自营工业监测模块1900/65A（167699-02）

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1、一类故障点也是故障多的地点)在继电器、接触器
如某生产线PLC控制系统的日常维护中，电气备件消耗量大的为各类继电器或空气开关。除了产品本身质量原因之外，主要是由于现场环境比较恶劣。例如，暴露于生产环境中的接触器触点易打火或氧化，逐渐发热变形，直至不能使用。该生产线所有现场的控制箱都是选用密闭性较好的盘柜，其内部元器件较其他采用敞开式盘柜内元器件的使用寿命明显要长。所以避免此类故障应尽量选用高性能继电器，并改善元器件使用环境，就可以减少更换的频率，降低对系统运行的影响。

2、二类故障多发点在阀门或闸板这一类的设备上

因为这类设备的执行机构相对位移较大；或者传动结构复杂，机械、电气、液压等各环节稍有不到位就会产生误差或故障。在长期的运行状态下，如果缺乏运行维护，易造成阀体部件的卡，堵，漏等现象。因此在系统运行时要加强对此类设备的巡检，发现问题及时处理。我厂对此类设备建立了严格的点检制度，定期检查阀门是否变形，执行机构是否灵活可用，控制器是否有效等，很好地保证了整个控制系统的有效性。

3、三类故障点可能发生在开关、极限位置、安全保护和现场操作上的一些元件或设备上

其原因可能是因为长期磨损，也可能是长期不用而锈蚀老化。如该生产线窑尾料球储库上的布料行走车来回移动频繁，而且现场粉尘较大，所以接近开关触点出现变形、氧化、粉尘堵塞等从而导致触点接触不好或机构动作不灵敏。对于这类设备故障的处理主要体现在定期维护，使设备时刻处于完好状态。对于限位开关尤其是重型设备上的限位开关除了定期检修外，还要在设计的过程中加入多重的保护措施。

4、四类故障点可能发生在PLC系统中的子设备

这类设备如接线盒、线端子、螺栓螺母等处。这类故障产生的原因除了设备本身的制作工艺原因外还和安装工艺有关，如有人认为电线和螺钉连接是压的越紧越好，但在二次维修时很容易导致拆卸困难，大力拆卸时容易造成连接件及其附近部件的损害。长期的打火、锈蚀等也是造成故障的原因。根据工程经验，这类故障一般是很难发现和维修的。所以在设备的安装和维修中一定要按照安装要求的安装工艺进行，不留设备隐患。
1. The first type of fault point is also the most fault point) in relays and contactors



For example, in the daily maintenance of the PLC control system of a production line, the largest consumption of electrical spare parts is various relays or air switches. In addition to the quality of the product itself, the main reason is that the site environment is relatively bad. For example, the contacts of contactors exposed to the production environment are easy to ignite or oxidize, and gradually heat and deform until they cannot be used. All on-site control boxes of the production line are made of panels and cabinets with good tightness, and the service life of its internal components is significantly longer than that of other open panels and cabinets. Therefore, to avoid such failures, high-performance relays should be selected as far as possible, and the use environment of components should be improved to reduce the frequency of replacement and reduce the impact on system operation.



2. The second type of fault frequently occurs on equipment such as valves or rams



Because the relative displacement of the actuator of such equipment is relatively large; Or the transmission structure is complex, and if the mechanical, electrical, hydraulic and other links are not in place, errors or faults will occur. Under long-term operation, if there is no operation and maintenance, it is easy to cause jamming, blocking and leakage of valve body parts. Therefore, when the system is running, it is necessary to strengthen the patrol inspection of such equipment and timely handle the problems found. Our factory has established a strict point inspection system for such equipment, regularly checking whether the valve is deformed, whether the actuator is flexible and available, and whether the controller is effective, which well ensures the effectiveness of the entire control system.



3. The third type of fault point may occur on some elements or equipment in switch, limit position, safety protection and field operation



The reason may be due to long-term wear, or corrosion and aging due to long-term use. For example, the distribution cart on the kiln tail ball storage of the production line moves frequently, and the dust on the site is large, so the contact of the proximity switch is deformed, oxidized, and blocked by dust, resulting in poor contact of the contact or insensitive action of the mechanism. The treatment of this kind of equipment failure is mainly reflected in regular maintenance to keep the equipment in good condition at all times. For limit switches, especially those on heavy equipment, in addition to regular maintenance, multiple protection measures should be added in the design process.



4. The fourth kind of fault point may occur in the sub-equipment of PLC system



Such equipment as junction box, wire terminal, bolt and nut, etc. The causes of such failures are not only related to the manufacturing process of the equipment itself, but also related to the installation process. For example, some people think that the tighter the wire and screw connection is, the better, but it is easy to cause difficulties in disassembly during secondary maintenance, and it is easy to cause damage to the connector and its nearby components during heavy disassembly. Long-term sparking and corrosion are also the causes of the failure. According to engineering experience, such failures are generally difficult to find and repair. Therefore, the installation and maintenance of the equipment must be carried out according to the installation process required by the installation, without leaving any hidden danger of the equipment.