Servo drives are commonly used to control servo motors. In positioning systems requiring high precision, servo drives are a crucial component. Today, we'll discuss some common servo drive malfunctions and their troubleshooting methods in automation applications.
1
How to handle an overspeed fault (ERR 1) reported by the servo motor?
① The servo enable signal is generated as soon as it is received;
Check whether the wiring of the servo motor power cable (U, V, W phase sequence) and encoder cable is correct and whether there is any damage.
② Occurs during high-speed operation after inputting a pulse command:
a. The pulse frequency output by the controller is too high; modify the program to adjust the pulse output frequency.
b. The electronic gear ratio is set too high;
c. The servo gain setting is too high; try readjusting the servo gain.
2
How to handle the position deviation counter overflow error (ERR 4) that occurs when the servo motor is rotating at high speed?
① A position deviation counter overflow error occurred when a high-frequency command pulse was input;
Countermeasures:
a. Check if the wiring of the motor power cable and encoder cable is correct and if the cables are damaged;
b. The gain setting is too high. Manually adjust the gain or use the automatic gain adjustment function.
c. Extend the acceleration and deceleration time;
d. The load is too heavy, so it is necessary to select a larger capacity motor or reduce the load, and add a speed reducer or other transmission mechanism to improve the load capacity.
② A position deviation counter overflow error occurred during operation.
Countermeasures:
a. Increase the overflow level setting of the deviation counter (P080, unit: revolutions);
b. Slow down the rotation speed;
c. Extend the acceleration and deceleration time;
d. The load is too heavy, so it is necessary to select a larger power motor or reduce the load, and add a speed reducer or other transmission mechanism to improve the load capacity.
3
The servo motor is reporting an overload error (ERR 13). How should I handle this?
① If the servo enable signal is received but no pulse is sent:
a. Inspect the servo motor power cable wiring to check for poor contact or cable damage;
b. Is the speed loop gain set too high?
c. Is the integral time constant of the speed loop set too small?
② If the servo only occurs during runtime:
a. Is the position loop gain set too high?
b. Check if the positioning amplitude is set too low;
c. If it is a servo motor with a brake, be sure to open the brake;
d. Check that there is no stall on the servo motor shaft and readjust the mechanism.
4
How to fix a servo motor that doesn't run when there's a pulse output?
① Monitor the current value of the pulse output of the controller and whether the pulse output light is flashing to confirm that the command pulse has been executed and the pulse has been output normally;
② Check the control cables, power cables, and encoder cables from the controller to the drive for incorrect wiring, damage, or poor contact;
③ Check if the brake of the servo motor with the brake has been disengaged;
④ Monitor the servo drive panel (d-cp.) to confirm whether the pulse command has been input;
⑤ Check if the servo Run indicator light is on;
⑥ The position control mode must be selected (P004=0);
⑦ Are the input pulse type and command pulse settings of the servo driver consistent?
⑧ Ensure that the forward drive prohibition signal, reverse drive prohibition signal, and deviation counter reset signal are not input, disconnect the load and run normally under no-load, and check the mechanical system.
5
How to fix inaccurate positioning when using a servo motor for position control?
① First, confirm whether the current value of the pulse actually emitted by the controller is consistent with the expected value. If not, check and correct the program.
② Monitor whether the number of pulse commands received by the servo drive matches that issued by the controller. If they do not match, check the control cable.
③ Check whether the servo command pulse mode setting is consistent with the controller setting, such as CW/CCW or pulse + direction;
④ The servo gain setting is too high; try readjusting the servo gain.
⑤ Servo motors are prone to accumulating errors during reciprocating motion. It is recommended to set a mechanical origin signal, provided that the process allows, and to perform an origin search operation before the error exceeds the allowable range.
⑥ The mechanical system itself is not precise or there is an abnormality in the transmission mechanism (such as the coupling between the servo motor and the equipment system being misaligned).
6
How to handle abnormal noises or vibrations during servo motor operation?
① Servo wiring:
a. Use standard power cables, encoder cables, and control cables; check for any damage to the cables.
b. Check for interference sources near the control line, and whether it is parallel to or too close to nearby high-current power cables;
c. Check if there has been any change in the grounding terminal potential to ensure proper grounding.
② Servo parameters:
a. The servo gain setting is too high; it is recommended to readjust the servo parameters.
b. Resonance between the servo system and the mechanical system; try adjusting the notch filter frequency and amplitude.
③ Mechanical system:
a. The coupling connecting the motor shaft and the equipment system is misaligned, and the mounting screws are not tightened;
b. Poor meshing of pulleys or gears can also cause load torque fluctuations. Try running the system under no-load conditions. If it runs normally under no-load conditions, check for any abnormalities in the mechanical system's engagement parts.
c. Check if the load inertia, torque, and speed are too high. Try running under no-load conditions. If the no-load operation is normal, reduce the load or replace it with a driver and motor with one of higher power.
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