Among them, explosion-proof certification matching is a basic prerequisite, and motors and drivers must have corresponding explosion-proof levels (such as ExdIICT4Gb) and ensure compliance with national standards such as GB3836.

01 Core matching principle: equal emphasis on explosion-proof and performance

The matching of domestic explosion-proof servo systems should follow a dual principle: equal emphasis on safety and performance. Explosion proof matching is the foundation, while performance matching is the key.

The fundamental difference between explosion-proof servo motors and ordinary motors lies in their special explosion-proof design, such as high-strength cast iron casing, sealed structure, and special treatment of internal circuits.

The explosion-proof level and protection level must match the environmental hazard category. Select equipment that meets explosion-proof standards (such as ATEX, IECEx, GB3836) based on the type of explosive gas or dust in the work environment.

At the same time, the protection level (such as IP65, IP67) must meet environmental requirements to ensure that dust or moisture cannot enter the interior of the casing.

In terms of performance matching, torque, speed, and inertia must be considered comprehensively. The peak torque of the motor must be greater than the peak torque calculated by the application, with a safety margin of 10% -30%.

The rated torque must be greater than the effective torque calculated by the application, which is the key to preventing motor overheating.

02 Stability Guarantee: Load Analysis and Parameter Optimization

Load analysis is the core link to ensure the stable operation of the system. The matching of load inertia directly affects the response speed and stability of the system. It is generally recommended that the ratio of load inertia to motor rotor inertia be less than 5.

For high response applications, an inertia ratio of less than 3 or even 1 is better. Excessive inertia ratio can lead to sluggish system response and easy oscillation.

Parameter optimization is a key measure to ensure the smooth operation of explosion-proof servo systems. Setting the servo gain too high can cause motor vibration, especially at zero speed. This is usually due to setting the gain too high, and the gain value can be appropriately reduced.

Setting the control parameters of the servo integrated machine based on actual working conditions (such as PID parameters, speed curve, acceleration, etc.) can ensure smooth operation.

During the debugging process, setting the acceleration and deceleration time is particularly important. Setting too small acceleration and deceleration times can cause high inertia shaking of explosion-proof servo motors when suddenly started or stopped.

Adjusting the deceleration time appropriately can effectively solve this problem.

03 Installation and maintenance points: Ensure long-term stable operation

Standardized installation is the foundation for ensuring the stable operation of explosion-proof servo systems. The installation location should be chosen in a well ventilated area, away from direct heat sources and vibration sources.

The cable entry device must use armored cables and explosion-proof gland heads, and tighten the sealing ring until there are no visible gaps.

Grounding protection must be reliable, using at least double grounding wires (4mm ² copper core) with a grounding resistance of<4 Ω. Poor grounding can easily cause motor vibration.

Regular inspections are crucial in daily maintenance. Regularly inspect the sealing and integrity of equipment casings, cables, junction boxes, and other components to ensure that their explosion-proof performance is not compromised.

The stability of the encoder signal should be tested every 500 hours to prevent dust from entering and causing errors.

Real time monitoring of operational status can effectively prevent malfunctions. By utilizing the self diagnostic function of the servo all-in-one machine, real-time monitoring of the operating status (such as temperature, current, vibration, etc.) can be achieved, and abnormalities can be detected in a timely manner.

Set a fault alarm threshold, which will automatically sound an alarm or shut down when the device's operating parameters exceed the normal range.

04 Selection Strategy: Scientific Selection of Servo and Stepper

When selecting explosion-proof motors, the first step is to make a scientific choice between servo motors and stepper motors.

Explosion proof servo motors are suitable for scenarios with high dynamic response requirements, precision motion control, and continuous operation under heavy loads.

It adopts high-precision closed-loop control (± 0.01 °), with fast dynamic response, constant torque output, and strong overload capacity (3 times rated torque).

Explosion proof stepper motors are suitable for fixed position control, low-cost discrete control, and low-speed high torque scenarios.

It adopts open-loop control, and the accuracy depends on the step angle (usually ± 0.05 °~0.5 °). At low speeds, the torque is large, but at high speeds, the torque decreases significantly.

The selection decision can follow the following process: First, determine whether continuous speed regulation is needed? Yes → Select explosion-proof servo motor; No → proceed to the next step.

Then determine whether the positioning accuracy requires ≤ 0.1 °? Yes → Select explosion-proof servo motor; No → Consider explosion-proof stepper motors.