Mechanical binding faults, covers, axis in servomotors

Mechanical binding faults in servomotors can significantly impact performance, leading to issues such as overheating, vibration, or axis misalignment.

These problems often stem from mechanical wear, misalignment, or inadequate maintenance.

Here’s a comprehensive overview of potential causes and troubleshooting steps:

Common Causes of Mechanical Binding in Servomotors

1.- Bearing Wear or Failure

Over time, bearings can degrade due to lack of lubrication, contamination, or misalignment. Worn bearings increase friction, leading to overheating and potential encoder misalignment. Symptoms include unusual noises like grinding or whining, and increased vibration .

 

2.- Shaft Misalignment or Bendin

A bent or misaligned shaft can cause uneven load distribution, resulting in vibration and mechanical jitter. This misalignment can also affect the coupling between the motor and the driven component .

4.- Contamination and Lack of Lubrication

Dust and debris, or insufficient lubrication, can increase friction in bearings and cause them to seize. Regular cleaning, proper lubrication and replacing bearings with new ones are essential to prevent these problems.

5.- Shaft break

A servomotor shaft can break due to a variety of mechanical, operational, or installation-related causes.

• Mechanical Overload
• Misalignment
• Fatigue Failure
• Improper Coupling
• Sudden Stops or Faults in Drive Sytem
• Poor Maintenance or Repair Practices

6.- Keyway broken.

A broken keyway in a servo motor’s shaft is a critical mechanical failure that can compromise torque transmission, cause misalignment, and lead to costly downtime. The keyway works with a key to lock the shaft and hub together. When this connection fails, it often results from a combination of mechanical stress, design flaws, and maintenance issues.

• Excessive Torque or Shock Loads
• Improper Fit or Wear
• Misalignment and Poor Coupling
• Fatigue from Cyclic Loading
• Material Weakness and Notch Effect
• Improper Installation or Maintenance

7.- Bearing Wear in the covers

Bearing wear in the covers of servo motors is a prevalent issue that can lead to decreased performance, increased vibration, and potential motor failure. Understanding the root causes of this wear is essential for effective maintenance and prevention.

• Misalignment During Installation or Reassembly
• Contamination
• Electrical Discharge, Bearing currents (Fluting)
• Contamination
• Inadequate Lubrication
• Overloading and Excessive Vibration
• Thermal Stress

8.- Bad Repairs in Covers and Shafts.

Covers and shafts poorly repaired by other companies.

How to Extend the Lifespan of a Servo Motor:

Maintenance Practices and Inspections:

To prolong the life of servo motors, enhance their reliability and ensure optimal performance, proper maintenance and regular inspections are key.

A comprehensive maintenance routine can prevent the common issues that lead to premature servomotor failure.

Routine inspections:

Routine inspections are crucial for identifying potential issues before they result in engine failure. Here’s what to look out for during these inspections:

– Bearings and Lubrication

• Windings and Insulation
• Cables and Connections

Predictive Maintenance:

Predictive maintenance is a proactive approach that aims to predict and prevent servomotor failures before they occur, thereby minimising downtime and lower repair costs. This method relies heavily on monitoring tools and technologies to detect the early signs of wear and potential breakdowns.

• Reduced downtime: By anticipating servomotor failure, maintenance can be scheduled at convenient times, thus reducing the likelihood of unexpected breakdowns.
• Cost efficiency: Addressing potential issues before they escalate avoids the need for costly repairs and replacements.
• Extended Equipment Lifespan: Regular monitoring and maintenance based on the actual condition of the equipment can significantly extend the lifespan of servo motors.

Tools and Technologies Used

• IoT Sensors
• Vibration analysis
• Ultrasonic analysis
• Thermal Cameras
• Motor current analysis
• Temperature monitoring
• Laser-shaft alignment
• Oil analysis

Proper installation

Correct installation of servomotors is crucial for ensuring optimal performance and a long service life. Improper installation can result in increased wear and tear, operational inefficiencies and premature failure.

Installation tips:

• Alignment:  Proper alignment of the servomotor with the driven equipment prevents undue stress on motor bearings and shafts, thereby reducing wear.
• Secure connections:  Ensure that all electrical and mechanical connections are secure to prevent potential power issues or physical disruption.
• Appropriate cabling:  Using the correct cables and ensuring they are properly routed and connected avoids electrical interference and physical damage.

Temperature control:

Maintaining optimal operating temperatures is crucial for maximising the lifespan of servo motors. Excessive heat can cause premature wear and failure of motor components, which affects overall performance and lifespan.

The importance of temperature management:

• Prevents overheating: Servomotors generate heat during operation. Without adequate cooling, this heat can damage insulation materials and motor windings.
• Operating within their ideal temperature range enhances the efficiency and reliability of servomotors.

It is important to note that regular and predictive maintenance are crucial for ensuring that your servo motor functions at optimal capacity.

Ensuring the longevity of servo motors and drives involves more than just selecting the best product; it requires a holistic approach encompassing installation, operational monitoring and continuous care.