Case Study: Troubleshooting Problems | Solution Heat Treatment System
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How to do basic automation control troubleshooting.
(This article is not about how to heat treat steel.)
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Induction Hardening System Example:
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A typical Raydyne ScanMaster induction hardening (heating) control system simultaneously controls scan speeds, rotation speeds, heat levels, heat times, quench times, quench temperature and time delays.
Induction Hardening System
This is a case study of troubleshooting problems and solution for a heat treatment induction hardening machine control. Some may consider it an advanced heat treat troubleshooting problem as it is on the automation control side of the Raydyne induction heat treatment system. But as far as automation control troubleshooting problems go, it is a simple and common example that the layman to machine automation control troubleshooting can learn a lot from. Common to robotics troubleshooting, mechatronics, servo encoder troubleshooting too. Hope it helps those just starting out.
Reported problem – heat treatment system:
Hi:
I am in the IT department and need some help troubleshooting the Allen Bradley PLC in our Radyne induction heat treating machine.
The problem is – the rotating plate-shaped platform has gone well below the level it usually does, I found the back plain of PLC is an old 32-bit system. How do I connect with it, solve the problem? Our go-to PLC person no longer works here. Any insight or guidance would be humbly appreciated! (I’ll email you pictures of the back plain, plate, and control panel.)
Thanks
Henry
The picture sent was of a computer backplane, not a PLC backplane. Hey, he was an IT person and you go with what you know. But I have to mention that so you understand my reason for such details below on the basics of troubleshooting and PLC basics. My desire was to give Henry enough basic knowledge so he could make a sound decision on which way he wanted to go about finding a solution for his heat treatment system. Well. On to my initial reply ...
Hi Henry:
The picture you sent us of the backplane you were looking at, was not a PLC, but a supporting computer. (Above is where we mocked up the picture of the heat treatment control panel you sent, to show you where the PLC is, and what type it is. The odds are, your problem is not in the computer you were looking down into at the backplane.
The probability of failure/change are as follows …
- A sensor failure or adjustment like encoder or limit switch (physical/mechanical problem) 90% to 99% chance
- Someone accessed menu on HMI screen on the front of the panel and changed offset 1–10% chance
- Computer you have been looking at 2% (3–20% if extreme heat in the panel, but symptoms do not match that type failure)
- Servo Driver (device below PLC in the panel) 1% (2–10% if extreme heat in the panel, but symptoms do not match that type failure)
- PLC (See picture above) 1% (Within PLC, sensor input I/O most likely, symptoms do not match microprocessor itself failure)
Heat Treatment System Troubleshooting Solutions
- Get RSLogix 500 PLC training and use PLC to troubleshoot.
- Get a local person trained in RSLogix 500 to troubleshoot. (I’ll get Clifford of Omega Star to reach out to you.)
- Call the phone number I gave you and have the machine manufacturer schedule an on-site service call.
If we trained you, what you would need for PLC troubleshooting is ...
- Laptop with RSLogix 500 and RSLinx software on it. (XP would be more reliable and cheaper)
- An Allen Bradley 1747-UIC or old PIC box cable to connect to the RJ485 port
- Discriptored backup copy of ladder logic program
PLC Troubleshooting procedure:
Power up laptop, connect to PLC RJ485 port, go online with PLC, save a backup copy of current PLC program in the machine. Saving current copy is very important. Then search ladder logic for plate home position sensor and encoder input data. Study related ladder logic to see why it is not going to normal position. You would need the machine manual from Radyne aftermarket support to navigate HMI screens.
Also note: If a computer, servo driver, HMI, or PLC failed due to high heat, they typically have catastrophic failure. Yet another indicator they are most likely not your problem.
After considering the information above, Henry opted for Clifford of Omega Star Controls & Technologies to go onsite. The next day Clifford generated a detailed report…
Initial troubleshooting of the heat treatment machine system HMI and controller revealed the software is sending and receiving inputs and outputs as expected.
Utilized the HMI to “Slow Jog” the Rotating up and the controller would fault immediately with the “Abort, Error Limit” message…
The broken connector and wire could be the initial problem… Conclusion: Replacing the servo motor (including brake and encoder) is recommended.
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TOPICS: Heat treatment | heat treatment of steel | advanced heat treat | solution heat treatment annealing steel and induction hardening case study referenced in this automation control troubleshooting case study at Houston Heat Treat are also relevant to Robotics troubleshooting, mechatronics, servo encoder troubleshooting too.
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