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Servo Motor and Drive Troubleshooting Guide

Quick Links:Mutual Servo Motor Issues | How to Repair Servo Motor Components | Demand Assist After Troubleshooting?

A servo motor is a torque-based engine comprised of a rotary actuator or linear actuator. This type of motor allows for precise controls adjusting for angular and linear position, torque, velocity and dispatch. Four components, motor, a drive, controller and feedback unit, comprise modern servo systems.

Servo motors are usually quite small-scale, simply they still pack a lot of power and efficiency which is why a lot of applications apply them, namely industrial. You'll discover them in industries like robotics, metal cutting and forming, press, woodworking, conveyor belt setups and more than.

When selecting a servo motor, the inertia load should never exceed ten times its capabilities. Many different types of servo motors and drives exist just all are a ways to an end. Ultimately, they ability industrial grade equipment and machines and keep a plant fully operational. Just like anything, they tin malfunction.

When that happens, it can be costly for your visitor and crew. Repairs can have longer if you don't take an experienced maintenance team, leaving the equipment offline for hours, days, or even weeks.

It's always good to have backup equipment that you can replace malfunctioning devices with, especially if you demand to ship the affected machine or motor out for repair. Shipping out to fix a problem can as well take an extended period and exacerbate the reanimation of your team or equipment.

Browse through this troubleshooting guide to see if you tin can identify and prepare the problem before calling in a repair team or shipping your gear out for repair as it tin save y'all time and money.

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Common Issues and Possible Causes: Servo Motor Troubleshooting

Any piece of hardware or equipment will encounter issues later a while, simply the more common problems can unremarkably be handled if you know how to deal with them. Some of the more common bug will happen regardless of maintenance or upkeep, and may even cause a motor failure in the middle of an operation.

Before you begin pulling apart the servo to audit components, you'll want to encounter if in that location's a quick fix. Here'due south a brief list of issues your squad might come up across, and what they can do about them:

Overheating

Believe it or not, most servos are susceptible to heat, especially when they're running for extended periods of time. While maintenance crews do report a college telephone call book for overheating during summer months, information technology tin happen even during libation weather condition.

Servos tin can overheat for a number of reasons, similar the increment of indoor and outdoor temperatures, extended operating times, poor ventilation or even the condition of your visitor's equipment. Older machines tend to overheat more often as their internals wear out.

An overheating servo is never good because the elevated heat levels can damage your equipment and fifty-fifty ruin other parts of your connected arrangement. Any good servo will have a failsafe, of class, and shut downwardly when the temperature surpasses a dangerous threshold. That doesn't alter the fact that it can cause severe impairment to visitor's equipment and waste a lot of your team'southward time.

Ensure your plant is climate-controlled and keep the temperature inside regulated equally much every bit possible. You don't necessarily need to go along it freezing inside your plant, but you practice want to prevent temperatures from climbing as well high in full general.

Furthermore, never attempt to cool the servo while information technology's running by opening the chiffonier door or placing a fan nearby. This tactic will only put actress wear on the system. Excess grit and dirt tin and volition seep in, damaging components.

If the overheating equipment is erstwhile, accept it serviced, and make sure the major components are in proper society. You may need to supercede a few — or several parts — especially when it comes to an older motor.

Finally, e'er brand certain to turn off an overheating system and allow it cool off for a decent corporeality of time. If this becomes constant, where the equipment is idle more it's operational, you may want to consider replacing it.

Servo Motor Won't Plow

Every once in a while, you might come to notice that your motor just isn't moving. This discovery may seem like bad news since a servo motor has then many components that information technology tin be difficult pinpointing the exact trouble. If you know this quick tip, however, that's not the case.

Just check the controller'due south Digital-Analog-Converter output. If you discover a DAC parameter value of 0 or just shy of information technology, then that'due south why the drive is not moving. There's something wrong with the controller, and you may need to replace it. But if that number is larger, then the controller is doing what it's supposed to, and yous can move on.

If the equipment problem is because of the drive, so you should be able to run a self-test. This test forces the motor to operate at a depression efficiency so that y'all tin can see whether or not it's working properly. If zippo happens, then you know the problem is with the drive.

Servo Drive Replacement Parts

Servo Making Aberrant Noises

A servo motor volition e'er brand a modest amount of noise, it'southward natural. Bustling is the nearly common noise a servo drive or motor will produce during normal operation.

That said, it should never be loud to the betoken of being obnoxious. If the servo does make foreign noises, the trouble is nigh likely incorrect wiring or electric issues. Check to brand sure the servo is grounded properly and that it'south getting the appropriate amount of ability. Evidently, be sure the servo is off before working on the electrical circuits.

Servo Motor Producing Reduced Torque

Torque is the amount of muscle, energy or power required to rotate and move a machinery. It comes from three bones sources: friction, external forces like fighting gravity and accelerating a machinery's inertia.

Past nature, motors will only put out a certain corporeality of torque and so that if you choose the wrong ane, it may not exist able to handle the workload your team needs it to. Sometimes, you lot may also accept a servo motor malfunction, and it volition cease producing plenty torque. Some of the most pop servos operate between iv.8v and half dozen.0v which is 130.5 oz-in and 152.8 oz-in respectively.

Aside from the motor not having enough ability, here are some other things y'all can check:

• The servo amplifier rating.
• The servo's workload limits.
• Low voltage or voltage drops within the organisation.
• Bad capacitors.
• Inadequate or improper connections.

You and your squad will want to become familiar with how to test servo motor and drive systems because this can often happen, particularly with older and dated equipment.

