PILZ安全繼電器常見故障及維修處理
PILZ安(an)全(quan)繼電(dian)(dian)器(qi)在使用過程(cheng)中，由于各(ge)種原因，如產(chan)品質量不(bu)高、使用不(bu)當、維(wei)修不(bu)好(hao)等，常(chang)(chang)常(chang)(chang)發生(sheng)各(ge)種各(ge)樣的(de)故障(zhang)。對于電(dian)(dian)子PILZ安(an)全(quan)繼電(dian)(dian)器(qi)，因目前機車上所用種類還少，其故障(zhang)及(ji)(ji)處理以及(ji)(ji)檢查、試驗(yan)具有自己的(de)特(te)點(dian)(dian)。在此，主(zhu)要(yao)介紹有觸(chu)點(dian)(dian)PILZ安(an)全(quan)繼電(dian)(dian)器(qi)的(de)故障(zhang)及(ji)(ji)處理。
最常見的有以下幾種：
(一)觸頭故障
1.由于觸頭的機械(xie)咬合(觸頭上形(xing)成的針狀凸起與(yu)凹坑相互咬住)、熔焊或冷焊而產(chan)生無法斷開的現象(xiang)。
2.由于(yu)接觸電阻變大和不(bu)穩定使電路無法(fa)正常接通(tong)的現象。
3.由于負(fu)載(zai)過大，或(huo)觸頭容量過小，或(huo)負(fu)載(zai)性質變化等引起觸頭無法分、研華工控機合電路的故(gu)障。
4.由于(yu)電壓(ya)過高，或觸(chu)頭開距變小(xiao)而(er)出現(xian)觸(chu)頭間隙(xi)重新擊穿的故障(zhang)。
5.由于電源(yuan)頻率過(guo)(guo)高(gao)，或觸頭間隙電容過(guo)(guo)大而產生無法準確開斷電路的故障。
6.由于各(ge)種(zhong)環境(jing)條件(jian)不滿(man)足要(yao)求而造成觸頭工作(zuo)的失誤。
7.由于沒(mei)有采用(yong)熄弧裝置(zhi)或措(cuo)施，或參數(shu)選用(yong)不當而造成觸頭磨損(sun)，或產生不必要(yao)的干(gan)擾。
(二)線圈故障
1.由(you)于(yu)環境溫度(du)的(de)變(bian)化(超過(guo)技術(shu)條件規(gui)定值)導致線(xian)圈溫升(sheng)超過(guo)允許值而(er)引(yin)起(qi)線(xian)圈絕緣的(de)損壞；由(you)于(yu)潮濕而(er)引(yin)起(qi)絕緣水平的(de)嚴重降低；由(you)于(yu)腐蝕(shi)而(er)引(yin)起(qi)內(nei)部斷(duan)線(xian)或(huo)匝間短路。
2.由于線圈電壓(ya)超過110%額定電壓(ya)而(er)導致(zhi)線圈損壞。
3.在使用維修時(shi)，可能由于(yu)工具的(de)碰傷而使線圈絕緣損壞(huai)，或引起(qi)線折斷。
4.由于線(xian)圈(quan)電(dian)(dian)壓接(jie)錯(cuo)，如額定電(dian)(dian)壓為110V的(de)線(xian)圈(quan)接(jie)到220V的(de)電(dian)(dian)源電(dian)(dian)壓上(shang)，或將(jiang)交流電(dian)(dian)壓線(xian)圈(quan)接(jie)到同(tong)樣(yang)等(deng)級的(de)直流電(dian)(dian)壓上(shang)而使線(xian)圈(quan)立即燒壞(huai)。
5.交流線圈可能由于(yu)線圈電(dian)(dian)壓(ya)超過110%額(e)定電(dian)(dian)壓(ya)，或操作頻率過高，或當(dang)電(dian)(dian)壓(ya)低于(yu)85%額(e)定電(dian)(dian)壓(ya)時因銜(xian)鐵吸(xi)合不上而燒壞。
6.當交流線圈接上電(dian)壓時，可能由于傳動機構不(bu)(bu)靈(ling)或卡(ka)死等原因，使銜鐵不(bu)(bu)能閉合而(er)使線圈燒壞。
(三)磁路故障
1.棱角和轉軸的(de)磨損，導致銜(xian)鐵(tie)轉動(dong)不靈(ling)或(huo)卡死的(de)故障。
2.在有(you)些直(zhi)流PILZ安全繼電器中，由于(yu)機械(xie)磨(mo)損，或非磁(ci)性墊片(pian)損壞，使銜(xian)(xian)鐵閉合(he)后的最小氣隙變小，剩磁(ci)過大，導(dao)致銜(xian)(xian)鐵不(bu)能釋放的故障。
3.交流PILZ安全繼電器鐵(tie)心(xin)上(shang)分磁環(huan)斷裂，或銜鐵(tie)和鐵(tie)心(xin)極(ji)面生銹或侵入雜質時，將引起銜鐵(tie)振動(dong)，產生噪音。
4.交流PILZ安全(quan)繼電器E型(xing)鐵(tie)心(xin)(xin)中(zhong)，由于(yu)兩側鐵(tie)心(xin)(xin)的(de)磨(mo)損而使中(zhong)柱的(de)氣隙消失時，將產生銜鐵(tie)粘住不放的(de)故障。
(四)其它故障處理
