Lişkariyên Şerîdarî yên Şêş Li Pêşkirina Pirsgirêka Motorê Servo Rêzikariya Sêtara

Motorên servoyê stepper, wê gotarên pîvandî yên automasyonê endustriyeyê, di navbera stabilitê û dengdizgireşê de bêtirina cihazan ê直接影响设备性能。然而，在实际应用中，电机可能会因参数配置、机械负载或环境因素而出现异常。本文提供了针对六个典型问题的系统解决方案，并结合实际工程案例，帮助技术人员快速识别和解决问题。

1. Motor Vibration û Sese Neayî

Vibration û sese neayî an gotarên çewtî yên bi tevahîn di sisteman de dest pê dike. Yek hatiye paqulîkirin bi serkavetîna motoran wek sese neayî tê şîro wergerandin. Testan guman diha ku frekança rezonansî ya hêsan bi frekança natural a strukturan mekanîk a çapra kir. Çareseriyên jêrîn in: yekem, biguherîne parametreyên riger (mînusel PA15, PB06) di drive-a servoya ve û aktiv bikin funksyonên filterên adaptîve yên digirtina vibrationan di frekançan spesifikan de; duyem, kontrol bikin paralellitya coupling-an—deviativê paralellityan divê be naverok 0.02 mm; herêmî belt transmission bikar bînin, uniformity tension kontrol bikin. Li serbirê, ji bo seroperanê (mînusel, ji ber 300 rpm), Hybrid Decay mode aktiv bikin tu dike mid-frequency vibration. Ji bo high-frequency noise, ferrite core filters saz bikin di input-a power-a motoran de. Yek kompaniya ji bo medical devices re noise-ê 12 dB dikarin.

2. Drift Dengan Accuracy Positioning

Yek CNC machine cumulative error 0.1 mm/hour dikarin di seroperan machining de, li ser encoder signal interference. Çareseriyên jêrîn in: (1) differential probe bikar bînin ji bo kontrol integrity encoder cables (A+/A-, B+/B-); ji bo cableyan shielded twisted-pair bike if waveform distortion 15% dibit; (2) verify servo drive’s electronic gear ratio (PA12 / PA13) match mechanical reduction ratio—one automated production line had an erroneous denominator setting of 32767, causing 0.03° error per revolution; (3) for absolute encoder systems, perform periodic homing calibration, preferably using a dual-frequency laser interferometer for compensation. In practice, installing signal isolation amplifiers enhances noise immunity—one semiconductor equipment manufacturer achieved ±1 μm repeatability after implementation.

3. Trigger Overheating Protection Motor

When motor surface temperature consistently exceeds 80°C, thermal protection forces shutdown. An injection molding robot frequently reported Err21.0 overheating faults. Analysis showed: (1) excessive current loop settings (PA11)—with actual load current at only 60% of rated value, reducing current limit by 20% resolved the issue; (2) inadequate motor cooling—adding forced-air cooling lowered temperature by 15–20°C; (3) for frequent start-stop operations, select motors with better inertia matching. In one case, increasing pulse resolution from 1600 ppr to 6400 ppr reduced iron losses by 37%. Note: for every 10°C rise in ambient temperature, motor rated torque must be derated by 8%.

4. Sudden Step Loss

At high speeds (e.g., above 1500 rpm), stepper motors are prone to step loss due to insufficient torque. A chip mounter showed position lag during acceleration. Solutions include: (1) optimizing S-curve acceleration/deceleration profiles—set jerk (jerk parameter) to 30–50% of acceleration value; (2) monitoring power supply voltage fluctuations—the minimum operating voltage for a 24V system should not drop below 21.6V; (3) for high-inertia loads, enable feedforward compensation (parameter PF03) in the servo drive. A textile machinery manufacturer reduced high-speed step loss rate from 0.3% to below 0.01% by adding flywheel inertia compensation. Critical note: when load-to-motor inertia ratio (JL/JM) exceeds 30:1, motor reselection is mandatory.

5. Troubleshooting Communication Interruption

Bus-controlled systems (e.g., EtherCAT, CANopen) are susceptible to communication timeouts. A lithium battery production line experienced servo network disconnections every two hours, ultimately traced to: (1) missing termination resistors causing signal reflection—adding 120Ω resistors at end nodes reduced bit error rate by 90%; (2) suboptimal network topology—replacing daisy-chain with star topology improved reliability; one case showed fiber-optic repeaters reduced communication latency from 200 μs to 50 μs; (3) outdated servo drive firmware—a known CRC checksum defect was fixed in the latest version. Important: for PROFINET networks, ensure each node’s device name is correctly bound to its IP address.

6. Handling Brake Malfunction

For servo motors with electromagnetic brakes, a warehouse stacker crane once experienced post-power-off slippage. Corrective actions included: (1) verifying brake response time—24V brakes must actuate within <50 ms; (2) regularly measuring brake pad wear—replace when remaining thickness <1.5 mm; (3) adding pre-braking logic in the PLC program to trigger the brake signal 50 ms early. A port AGV system added supercapacitor backup power to ensure reliable brake engagement during outages. For vertical-axis applications, recommend additional mechanical stops as secondary protection.

Advanced Optimization Recommendations

Beyond the above solutions, establish a preventive maintenance system: 

• Monthly record three-phase current imbalance (alert if deviation >10%); 

• Quarterly insulation resistance testing of windings with a megohmmeter (≥100 MΩ); 

• Utilize the servo drive’s built-in fault waveform capture for anomaly analysis. One automotive welding line found that when current total harmonic distortion (THD) exceeded 8%, motor failure probability increased fivefold—proactive replacement of filter capacitors improved MTBF by 40%.

Through systematic fault analysis and solution implementation, overall efficiency of stepper servo systems can improve by over 25%. Engineers are advised to maintain complete parameter backup archives to rapidly restore optimal configurations during equipment relocation or component replacement. With the advancement of predictive maintenance technologies, future integration of vibration sensors and current waveform analysis will enable more precise fault prediction.