Monitoring moons servo moto status during operation
In ball screw linear housings operation, the need for multi-dimensional monitoring to detect potential problems in a timely manner to ensure its stable operation, specifically from the following aspects.
First, the core parameters of real-time monitoring
electrical parameters
current: through the servo drive display or supporting software to observe the output current in real time, the current should be stabilized at 60% -80% of the rated current in normal operation, if it continues to exceed the rated value (such as more than 1.2 times), it may be too large a load, the motor stagnation or drive parameters are set improperly (such as gain is too high), it is necessary to set up the drive parameters. If the rated value is persistently exceeded (e.g. more than 1.2 times), it may be due to excessive load, motor stagnation or improper setting of drive parameters (e.g. too high gain), and it is necessary to stop the machine immediately for inspection.
Voltage: Monitor whether the power supply voltage is in the rated range (e.g. AC220V motor allows fluctuations of ±10%), a sudden rise in voltage may lead to the drive over-voltage alarm, while too low a voltage will make the motor torque is insufficient, appearing to rotate speed down or lose steps.
Temperature: The temperature of the motor casing is monitored in real time by the temperature sensing module built into the servo drive or by an external infrared temperature measurement device. The temperature of the motor case should be controlled within 70℃ for conventional motors and 85℃ for high-temperature tolerant motors.
Operation Parameters
Speed: Read the actual speed through the display of the drive or the software of the host computer, and compare it with the commanded speed, the deviation should be ≤1%, if the deviation is too large (e.g., more than 5%), it may be the encoder signal interference, load fluctuation, or mismatch of the PID parameters, and it is necessary to troubleshoot the wiring or re-tuning of the parameters.
Positional accuracy: In the positioning scene, the deviation between the actual position and the commanded position is detected by laser interferometer or scale, and the normal deviation should be ≤0.01mm (high-precision scene), if the deviation continues to increase, it is necessary to check whether the coupling is loose, whether the motor is losing steps or whether the resolution of the encoder meets the requirements.
Second, the physical state observation
Sound and vibration
During normal operation, moons servo moto should emit uniform low-frequency running sound, no sharp noise or periodic "jamming sound". If there is a high-frequency scream, it may be bearing wear or rotor and stator friction (sweeping); if there is a "buzzing" resonance sound, mostly mechanical resonance caused by improper PID parameters, need to reduce the gain or increase damping.
Appearance and connection
Observe whether there is oil leakage on the surface of the motor (may be bearing sealing failure), whether the winding leads are overheated and discolored (signs of insulation aging); check whether the encoder cable is pulled, broken, and the connector is not loose (poor contact will lead to loss of signals, leading to generator "out of step").
Third, with the help of tools and system monitoring
drive and debugging software
Use the real-time data recording function of the servo drive (such as trend graph), tracking current, temperature, speed and other parameters of the change curve, through the curve fluctuations to determine whether there is a periodic load fluctuations (such as a current peak every 10 seconds, it may be a load stall).
Some high-end drives support remote monitoring (e.g. through EtherCAT bus), which allows you to view the running status of multiple motors in real time in the central control room, set parameter thresholds (e.g. automatic alarm when the temperature is ≥80℃), and warn of failures in advance.
Upper computer and PLC system
In the automated production line, collect the running data of the motor through PLC or SCADA system, and write logic judgment program: when the current exceeds 1.1 times of the rated value, it will automatically reduce the running speed; when the temperature reaches the threshold, it will trigger the acoustic and visual alarm and shut down, so as to avoid the expansion of the fault.
Fourth. Immediate Handling of Abnormal Situations
If there is a drive alarm (such as "overcurrent", 'overtemperature', "encoder failure"), it is necessary to shut down immediately. According to the alarm code to consult the manual to troubleshoot the cause (such as "overcurrent" may be a short circuit of the motor, excessive load or drive damage), can not be forced to reset the operation.
Found that the motor smoke, smell of burning, need to immediately cut off the power supply, check whether the winding burned (using a multimeter to measure the winding resistance, normal should be three-phase balanced, short-circuit resistance tends to be close to 0), replacement of windings or motors, need to check whether the power supply is over-voltage, whether the load is stalled, and other root causes of the problem.
Through the above multi-dimensional monitoring, the abnormal state of moons servo moto can be captured in time, and faults can be nipped in the bud, especially in high-precision, high-load industrial scenarios, continuous monitoring is a key link to ensure the continuous operation of the equipment.
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