如各(ge)種(zhong)零件(jian)產生變形或(huo)松動，機(ji)械損壞，鍍層裂開或(huo)剝落，各(ge)帶電部分與外殼間的(de)絕緣不夠(gou)，反(fan)力彈(dan)簧因疲勞而(er)失去(qu)彈(dan)性，各(ge)種(zhong)整(zheng)定值(zhi)調整(zheng)不當，產品已(yi)達額定壽(shou)命等。
PILZ安全(quan)繼(ji)電器產生故障的(de)原(yuan)因很多(duo)，除了要求(qiu)生產廠確(que)(que)保產品的(de)質量以外，正確(que)(que)使用和(he)認真維修也是減少(shao)故障、保證可靠工作的(de)重要環節。
PILZ安全繼電器的維修
前(qian)已述(shu)及，PILZ安(an)全繼(ji)(ji)電(dian)(dian)(dian)(dian)器(qi)(qi)是電(dian)(dian)(dian)(dian)力機(ji)(ji)(ji)(ji)車(che)(che)控(kong)制(zhi)電(dian)(dian)(dian)(dian)路和監測(ce)保(bao)(bao)(bao)護(hu)系(xi)統的(de)(de)(de)主(zhu)(zhu)(zhu)要(yao)配件。電(dian)(dian)(dian)(dian)力機(ji)(ji)(ji)(ji)車(che)(che)運行時(shi)，當主(zhu)(zhu)(zhu)電(dian)(dian)(dian)(dian)路和輔助電(dian)(dian)(dian)(dian)路中的(de)(de)(de)電(dian)(dian)(dian)(dian)機(ji)(ji)(ji)(ji)、電(dian)(dian)(dian)(dian)器(qi)(qi)或聯接線(xian)路出現故(gu)障(zhang)時(shi)，可通(tong)過相應監測(ce)保(bao)(bao)(bao)護(hu)系(xi)統的(de)(de)(de)PILZ安(an)全繼(ji)(ji)電(dian)(dian)(dian)(dian)器(qi)(qi)，將故(gu)障(zhang)轉(zhuan)化(hua)為電(dian)(dian)(dian)(dian)訊(xun)號(hao)，一方面反饋(kui)到(dao)主(zhu)(zhu)(zhu)斷路器(qi)(qi)的(de)(de)(de)分閘線(xian)圈，使主(zhu)(zhu)(zhu)斷路器(qi)(qi)跳閘，切(qie)斷電(dian)(dian)(dian)(dian)力機(ji)(ji)(ji)(ji)車(che)(che)總電(dian)(dian)(dian)(dian)源(yuan)，對電(dian)(dian)(dian)(dian)力機(ji)(ji)(ji)(ji)車(che)(che)進行保(bao)(bao)(bao)護(hu)；另(ling)一方面反饋(kui)到(dao)信號(hao)裝(zhuang)置(包括機(ji)(ji)(ji)(ji)械(xie)信號(hao)和電(dian)(dian)(dian)(dian)信號(hao))，使其顯(xian)示不(bu)同的(de)(de)(de)故(gu)障(zhang)狀態，指示電(dian)(dian)(dian)(dian)力機(ji)(ji)(ji)(ji)車(che)(che)乘(cheng)務(wu)員(yuan)及時(shi)而(er)正確的(de)(de)(de)處(chu)理故(gu)障(zhang)。可見，PILZ安(an)全繼(ji)(ji)電(dian)(dian)(dian)(dian)器(qi)(qi)雖(sui)然不(bu)直接控(kong)制(zhi)主(zhu)(zhu)(zhu)電(dian)(dian)(dian)(dian)路和輔助電(dian)(dian)(dian)(dian)路，但在電(dian)(dian)(dian)(dian)力機(ji)(ji)(ji)(ji)車(che)(che)上(shang)的(de)(de)(de)作用卻(que)是極(ji)其重要(yao)的(de)(de)(de)。
由于(yu)電(dian)力機車電(dian)器(qi)的(de)(de)(de)工(gong)作(zuo)條件(jian)惡劣，各(ge)(ge)PILZ安全(quan)繼電(dian)器(qi)及(ji)部件(jian)的(de)(de)(de)性(xing)能與參數(shu)也將隨著工(gong)作(zuo)任務與使用(yong)(yong)時間的(de)(de)(de)改(gai)(gai)變(bian)而改(gai)(gai)變(bian)，而且還經常(chang)(chang)受(shou)到各(ge)(ge)種偶然(ran)因素的(de)(de)(de)影(ying)響。