The Beginning of the Chaos
A client called us because their machine would start… whenever it wanted. Sometimes it would start, sometimes it wouldn’t. And when it was finally working, boom! It would stop without explanation.
First Suspicion
When something starts and then shuts down on its own, there’s almost always a classic culprit: the stop signal.
So we went straight to checking buttons, terminal blocks, and wiring.
The Real Problem
And there it was: the stop button had an intermittent, loose connection. At first glance, it looked fine, but when you moved it even slightly, the signal would jump as if someone were pressing it.
Action Plan
We proposed replacing the button, checking the wiring continuity, and ensuring it was securely mounted on the panel. No magic bullets. Just eliminating the exact cause of the phantom stop.
Closing Message
A loose stop button can cause more losses than a major failure.
Sometimes the smallest thing is what stops things the most.
Would you check the simple hardware first… or go straight to the PLC?