Servo Motor Repair Services

Servo Smells Funny or Produces Smoke

More than than probable, if your servo produces a stiff odor, it'south going to be reminiscent of something burning. If y'all notice this or run into smoke of any kind, it indicates that your organisation is overheating.

Cheque the cooling system or air flow to ensure it's not restricted in any way. If your servo is already exposed, ensure that nothing like clay or grit particles made its mode inside. If neither of these steps help, check to see if the bearings are in proper order. They tin have several issues including also much lubricant, worn bearings and overheating.

You may likewise see the odour of ozone, which indicates called-for windings or wiring. If that'south the case, you need to ensure the wires are contactless and the organisation is grounded properly.

Servo Motor Shuts Off After Reaching High or Total Speed

If your servo motor starts fine merely turns off after reaching a high speed, it indicates a serious malfunction. This problem may be a little harder to repair. A few factors may crusade your motor to shut off, such as:

• Defective overload protection system.
• Rapid overheating.
• Inadequate or improper bearings.
• Blown fuses or old ones in need of replacement.
• Bad capacitors.
• RPM meter malfunction or inaccurate readings.
• Voltage drops or poor wiring.

Depending on what you and your team detect, you lot can begin repairs on your servo motor or contact a professional to fix your equipment.

How to Repair Servo Motor Components: Fixing the Trouble

One time your maintenance crew has identified the trouble, you lot can move on to the actual repairs. Before you practise, take note that most of the issues or indicators are similar. Bad capacitors, for example, tin can be responsible for several bug, and the same applies to voltage drops or shoddy wiring.

Make sure you take the advisable testing tools and meters before moving on to the side by side section. Equally a forewarning, this equipment is more than complex, then you will not be able to discover it in conventional retail stores.

Troubleshooting and Repairing

Servo drive troubleshooting and servo motor troubleshooting are the lifeblood of identifying and fixing a problem. The ultimate goal is to work with and sometimes operate the servo to deduce what's going wrong. Luckily, most servo drive and motor systems are attached to an alarm which volition sound when something is upwardly.

Alarm : Troubleshooting a servo drive can exist a circuitous and dangerous process. It requires working cognition of electromechanically controlled motors, actuators and a volt-ohm meter. If whatever of these components seem foreign to you or your team, outsource help. While reading up on how to repair servo motor and drive system, yous'll desire to be prepared before taking activity.

Your servo may exist slightly dissimilar than what we are describing, nevertheless the following troubleshooting steps should remain the same:

1. Earlier supplying power to the unit, inspect the MOSFETs, inputs and outputs, IGBT's relays, feedback circuits, ability supplies and capacitors.
2. Plough on the machine or main breaker and check the LED or readout brandish. If at that place is a screen and it does not come up on, brand sure in that location is power supplied. If the alarm comes on immediately before anything else powers on, then your problem is probably the servo drive. If the drive begins working before the alarm sounds, you can rule it out.
3. Inspect the servo drive and motor to identify missing, broken or bent parts.
4. Cheque the motor or cablevision plugs. If you notice any irregularities, you lot may need to replace these components.
5. Review the diagnostic or lead meters to run across if there'due south unnecessary friction in the motor axis. Friction is a rare problem, but it can happen and normally does when there'due south too little — or besides much — lube.
6. Inspect the motor box coolant or air catamenia system. Make sure to clean or remove particles, dry out whatever plugs and check all cables.
7. Check for a bind in the axis or if the brushes are worn down in the DC motor.
8. Employ a volt ohm meter to check for an incoming power supply. You'll mainly want to test the servo drive to ensure the voltage is correct.

Of course, your maintenance squad may run through all these steps and nonetheless accept trouble identifying what'due south wrong. That's okay.

Look at these questions and see if they fit the trouble your equipment is having:

• Does the alarm sound, or does the motor have problems in feed or during rapid motility? There may be a bind.
• Is there a loud hum coming from the servo motor? Your motor centrality likely has a demark.
• Is at that place a loud growl or similar racket during high-speed operation? The bearings are bad.
• Does the motor slows down or stops abruptly? You lot might have an electrical problem. Bank check to make sure that coolant didn't seep into the electrical box or one of the axes.

Once you complete a repair or replacement of parts, you'll want to exam the servo motor before putting information technology dorsum into regular functioning. Y'all tin exercise this by plugging information technology into a universal tester, which will provide data on the feedback, phases, rotation, speeds and direction nether load. Besides, don't subject information technology to a heavy workload right away. Ease it back into operation past starting slow, just to ensure everything is in proper working lodge.

If you need specific repair instructions for the various components, you can find a comprehensive guide hither.

Demand Help After Troubleshooting?

Fifty-fifty subsequently the most rigorous troubleshooting and budget regimen yous and your team may all the same need help getting the servo up and running once more. At this stage, your team may not want to admit that they need help, simply it's perfectly okay. When y'all use a reliable servicing company — similar Global Electronic Services — we'll have you back in operation in no time, and nosotros won't sweep away all your profits to practice it.

Global Electronic Services technicians will practise everything from inspecting the motor to performing necessary fixes and painting the station. Before shipping anything back, the quality control team will check and audit the components to ensure that everything is functional.

We offer you lot complete servo motor and repair aid and nosotros operate with a qualified team of OEM-trained servo technicians. Every tech follows a strict prepare of procedures when repairing servo motors and drives, which ensures that they can fix any damage or problem without creating more. Call the states today!

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Source: https://gesrepair.com/servo-motor-drive-troubleshooting-guide/

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