The electronic jacquard faucet is a core component in textile machinery, responsible for controlling the opening motion of warp yarns to achieve the weaving of complex patterns. Its malfunction may involve multiple systems such as mechanical, electrical, electronic, and software, directly affecting production efficiency and product quality. The following is a detailed analysis of common faults and solutions for electronic jacquard faucets:
1. Mechanical system faults
1. Abnormal movement of the lifting blade (integrated piece)
Fault phenomenon: The lifting blade movement is stuck, shaking or unable to be in place, resulting in unclear opening or broken warp yarn. Possible cause: Mechanical wear: Wear of the lifting guide rail, slider, or bearing, resulting in increased resistance to movement. Insufficient lubrication: After long-term operation, the lubricating grease dries up and friction increases. Installation deviation: The clearance between the lifting blade and the guide rail is too large or skewed, causing collision or jamming.
Thread wrapping: After the warp yarn breaks, the thread wraps around the lifting knife, hindering movement.
.Solution: Regularly check the guide rail and slider, replace worn parts (such as checking every 6 months).
. Use high-temperature resistant grease (such as molybdenum disulfide based grease) to lubricate the guide rails and bearings, and replenish them every 3 months.Adjust the installation position of the lifting tool again to ensure even clearance with the guide rail (usually 0.1-0.2mm).
After stopping the machine, clean the tangled yarn in a timely manner and check whether the warp tension is uniform.
.2. Electromagnetic (needle selector) malfunction
Fault phenomenon: The electromagnetic does not engage or releases slowly, resulting in incorrect needle selection or disordered patterns.
. Possible causes: Electrical faults: coil open circuit, short circuit, or unstable voltage (such as voltage below 20% of rated value). Mechanical jamming: There are foreign objects or rust in the gap between the iron core and the armature of the electromagnet. Spring fatigue: The elasticity of the reset spring decays, making it difficult to quickly release the armature.Solution: Use a multimeter to check the coil resistance (the normal value is usually between tens of ohms and hundreds of ohms). If there is an open circuit, replace the electromagnet.
. Clean the oil or iron filings between the iron core and the armature, and apply a thin layer of conductive paste (such as silver based conductive paste) to reduce friction. Replace the reset spring (it is recommended to use spring steel material with an elastic coefficient that meets the design requirements). Check if the power supply voltage is stable and install a voltage regulator if necessary.2. Electrical system malfunction
1. Abnormal sensor signal
Fault phenomenon: The jacquard faucet cannot recognize the position or opening height of the warp yarn, resulting in misaligned or broken patterns.
. Possible cause: Sensor contamination: The photoelectric sensor lens is obstructed by dust or oil. Sensor damage: Hall sensor or internal components of proximity switch fail. Signal interference: Strong electromagnetic fields (such as frequency converters) interfere with sensor signal transmission. Solution: Use a dust-free cloth dipped in alcohol to clean the sensor lens, and clean it once per shift.Use a multimeter to detect the output signal of the sensor (such as the output of a Hall sensor should be a square wave or pulse signal). If it is abnormal, replace the sensor.
. Use shielded twisted pair cables for sensor signal lines and keep them away from power cables (spacing ≥ 30cm).2. Power module malfunction
Fault phenomenon: The jacquard faucet has no display or some functions fail, and the power indicator light flashes or goes out.
. Possible cause: Power overload: The total power of the jacquard faucet exceeds the rated capacity of the power module (e.g. the rated power of the power module is 500W, but the actual load is 600W). Poor heat dissipation: The protection is triggered when the temperature of the power module is too high (usually exceeding 70 ℃). Electrolytic capacitor aging: power module output voltage fluctuation (such as ripple voltage>5%). Solution: Calculate the total power of the jacquard faucet (number of electromagnets x individual power+control board power), and replace it with a larger capacity power module (such as upgrading to 800W). Clean the dust on the cooling fan and fins of the power module to ensure good ventilation (wind speed ≥ 2m/s). Use an oscilloscope to detect the output voltage ripple. If it exceeds the standard, replace the electrolytic capacitor (it is recommended to use a 105 ℃ temperature resistant capacitor).3. Electronic control system malfunction
1. Communication interruption on the control board
Fault phenomenon: The jacquard faucet cannot be connected to the main control computer, displaying "communication error" or "device offline".
. Possible cause: Communication protocol mismatch: The communication protocol (such as CAN, RS485) version used between the main control computer and the jacquard faucet control board is inconsistent. Communication line fault: Communication line is open, short circuited, or has poor contact (such as RJ45 connector oxidation). Control board damage: Communication chip (such as MAX485) or microprocessor (such as STM32) malfunction. Solution: Confirm that the main control computer and the jacquard faucet control board use the same communication protocol (such as Modbus RTU protocol). Use a network tester to check the connectivity of communication lines and replace damaged communication lines or connectors.Re burn the control board program (the original program needs to be backed up). If it still doesn't work, replace the control board.
.2. Pattern data loss or error
Fault phenomenon: The woven pattern does not match the design pattern, or there are messy or missing patterns.
. Possible reasons: Data transmission interruption: Data loss during USB or network transmission (such as poor contact of the USB drive). Memory failure: The control board's Flash memory is damaged or has insufficient capacity.Software version incompatibility: The pattern design software does not match the firmware version of the control board.
.Solution: retransmit pattern data and verify data integrity (such as calculating MD5 checksum).
. Back up the control board memory data with a programmer. If it is damaged, reinitialize the memory and write default data. Upgrade the pattern design software and control board firmware to the latest version (to be downloaded through official channels).