Causes and countermeasures of common faults of servo drives. Due to long-term use, servo drives will inevitably fail, and the most important thing is to find out the cause in time, solve the fault accordingly, and resume normal use as soon as possible.
Causes and countermeasures of common faults of servo drives
Servo motor drive manufacturer products in Shanghai, China
Xiaobian here is a compilation of common fault causes and countermeasures of servo drives for your reference. 
1. How to deal with the servo motor if it does not run when there is a pulse output?
(1) Monitor the current value of the pulse output of the controller and whether the pulse output light flashes, confirm that the command pulse has been executed and the pulse has been output normally;
(2) Check whether the control cable, power cable and encoder cable from the controller to the drive are misaligned, damaged or poorly contacted;
(3) Check whether the brake of the servo motor with brake has been opened;
(4) Monitor the panel of the servo drive to confirm whether the pulse command is entered;
(5) The Run operation instruction is normal;
(6) The control mode must select the position control mode;
(7) Whether the input pulse type set by the servo drive and the setting of the command pulse are consistent;
(8) Make sure that the forward side drive is disabled, the reverse side drive prohibition signal and the deviation counter reset signal are not entered, the load is disengaged and the no-load operation is normal, and check the mechanical system.
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2. How to deal with the motor deviation counter overflow error when the servo motor rotates at high speed?
(1) Motor deviation counter overflow error occurs when rotating at high speed;
Countermeasure:
Check whether the wiring of the motor power cable and the encoder cable is correct, and whether the cable is damaged.
(2) Motor deviation counter overflow error occurs when a long command pulse is input;
Countermeasure:
a. The gain setting is too large, readjust the gain manually or use the automatic gain adjustment function;
b. Extend the acceleration and deceleration time;
c. The load is too heavy, it is necessary to re-select a larger capacity motor or reduce the load, and install a transmission mechanism such as a reducer to improve the load capacity.
(3) A motor deviation counter overflow error occurs during operation.
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Countermeasure:
a. Increase the deviation counter overflow level setpoint;
b. Slow down the rotation;
c. Extend the acceleration and deceleration time;
d. The load is too heavy, it is necessary to re-select a larger capacity motor or reduce the load, and install a transmission mechanism such as a reducer to improve the load capacity.
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3. The servo motor is not accurate in position control, how to deal with it?
(1) First, confirm whether the current value of the pulse actually sent by the controller is consistent with the expected, and check and correct the program if it is inconsistent;
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(2) Monitor whether the number of pulse instructions received by the servo drive is consistent with the controller issued, and check the control line cable if it is inconsistent;
(3) Check whether the setting of the servo command pulse mode is consistent with the controller setting, such as CW/CCW or pulse + direction;
(4) The servo gain setting is too large, try to adjust the servo gain manually or automatically again;
(5) The servo motor is prone to cumulative errors when performing reciprocating motion, it is recommended to set a mechanical origin signal under the conditions allowed by the process, and perform the origin search operation before the error exceeds the allowable range;
(6) The accuracy of the mechanical system itself is not high or the transmission mechanism is abnormal (such as the coupling part between the servo motor and the equipment system is offset, etc.).
4. How to deal with the overspeed fault of the servo motor when running the position control operation?
(1) The servo Run signal occurs as soon as it is connected;
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Check whether the wiring of the servo motor power cable and the encoder cable is correct and whether it is damaged.
(2) Occurs during high-speed operation after entering pulse command:
a. The pulse frequency output by the controller is too large, modify the program to adjust the frequency of the pulse output;
b. The electronic gear ratio is set too large;
c. The servo gain setting is too large, try to adjust the servo gain again manually or automatically.
Causes and countermeasures of common faults of servo drives
5. The servo motor is not overloaded with load, how to deal with it?
(1) If the servo Run signal is connected and no pulse is generated:
a. Check the servo motor power cable wiring, check whether there is poor contact or cable damage;
b. If it is a servo motor with brake, be sure to turn on the brake;
c. Whether the gain of the speed loop is set too large;
d. Whether the integration time constant of the speed circuit is set too small.
(2) If the servo only occurs during operation:
a. Whether the position loop gain is set too large;
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b. Whether the amplitude of positioning completion is set too small;
c. Check that there is no stall on the servo motor shaft and readjust the machinery.
6. How to deal with abnormal sound or jitter when the servo motor is running?
(1) Servo wiring:
a. Use standard power cable, encoder cable, control cable, cable is not damaged;
b. Check whether there are interference sources near the control line, whether they are parallel to each other or too close to the nearby high-current power cables;
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c. Check whether the potential of the grounding terminal has changed, and ensure that the grounding is good.
(2) Servo parameters:
a. The servo gain setting is too large, it is recommended to readjust the servo parameters manually or automatically;
b. Confirm the setting of the time constant of the speed feedback filter, the initial value is 0, you can try to increase the setting value;
c. The electronic gear ratio setting is too large, it is recommended to restore to the factory setting;
d. Resonance of servo system and mechanical system, try to adjust the notch filter frequency and amplitude.
(3) Mechanical system:
a. The coupling connecting the motor shaft and the equipment system is offset, and the installation screws are not tightened;
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b. Poor occlusion of pulleys or gears will also lead to load torque changes, try no-load operation, if no-load operation is normal, check whether the joint part of the mechanical system is abnormal;
c. Confirm whether the load inertia, torque and speed are too large, try no-load operation, if no-load operation is normal, reduce the load or replace the drive and motor with larger capacity.