Servo system is an important core component in industrial automation and robotics technology, and its performance directly affects the accuracy, efficiency, and reliability of equipment. As an important component of the servo system, the long-term stable operation of the electric servo operator is crucial for ensuring the continuity of the production process. Here are some common diagnostic methods for faults and key maintenance techniques to ensure long-term stable operation of electric servo operators.

1、 Common fault diagnosis of servo system

（1） Motor overheating

Fault manifestation

Abnormal temperature rise during motor operation may cause servo drive alarm or motor shutdown.

Possible reasons

Poor heat dissipation: Motor cooling fan malfunction or blocked cooling channels, resulting in ineffective heat dissipation.

Overloading: The motor operates under overload for a long time, resulting in excessive current and generating too much heat.

Motor insulation aging: The insulation material of the motor winding is aging, causing leakage or short circuit, and increasing motor heating.

diagnostic method

Check if the motor cooling fan is running properly and clean the dust and debris in the cooling channel.

Check the load condition of the motor and confirm whether it has been operating at overload for a long time.

Use an insulation resistance tester to check the insulation resistance of the motor winding and determine if there is any insulation aging problem.

Solution

Clean the cooling channel and replace the damaged cooling fan.

Adjust the motor load to ensure it operates within the rated power range.

Replace the motor winding or the entire motor with insulation aging.

（2） Position deviation

Fault manifestation

The actual position of the servo motor deviates significantly from the commanded position, resulting in a decrease in equipment operating accuracy.

Possible reasons

Encoder malfunction: The position feedback encoder is damaged or the signal is interfered with, resulting in inaccurate position feedback.

Mechanical transmission issues: Wear or looseness of transmission components such as gears, belts, or screws, resulting in positional deviation.

Driver parameter setting error: Improper gain parameter setting of the driver resulted in inaccurate system response.

diagnostic method

Check the power and signal lines of the encoder to confirm if there is any looseness or interference.

Check the wear of mechanical transmission components and confirm if there is any looseness or damage.

Check the parameter settings of the drive to confirm if they meet the device requirements.

Solution

Replace the damaged encoder to ensure stable signal transmission.

Replace worn mechanical transmission components and readjust the transmission mechanism.

Adjust the parameter settings of the drive again to optimize system response.

（3） Motor vibration

Fault manifestation

The motor experiences shaking or vibration during operation, which affects the smooth operation of the equipment.

Possible reasons

Driver malfunction: Internal circuit failure or unreasonable parameter settings of the driver result in unstable motor control signals.

Power supply voltage fluctuation: Unstable or interfering power supply voltage can cause unstable motor operation.

Mechanical resonance: The mechanical structure of the equipment has a resonance frequency that coincides with the operating frequency of the motor.

diagnostic method

Check the alarm information and working status of the drive to confirm if there are any internal faults.

Check if the power supply voltage is stable and if there is any interference.

Analyze the mechanical structure of the equipment and confirm whether there is resonance phenomenon.

Solution

Replace the faulty drive and reset the drive parameters.

Install a voltage regulator or filter to improve the quality of the power supply.

Adjust the mechanical structure of the equipment, change the resonance frequency, or adjust the operating frequency of the motor to avoid resonance.

2、 Maintenance techniques to ensure long-term stable operation of electric servo operators

（1） Regular inspection and cleaning

Clean the heat dissipation components

Regularly clean the heat dissipation channels of the motor and driver to ensure the normal operation of the cooling fan and avoid overheating of the equipment due to poor heat dissipation.

Inspect mechanical components

Regularly inspect the wear of mechanical transmission components (such as gears, belts, screws, etc.), replace worn parts in a timely manner, and ensure transmission accuracy.

Check electrical connections

Regularly check the electrical connections of the motor, encoder, and driver to ensure that the connections are secure and free from looseness or virtual connections.

（2） Reasonable adjustment and optimization

Adjust drive parameters

According to the actual operation of the equipment, adjust the gain, filter and other parameters of the driver reasonably, optimize the system response, and improve operational stability.

Optimize the operating environment

Ensure that the temperature, humidity, and cleanliness of the equipment operating environment meet the requirements to avoid equipment failures caused by environmental factors.

load management

Reasonably allocate motor load, avoid long-term overload operation, and extend equipment service life.

（3） Preventive maintenance

Regularly replace vulnerable parts

According to the usage of the equipment, regularly replace vulnerable parts (such as motor carbon brushes, encoder bearings, etc.) to avoid malfunctions caused by component aging.

Backup important parameters

Regularly backup important parameter settings of drives and controllers to facilitate quick recovery and operation in case of equipment failure.

Train operators

Train operators to familiarize themselves with the operating procedures and common troubleshooting methods of the equipment, in order to avoid equipment damage caused by misoperation.

（4） Fault warning and monitoring

Install monitoring system

Install temperature, current, vibration and other sensors to monitor the real-time operation status of the equipment and detect abnormalities in a timely manner.

Analyze alarm information

Carefully analyze the alarm information of the equipment, promptly handle potential faults, and avoid the expansion of faults.

Establish and maintain archives

Establish equipment maintenance records to document each maintenance and troubleshooting process, facilitating analysis of equipment operation trends and optimization of maintenance strategies.

By using the above fault diagnosis methods and maintenance techniques, the failure rate of the servo system can be effectively reduced, ensuring the long-term stable operation of the electric servo operator, thereby improving production efficiency and equipment reliability.