How do you test non-standard automated equipment when it malfunctions?

1. Inspect all power supplies, pneumatic valves, and hydraulic power sources of the automated machinery.

Problems with power supplies, pneumatic valves, and hydraulic power sources often cause malfunctions in automated machinery. For example, power supply problems may include faults in the entire production workshop's power supply system, such as low rated power, blown fuses, poor contact in power cord plugs, etc.; air pumps or hydraulic pumps may not be turned on, pneumatic triple or duplex units may not be turned on, and unloading valves or some pressure valves in the hydraulic transmission system may not be turned on. Inspecting automated machinery should include the following aspects: power supply, including the power supply for each machine and the workshop's lighting; pneumatic valves, including the standard air pressure source required for pneumatic equipment; hydraulic power sources, including the operation of the hydraulic pumps required for the automated machinery's hydraulic control valves.

2. Check if the sensors of the automated machinery are misaligned.

Due to carelessness by equipment maintenance personnel, some sensors may be misaligned, such as not being used in time, sensor malfunction, or sensitivity failure. Regularly check the sensor's position and sensitivity. Adjust immediately if errors occur. Replace any damaged sensors immediately. In many cases, due to vibrations from automated machinery, most sensors will become loose after prolonged use. Therefore, during routine maintenance, regularly check whether the sensor's position is correct and securely fixed.

3. Check the relays, flow control valves, and pressure control valves of the automated machinery.

Like induction coil sensors, relays can also become stuck to ground after prolonged use, thus failing to ensure the normal operation of the electrical control circuit and requiring replacement. In pneumatic or hydraulic systems, the opening of the one-way throttle valve and the pressure adjustment spring of the pressure valve can also become loose or roll over due to equipment vibration. These devices, like sensors, are components in automated machinery that require routine maintenance.

4. Check the electrical, pneumatic, and hydraulic control circuit connections.

If the above three steps do not reveal any problems, then check the entire control circuit. Check if the power supply lines are short-circuited, especially if the lines in the cable trays have been severed by the cable trays. Inspect the air ducts for any damaging creases. Check the high-pressure oil pipes for blockages. If the air ducts are severely creased, replace them immediately. The high-pressure oil pipes also need to be replaced.

5. After ensuring the above procedures are accurate, the fault may be in the control board of the automated machinery, but it is unlikely to be a program problem. First, it is not necessarily a control board failure. As long as there has been no serious short circuit, the control board has overcurrent protection, and general short circuits will not damage the control board.