil level and quality of the lubricating oil, and add or replace the lubricating oil in time.

Control system maintenance ‌

Regularly check the Settings and parameters of the control system to ensure its correctness and stability.

Safe operation ‌

Strengthen the training and safety awareness of operators to ensure correct operation and the use of equipment protection measures.