Three kinds of mechanical fault diagnosis methods commonly used in ordinary machine tools - News - Global IC Trade Starts Here.

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Before deciding whether to replace or repair a faulty component or the entire device, it's essential to gather diagnostic results from real-world usage. This information helps determine the most suitable preventive maintenance schedule and tasks. Any machine should not be rushed into disassembly without first conducting a thorough pre-demolition inspection—both static and dynamic. This step is crucial for gathering as much data as possible for fault analysis and developing an initial repair plan. Without this process, blind dismantling can lead to unnecessary damage, reduced equipment accuracy, or even new faults. Diagnostic procedures typically involve no-load and load testing to identify key issues in mechanical equipment. These tests are often combined with operator reports, daily logs, replacement records, accident analyses, and maintenance files to focus on potential failures. During no-load operations, technicians use their senses—sight, sound, smell, and touch—to detect early signs of failure. For example, abnormal noises from gears inside a gearbox can indicate wear or damage to components like gears, shafts, or bearings. By identifying the speed at which the noise occurs, technicians can narrow down the possible causes. A visual inspection of the gear’s condition, along with measurements of shaft distortion and bearing clearance, can help pinpoint the issue. Another common problem is overheating in rotating or sliding parts, such as bearings. Causes may include excessive wear, improper lubrication, or incorrect clearance. When overheating is detected, checking the lubrication levels and adjusting the clearance can help diagnose the root cause. In severe cases, disassembly and detailed inspection may be necessary. Vibration is another critical indicator of mechanical issues. Unbalanced parts, worn supports, loose mechanisms, or poor contact between moving components can all lead to vibration. Identifying the frequency of the vibration and analyzing its source through transmission relationships can help locate the problem. Oil leaks in lubrication or hydraulic systems are also common. These can result from design flaws, improper seal selection, or structural damage. Diagnosing these leaks requires careful observation during operation and trial-and-error methods to find the exact source. During load operations, the focus shifts to assessing wear in critical parts like guides and bearings, as well as accuracy issues caused by improper assembly. For machines like lathes or milling machines, test parts are used to evaluate geometric accuracy and surface finish. Analyzing shape errors and surface irregularities can reveal underlying equipment problems. In load testing, the performance of the equipment under stress is evaluated, especially regarding vibration, temperature, noise, and functional loss. Experimental methods, such as isolation and heuristics, are often used to narrow down potential causes. Isolation involves removing suspected components to see if the fault disappears, while heuristics rely on experience to make educated guesses about the most likely cause. For complex faults involving multiple factors, a combination of techniques is usually required. By isolating variables, comparing symptoms, and using heuristic judgment, technicians can accurately identify and resolve issues. Following a systematic approach not only improves diagnostic accuracy but also enhances overall efficiency. Real-world examples show that most faults are diagnosed through a combination of methods rather than a single technique.