Eye drops filling lineAs an automation equipment with high precision and high cleanliness requirements, common faults mainly focus on abnormal startup, filling accuracy deviation, inability to fill materials, and dripping problems. The following are specific fault manifestations, causes, and solutions:

　　1、 No response during startup, unable to function properly

Fault manifestation: After pressing the start button, the device has no action, and the touch screen or indicator light does not respond.

Possible reasons:

1. Power supply issue: Line break, blown fuse, or no output from the switch power supply.

2. Emergency stop button not reset: The device was not unlocked after being urgently stopped.

3. Communication failure: The communication line between the touch screen and PLC (programmable logic controller) is loose or damaged.

resolvent:

1. Check the power supply:

-Turn off the main power of the device and check if the circuit is damaged and if the terminals are loose.

-Use a multimeter to measure if the fuse is blown. If it is blown, replace it with a fuse of the same specification.

-Check if the input/output voltage of the switch power supply is normal (usually 24V DC).

2. Reset the emergency stop button: Rotate the emergency stop button clockwise to the pop-up position and restart the device.

3. Check the communication line:

-Confirm that the communication lines (such as RS485, Ethernet) between the touch screen and PLC are securely connected.

-If the communication line is damaged, it needs to be replaced and the communication parameters need to be reconfigured.

　　2、 Inaccurate filling volume

Fault manifestation: The actual filling volume deviates significantly from the set value, or the filling volume at different workstations is inconsistent.

Possible reasons:

1. Valve switching speed issue: The opening and closing speed of the upper and lower valves does not match the viscosity of the liquid. The higher the viscosity, the slower the valve switching.

2. Calibration deviation of weighing system: Sensor zero drift or incorrect range setting.

3. Abnormal flow rate of filling head: blockage of filling head, slow action of solenoid valve, or poor sealing of cylinder.

resolvent:

1. Adjust the valve spring pressure:

-Increasing the pressure of the valve spring can accelerate the opening and closing speed, suitable for high viscosity liquids such as syrup.

-Reducing the spring pressure can slow down the switching speed, suitable for low viscosity liquids such as water.

2. Recalibrate the weighing system:

-Use standard weights to calibrate the zero point and range of the weighing sensor.

-Check if the sensor connection wire is loose and replace the sensor if necessary.

3. Check the filling head and solenoid valve:

-Clean the impurities or crystals inside the filling head to ensure smooth flow.

-Check if the solenoid valve coil is damaged. If it is damaged, replace it with a solenoid valve of the same model.

-Check if the cylinder sealing ring is aging. If it is aging, replace the sealing ring.

　　3、 The material cannot be filled

Fault manifestation: The equipment is running but there is no liquid flowing out, or the filling volume is extremely low.

Possible reasons:

1. Material nozzle closed or blocked: The material nozzle is not open or blocked by impurities.

2. Insufficient air pressure: Injection cylinder or cylinder leaks, resulting in insufficient driving force.

3. Insufficient materials: The liquid level in the hopper is below a relatively low level, which cannot meet the filling requirements.

resolvent:

1. Check the status of the nozzle:

-Confirm if the nozzle is in the open position. If it is closed, it needs to be manually opened.

-Clean the impurities or crystals inside the nozzle to ensure smooth flow.

2. Check the air pressure system:

-Use a pressure gauge to measure whether the gas source pressure is within the set range (usually 0.4-0.6MPa).

-Check the sealing of the injection cylinder and cylinder. If there is a leak, replace the sealing ring or repair the cylinder body.

3. Supplementary materials:

-Add enough liquid to the hopper to ensure that the liquid level is above the lower level mark.

-Check if the material pipeline is blocked, and if it is blocked, clean or replace the pipeline.

　　4、 Dripping after filling

Fault manifestation: After stopping filling, liquid continuously drips from the filling head or nozzle, contaminating the bottle body or tabletop.

Possible reasons:

1. Damaged filling head orifice: The orifice diameter is too large or the edge is worn, causing the liquid to be unable to be completely cut off.

2. Poor sealing of ball valve: The ball valve inside the filling head is worn or aged, resulting in poor sealing.

3. Failure of anti drip design: The anti drip sleeve or suction valve malfunctions and cannot promptly suck back residual liquid.

resolvent:

1. Repair the filling head hole:

-Measure the diameter of the orifice with a caliper, and if it exceeds 7.5mm, replace the filling head.

-If the edge of the hole is worn, gently grind it flat on a water sandpaper to ensure a smooth surface.

2. Replace the ball valve:

-Remove the filling head and check if the ball valve is worn or stuck.

-If the ball valve is damaged, it needs to be replaced with a ball valve of the same model and reinstalled for debugging.

3. Check the anti drip device:

-Confirm whether the anti drip sleeve is installed in place, and if it is loose, it needs to be re fixed.

-Check if the suction valve is working properly. If there is a malfunction, replace the suction valve.

5、 Multi station filling deviation

Fault manifestation: Some workstations have normal filling volume, while others have significant and irregular deviations.

Possible reasons:

1. Inaccurate positioning of container conveying: Control sensor failure, mechanical conveying mechanism jamming, or incorrect parameter settings for stopping.

2. Unstable flow rate of filling head: Internal wear of filling head or inconsistent action of solenoid valve.

resolvent:

1. Check the container conveying system:

-Confirm whether the control sensors (such as photoelectric switches and encoders) are working properly, and replace them if there is a malfunction.

-Check whether the mechanical conveying mechanism (such as chains and belts) is stuck or worn. If it is stuck, clean or replace the components.

-Reset the stop parameters (such as conveying speed, stop time) to ensure accurate container positioning.

2. Stable filling head flow:

-Remove the filling head and check for internal wear or blockage. If worn, replace the filling head.

-Check if the action of the solenoid valve is consistent. If not, adjust or replace the solenoid valve.