Motion Control System Operation and Maintenance

The correct operation and maintenance of the motion control system can not only ensure and extend the life cycle of the equipment itself, but also is the patron saint of the production system and the creation of economic benefits. Adhering to the correct operation and maintenance rules of the motion control system can bring high economic benefits to the company.

If a worker wants to do good, he must first sharpen his tools. The motion control system is the heart of mechatronic equipment. The characteristics of the system's precision electromechanical architecture determine the importance of its operation and maintenance. In order to help maximize the investment benefits of end-users, proper operation and maintenance will not only ensure and extend the life cycle of the equipment itself, but will also be the patron saint of the manufacturing system to create economic benefits.

Figure 1 Servo driver and servo motor are the key to constitute a servo system

Servo system operation and maintenance

Delta servo system includes servo driver and servo motor. The driver uses precise feedback combined with high-speed digital signal processor DSP to control IGBT to produce accurate current output. It is used to drive three-phase permanent magnet synchronous AC servo motor to achieve precise speed adjustment and positioning. . Compared with ordinary motors, because the AC servo driver has many protection functions inside and the motor has no brush and commutator, the work is reliable, and the workload of maintenance and maintenance is relatively small.

In order to extend the service life of the servo system, the following problems should be paid attention to during use. For the environment in which the system is used, the five elements of temperature, humidity, dust, vibration, and input voltage must be taken into account.

The servo drive must be installed in a concealed control box to maintain good ventilation and heat dissipation, and it is required that there is no water vapor, flammable or corrosive gas in the air. To keep the control box clean and tidy, there are no conductive fines such as copper wire and iron chips, so as to avoid short circuit in the driver circuit board.

As there are no rotating electrical contacts such as slip rings or rectifiers, the maintenance of servo motors is mainly external cleaning and bearing replacement. External cleaning should be done periodically to remove contaminants that affect heat dissipation. The cleaning cycle depends on the specific environmental conditions and the degree of accumulation of pollutants. If the motor or housing is air-cooled, check and clean the fan regularly. The bearing life is generally 10 000~20 000 h. If the motor is operated under the limit conditions of rated speed, thrust and radial bearing load, the bearing life will be longer. Every 2500h should check the bearing for obvious or abnormal noise. If you hear this noise, replace the bearings in the motor immediately.

Figure 2 Delta H4 series CNC operation panel

Many alarm signals are set in Delta's servo drive. Under some unexpected conditions, the drive and motor can be protected from damage in time. The following common fault signals and solutions are listed below:

(1) If there is an encoder connection error or an encoder failure, check the encoder connection cable carefully and check if the motor shield cable is connected to the driver.

(2) If overload occurs and motor power wiring is incorrect, check whether motor shaft installation is biased.

(3) If the power line connection is bad or the motor encoder is faulty, check the power line.

(4) The input voltage of the main circuit is too low. Check if the input power meets the requirements.

(5) There is a lack of phase in the main circuit power supply. Check if the power cable connection is loose.

CNC system operation and maintenance

The main content of the CNC system operation is to strictly follow the operating procedures; to prevent the CNC device from overheating; to constantly monitor the grid voltage of the CNC system; to prevent dust from entering the CNC device; and to use the battery for regular inspection and replacement. The programming, operation and maintenance personnel of the CNC system must undergo special technical training, be familiar with the CNC machine tools, numerical control systems, strong electrical equipment, hydraulic pressure and gas sources, etc., and the use environment and processing conditions of the CNC machine tools; they can be used by machine tools and systems. The requirements of the instructions are used correctly and reasonably.

Figure 3 Delta H8 series CNC operation panel

Should try to avoid failure due to improper operation. In addition, the following general rules must be observed for the maintenance of CNC systems:

1. Prevent the NC from overheating

Regularly clean the cooling ventilation system of the numerical control device. Always check if the cooling fans on the CNC device work properly. The inspection should be conducted once every six months or one quarter depending on the conditions of the workshop environment.
Because the ambient temperature is too high and the temperature inside the numerical control device exceeds 55 60 °C, an air conditioning device shall be installed in time.

2. Regularly monitor the grid voltage of the CNC system

Usually, the allowable grid voltage range of the numerical control system is between +10% and -15% of the rated value. If it is beyond this range, the numerical control system can not be stably operated, and the important electronic components may be damaged. Therefore, always pay attention to the fluctuation of the grid voltage. For regions where the quality of the power grid is relatively poor, AC power supply devices dedicated to the numerical control system should be configured in a timely manner, which will significantly reduce the failure rate.

3. Prevent dust from entering the CNC device

In addition to maintenance, the electrical cabinet doors should be opened as little as possible. Because the dust and metal powder floating in the air in the workshop does not fall on the printed circuit board and the electrical connector, it is easy to cause the insulation resistance between the components to drop, resulting in failure or even damage to the components.

4. Connector cleaner spray cleaning

Some circuit boards and connectors that have been contaminated by external dust and oil mist can be sprayed with special electronic cleaners. When cleaning the connector, you can spray enough liquid mist on the socket, insert the original plug or pin, and then pull it out to take out the dirt. This can be done repeatedly until the inside is clean. After inserting the plug, the excess liquid will naturally drip and wipe it dry. After a certain period of time, the naturally dry spray will form an insulating layer on the non-contact surface to make it well insulated. When the contaminated circuit board is cleaned, the circuit board may be sprayed with cleaning agent. After the spraying, the circuit board is laid upright so that the dust will flow out together with the excess liquid and can be used after being dried.

5. The battery is periodically checked and replaced with a battery

In general, the memory contents of some memories in the digital control system are maintained by battery power when the power is turned off. When the battery voltage drops to a certain value, it will cause the parameter to be lost. Therefore, to periodically check the battery voltage, when the voltage drops to a limit or a battery voltage alarm occurs, replace the battery in time. If the controller is not turned on for more than one month, the internal memory data may be lost. Once the parameters are lost, the parameters can be entered again after replacing the new battery.

6. Maintenance of CNC system when it is not used for a long time

When the CNC machine tool is idle for a long time, the CNC system should be regularly maintained. First of all, the CNC system should always be powered on. If the machine tool is locked, let it run without load. During the rainy season in which the air humidity is relatively high, electricity should be supplied every day. The heat generated by the electrical components themselves should be used to drive off the moisture in the CNC cabinet so as to ensure the stable and reliable performance of the electronic components. Practice has proved that often stop unused machine tools, after the rainy days, a boot is often prone to various failures.

Due to the limited working conditions of the end-users of the motion control system and the support capabilities of the company's first-line engineering and technical support, electromechanical systems are often unable to obtain good equipment management, which in turn reduces the life cycle of electromechanical integration equipment and reduces productivity due to equipment failure. Loss of economic efficiency. Through the discussion on the operation and maintenance of Delta's motion control system, the concluding core equipment technology management rules are fully applicable to other motion control systems.

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