Common Problem Handling Guide for CNC Steel Cage Workstations

Main Tendon Positioning Deviation

Phenomenon: Uneven spacing of the main bars, exceeding the allowable tolerance (>±3 mm)

Resolution:

1. Check the calibration status of the laser positioning system and recalibrate the reference point
2. Clear welding slag and debris from the track to ensure smooth movement of the sliding table
3. Verify the feedback value of the servo motor encoder; replace the damaged coupling if necessary
4. Adjust the hydraulic clamping device pressure to the standard range (0.6–0.8 MPa)

Unstable Welding Quality

Typical Defects: Porosity, undercut, incomplete penetration

Resolution:

• Check the purity of the shielding gas (CO₂ ≥ 99.8%)
• Clean the welding torch's contact tip and replace worn wire feeding hoses
• Recalibrate the stick-out length of the welding wire (recommended: 12–15 mm)
• Conduct process verification tests on welding parameters
(e.g., for 28 mm steel bars: current 280–320 A, voltage 28–32 V)

Servo Driver Alarm

Common Alarm Codes:

E-05 (Overload): Check for mechanical transmission resistance and measure motor winding insulation

E-11 (Encoder Error): Inspect encoder connections and replace damaged cables

Emergency Handling: After powering off and resetting, perform a low-speed trial run (30% of rated speed)

PLC Communication Interruption

Troubleshooting Steps:

1. Check for oxidation on the Profinet connector
2. Measure network terminal resistance (should be 110 Ω)
3. Restart the switch and update firmware
4. Check for IP address conflicts among all nodes
5.  

Abnormal Noise from Rotating Disc

Solution:

√ Replenish grease (use EP2-grade lithium-based grease monthly)
√ Check slewing bearing clearance (axial clearance ≤ 0.15 mm)
√ Adjust reducer gear backlash (side clearance: 0.10–0.15 mm)

Hydraulic System Leakage

Key Inspection Areas:

1. Cylinder sealing rings (replacement cycle: every 2,000 hours)
2. High-pressure hose fittings (tightening torque: 120 N·m)
3. Valve block mounting surfaces (flatness tolerance: ≤ 0.02 mm)
4.  

Winter Construction Precautions

When ambient temperature is below 5 °C:

★ Preheat materials to 80–120 °C (measured with an infrared thermometer gun)
★ Extend interlayer cooling time by 30% compared to room temperature
★ Use low-temperature welding wires (e.g., JM-58)

Special Material Processing

For High-Strength Steel Bars (HRB600):

◇ Reduce welding speed by 20%
◇ Use argon-rich shielding gas (80% Ar + 20% CO₂)
◇ Apply post-weld slow cooling (cover with asbestos felt)

Visual System Calibration

1. Calibrate the chessboard pattern monthly
2. Maintain lighting intensity between 500–800 lux
3. Keep calibration error within ±0.1 pixel
4. Update the camera's internal parameter matrix

Database Management

Regular Tasks:

♦ Back up process parameters (incremental backup recommended weekly)
♦ Clear log files (retain logs from the last 30 days)
♦ Optimize SQL query indexes

Emergency Handling

In the event of a sudden power outage:

✓ Activate the emergency power supply immediately (ensure safe shutdown for at least 15 minutes)
✓ Manually release pressure from the hydraulic accumulator
✓ Record the current coordinate positions of all axes

Daily Safety Inspection

Must confirm:

Grating protection device response time is ≤ 50 ms

Emergency stop circuit impedance is < 1 Ω

Grounding resistance is < 4 Ω