因此，我們(men)必(bi)須對(dui)(dui)這些情(qing)況(kuang)經常(chang)(chang)地監視(shi)和及(ji)時地了解，對(dui)(dui)可(ke)能出現的(de)(de)(de)各(ge)(ge)種異常(chang)(chang)現象及(ji)早(zao)地提防，對(dui)(dui)某一PILZ安全(quan)繼電(dian)器(qi)或PILZ安全(quan)繼電(dian)器(qi)的(de)(de)(de)某一部件(jian)產生的(de)(de)(de)故障及(ji)時地修理或更換(huan)，以確保各(ge)(ge)PILZ安全(quan)繼電(dian)器(qi)的(de)(de)(de)使用(yong)(yong)壽命，保證電(dian)力機車正常(chang)(chang)而可(ke)靠(kao)的(de)(de)(de)工(gong)作(zuo)。所以，堅持預(yu)防為主(zhu)的(de)(de)(de)方針，建立必(bi)要的(de)(de)(de)維(wei)修制(zhi)度，對(dui)(dui)PILZ安全(quan)繼電(dian)器(qi)進行經常(chang)(chang)的(de)(de)(de)和定期(qi)的(de)(de)(de)維(wei)修是(shi)十分必(bi)要的(de)(de)(de)。
盡管PILZ安全繼電(dian)器型(xing)號不同，檢(jian)修方法也有區別(bie)，但是在檢(jian)修時都應按(an)以下共同的要求進行(xing)。
(1)PILZ安全繼電器活(huo)動部(bu)分的動作應(ying)靈活(huo)、可靠，外罩及殼體應(ying)無(wu)損壞或缺(que)少零件等情況(kuang)。
(2)PILZ安(an)全繼電(dian)器線圈引出端子(zi)及外部(bu)連接線必(bi)(bi)須(xu)牢固、可靠，電(dian)磁PILZ安(an)全繼電(dian)器吸引線圈的阻值必(bi)(bi)須(xu)符合有關的技術規定。
(3)有指示(shi)件的(de)PILZ安全繼(ji)電器應檢查指示(shi)件的(de)自鎖和釋放作(zuo)用，保證其正確(que)、可靠。
(4)絕緣狀(zhuang)態良好，磨耗件及易損件(包括膠木件、外罩、分磁(ci)(ci)環(huan)、非磁(ci)(ci)性墊片等)有缺損時(shi)應(ying)更新，各連接(jie)部分的(de)緊(jin)固(gu)狀(zhuang)態應(ying)良好。
(5)測(ce)量PILZ安全繼(ji)電器觸頭厚度、開(kai)距、超程及終壓力(li)等技術(shu)參數，必(bi)須符(fu)合有關規(gui)程和工作文件的(de)要求。
(6)調整PILZ安(an)全繼電器動作(zuo)參數的整定(ding)值，并(bing)加漆(qi)封(feng)固定(ding)。有(you)特殊要求時(shi)，還應測(ce)量PILZ安(an)全繼電器的返回系數。
PILZ安全(quan)繼電器(qi)的檢(jian)修工作除一般的清(qing)掃、檢(jian)查外，主(zhu)要內容是測量PILZ安全(quan)繼電器(qi)的技術參(can)數(shu)并(bing)調(diao)整其動作的整定值，即(ji)上面提到的第5條和第6條。
電(dian)(dian)(dian)力機(ji)車上(shang)裝有(you)電(dian)(dian)(dian)磁式PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)、機(ji)械(xie)式PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)和(he)電(dian)(dian)(dian)子PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)。從PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)的(de)(de)輸(shu)入、輸(shu)出特性(xing)我們(men)知(zhi)道，PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)只有(you)當(dang)輸(shu)入量達到(dao)其(qi)規(gui)定(ding)(ding)(ding)的(de)(de)動(dong)(dong)(dong)(dong)作(zuo)(zuo)參(can)數(shu)時才會動(dong)(dong)(dong)(dong)作(zuo)(zuo)，即電(dian)(dian)(dian)磁式PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)在達到(dao)規(gui)定(ding)(ding)(ding)的(de)(de)電(dian)(dian)(dian)壓、電(dian)(dian)(dian)流值(zhi)(zhi)(zhi)，或(huo)(huo)機(ji)械(xie)式PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)達到(dao)規(gui)定(ding)(ding)(ding)的(de)(de)壓力、速度(du)時，PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)才動(dong)(dong)(dong)(dong)作(zuo)(zuo)，并(bing)帶動(dong)(dong)(dong)(dong)相(xiang)應(ying)的(de)(de)聯鎖觸(chu)頭接(jie)觸(chu)或(huo)(huo)分斷相(xiang)應(ying)的(de)(de)控制電(dian)(dian)(dian)路，將故障或(huo)(huo)正常工(gong)況準(zhun)(zhun)確(que)的(de)(de)顯示(shi)出來。