Troubleshooting Process for Insulated Glass Equipment

When conducting a fault analysis, a specific procedure should be followed. This procedure is outlined below:

1. Analyze the symptoms while maintaining the status quo at the site

(1) Interview the operators: What kind of fault occurred? Under what circumstances and at what time did it occur? How long had the equipment been running? Were there any abnormal phenomena prior to the fault (e.g., unusual noises, alarm signals, smoke, or odors)? Was there any incorrect operation? Was the control system operating normally? Were there any changes to the operating procedures? Were there any particular difficulties or abnormalities during operation?

(2) Observation (including overall equipment condition and various operating parameters) Observe for any obvious abnormalities. Are there any parts that are jammed or damaged? Are any pipes loose or leaking? Are there any breaks, abrasions, or burn marks on cables or wires? What changes have occurred in the equipment’s operating parameters? Are there any obvious signs of damage?

(3) Check monitoring and measurement devices: Verify that all readings are normal, including pressure or instrument readings. Check whether filters, alarms, interlocks, printouts, or displays are functioning properly.

(4) Test the equipment in intermittent operation (if conditions permit): Examine intermittent operation, continuous operation, and conditions during fast or slow operation. Determine whether these conditions are representative and reproducible, whether they affect output, and whether they could cause damage or other hazards.

2. Equipment Inspection (including parts, components, and system wiring checks)

(1) Visual, Tactile, Auditory, and Olfactory Inspection (a process of in-depth observation) Touch: Check the temperature of vibrating components (or assemblies) (be careful! Use the back of your hand whenever possible). Listen: Check for abnormal noises. Smell: Check for burning odors or other unusual smells. Inspect: Check for changes in workpiece switches and positions, changes in equipment performance parameters, and circuit abnormalities. Circuit inspections should be conducted only after clearly understanding the system principles and being familiar with the specific system wiring and installation details. Circuit inspections should be conducted only after clearly understanding the system principles and being familiar with the specific system wiring and installation details.

(2) Evaluate Inspection Results: Assess whether the fault diagnosis is correct, whether clues to the fault have been identified, and whether the results of each inspection are consistent.

3. Determining the Fault Location

(1) Determine System Structure and Testing Methods: After familiarizing yourself with the equipment manual and understanding the basic principles of the equipment, identify the location of the equipment fault. Clearly define the testing methods to be used, the testing tools required, the types of test parameters or performance parameters that may be obtained, the operating conditions under which testing will be conducted, and the safety measures that must be followed. (2) System Testing Based on the preceding analysis, adopt the most appropriate measurement method and select suitable measurement points. Compare the results obtained from inputs or feedback with normal values or performance standards to identify suspected locations. There are many system testing methods, such as the direct comparison method (comparison with fault-free equipment), step-by-step isolation method (gradually narrowing the scope of inspection), condition variation method (used when fault symptoms are not obvious), trial and error method, measurement method, and sample testing method.

4. Repair or Replacement

(1) Repair: Identify the cause of the failure, repair it, and implement preventive measures; inspect related components to prevent the failure from spreading.

(2) Replacement: Correctly assemble and commission the replacement part, paying attention to related components.

5. Perform Performance Testing

(1) After starting the equipment and completing assembly and debugging, first operate manually (or in jog mode), then automatically (or continuously); first run under no-load conditions, then under load to measure performance.

(2) Adjust the load and speed gradually, starting from low to high and from light to heavy loads, respectively.

(3) Expand the scope of performance testing. Gradually extend the testing scope from local components to the entire system as needed, paying close attention to the operational status of non-faulty system areas. If performance meets requirements, the equipment is ready for delivery; if not, re-identify the faulty location.