由(you)此可見(jian)，PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)的(de)(de)動(dong)(dong)(dong)(dong)作(zuo)(zuo)參(can)數(shu)是決定(ding)(ding)(ding)PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)準(zhun)(zhun)確(que)動(dong)(dong)(dong)(dong)作(zuo)(zuo)的(de)(de)決定(ding)(ding)(ding)性(xing)因素，而(er)調(diao)節(jie)PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)動(dong)(dong)(dong)(dong)作(zuo)(zuo)參(can)數(shu)的(de)(de)過(guo)程，即對PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)的(de)(de)整(zheng)(zheng)(zheng)(zheng)定(ding)(ding)(ding)過(guo)程就(jiu)顯得尤為重(zhong)要(yao)了(le)。所以，在電(dian)(dian)(dian)力機(ji)車中修時，最主要(yao)的(de)(de)任務之一就(jiu)是必(bi)須對全(quan)(quan)(quan)部(bu)PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)重(zhong)新整(zheng)(zheng)(zheng)(zheng)定(ding)(ding)(ding)、校檢。PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)整(zheng)(zheng)(zheng)(zheng)定(ding)(ding)(ding)值(zhi)(zhi)(zhi)的(de)(de)調(diao)試應(ying)由(you)專職人員在專用(yong)的(de)(de)試驗(yan)臺上(shang)進(jin)行。電(dian)(dian)(dian)磁式PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)可借調(diao)整(zheng)(zheng)(zheng)(zheng)反力彈簧、初始氣(qi)隙及非(fei)磁性(xing)墊片(pian)等措(cuo)施(shi)來調(diao)整(zheng)(zheng)(zheng)(zheng)動(dong)(dong)(dong)(dong)作(zuo)(zuo)值(zhi)(zhi)(zhi)。一般地，調(diao)整(zheng)(zheng)(zheng)(zheng)初始氣(qi)隙可改變(bian)(bian)其(qi)動(dong)(dong)(dong)(dong)作(zuo)(zuo)值(zhi)(zhi)(zhi)，調(diao)整(zheng)(zheng)(zheng)(zheng)非(fei)磁性(xing)墊片(pian)可改變(bian)(bian)其(qi)釋(shi)放(fang)值(zhi)(zhi)(zhi)，而(er)調(diao)整(zheng)(zheng)(zheng)(zheng)反力彈簧則(ze)動(dong)(dong)(dong)(dong)作(zuo)(zuo)值(zhi)(zhi)(zhi)和(he)釋(shi)放(fang)值(zhi)(zhi)(zhi)都可改變(bian)(bian)。應(ying)當(dang)注意的(de)(de)是，各PILZ安(an)(an)(an)全(quan)(quan)(quan)繼(ji)(ji)(ji)(ji)電(dian)(dian)(dian)器(qi)(qi)整(zheng)(zheng)(zheng)(zheng)定(ding)(ding)(ding)完畢后(hou)應(ying)鉛(qian)封(feng)或(huo)(huo)漆(qi)封(feng)，以防(fang)錯動(dong)(dong)(dong)(dong)而(er)影響整(zheng)(zheng)(zheng)(zheng)定(ding)(ding)(ding)值(zhi)(zhi)(zhi)。
必(bi)要時，某些PILZ安全(quan)繼(ji)電(dian)器在檢修(xiu)后還應作振(zhen)動試驗，觸(chu)頭壓力及接觸(chu)電(dian)阻測(ce)試。
