1. Mechanical damage
The most common problem in servo response encoder is a variety of mechanical damage, including hardware damage to the internal component structure of the encoder (code disc, shaft and bearing, etc.) due to mechanical oscillation, collision, impact, wear and tear.
1) Oscillation
Excessive mechanical oscillation poles can cause damage to the encoder disc, shaft and bearing. Regarding the servo reaction, some oscillations are caused by the oscillation of the motor body, such as: the oscillation of the mechanical structure where the motor is located, the continuous movement of the motor demand with the load, etc., this situation is easier to prevent and avoid, because this oscillation looks more intuitive than the first, it is also easy to measure and adopt corrective measures, as long as the oscillation intensity of the motor body can be controlled within its nominal oscillation level (acceleration and frequency) range, it can basically avoid the damage caused by this oscillation to the servo motor and reaction. There are also some conditions, the oscillation is caused by the rotation of the mechanical shaft during the operation of the motor, for example: the output side of the servo motor shaft is subjected to excessive axial force effect, and the axial oscillation of the encoder mechanical shaft is formed by the forward and backward movement during work; Perhaps, when the servo motor is working, its output shaft is subjected to excessive radial force for a long time, resulting in wear and tear of the motor shaft and bearings, which causes the motor shaft to oscillate strongly due to eccentricity when rotating at high speed.
These oscillations are basically not much related to the oscillation of the motor body and the mechanical structure of the equipment, but are closely related to the force of the output shaft and the wear of the shaft/bearing when the motor is running. At the same time, because this kind of oscillation mainly occurs on the mechanical shaft that rotates at high speed inside the motor, it has a strong concealment, and its damage is often overlooked.
2) Shock
As with all electromechanical products, servo motors and reaction encoders will have nominal rated shock acceleration limits. Excessive impact forces may result in damage to the servo encoder disc, shafts, bearings, integrated circuit boards and chips, or even the destruction and scrapping of the entire reaction encoder. Therefore, in the process of using the servo motor, it is necessary to avoid the impact of any external force on the body as much as possible, especially to avoid the collision and knocking on the motor output shaft, whether it is from the axial or radial direction, for example: when installing various transmission shaft sleeves (synchronous pulleys, couplings, reducer shaft sleeves, etc.) on the motor output shaft, perhaps in the process of installing the motor to the transmission organization, do not knock the motor shaft and the shell body hard.
3) Wear and tear
Another type of mechanical damage is the wear of the servo-response encoder shaft and bearings. Although it is not very common, it needs to be taken seriously. It may be caused by prolonged oscillation (axial or radial) of the motor shaft; It may also be caused by the overspeed of the motor shaft, although the general servo motor rarely shows the situation of overspeed, and the maximum speed of the reaction encoder is much higher than the peak speed of the servo motor, but in some abnormal situations, such as: the reaction signal is disturbed, the servo motor is tuning error, the vertical load falls out of control, etc., the risk of damage to the reaction encoder due to the motor "being" overspeed work still exists.
2. Electrical damage
Electrical damage is also a common occurrence in various servo-response encoder faults. On the one hand, when the servo motor and encoder response circuit are in the electromechanical system environment with poor electromagnetic compatibility function, the signal circuit may be disturbed by strong electromagnetic noise and instantaneously high (thousands or even tens of thousands of volts) of high-frequency impulse voltage, resulting in damage to the encoder signal circuit. On the other hand, the abnormality of the encoder's external circuits, such as short circuits, open circuits, wrong wires, reverse polarity, abnormal power supply (such as shaking), etc., may also cause electrical faults or damage to the servo reaction.
The first two faults should be regarded as more simple electrical faults, and the electrical faults of the universal encoder are the same. There is also an electrical damage that is specific to the servo reaction and is caused by mechanical damage to the motor. If the servo motor is working, because the output shaft is subjected to excessive axial or radial force for a long time, the shaft and bearing are worn, and a lot of metal chips and dust will occur inside the motor, and when these metal dusts adhere to the circuit board of the reaction encoder, it is very likely that the internal circuit will be faulty or damaged due to short circuit.
3. Environmental impact
First of all, it still refers to the physical environment where the servo motor is located, including: humidity, temperature, dripping, oil, dust, corrosion... Wait a minute. In the maintenance report of many faulty servo motors after returning to the factory, it will be said that the reaction encoder is damaged due to the erosion of pollutants, such as immersion, dust, etc. There are many reasons for pollutants to enter the internal of the motor, perhaps because the protection level of the motor itself is not enough to withstand the harsh use environment, so the IP protection level of the servo motor itself, as well as the environmental protection measures adopted during product use integration and operation and maintenance, are very important.
However, it is still not enough to protect the use of the servo motor, because it will also be affected by the internal environment of the motor in terms of servo reaction. From the perspective of pollutants, the protection level of the servo reaction encoder is mostly IP20 - IP40, if the servo motor is working, its output shaft is subjected to excessive axial or radial force effect for a long time, it will form the wear of the motor shaft and bearing, so that a lot of dust and debris occur inside the motor, they may not only cause damage to its internal circuit due to attachment to the circuit board of the reaction encoder, but also may affect the heat dissipation of electrical components and the lubrication of mechanical bearings due to many accumulations. And this actually has nothing to do with the level of protection of the servo motor itself. If you look at the influence of the servo response encoder in terms of temperature, it is mainly from the inside of the servo motor, because the actual temperature of the winding coil in continuous operation is often much higher than the surrounding ambient temperature, which is a great challenge and threat for the servo response encoder installed at the end of the motor shaft. Generally, the operating temperature range of servo reaction can reach +110°C - +120°C, and too high motor operating temperature may lead to unstable operation or even heat damage to the internal circuit of the reaction encoder. Therefore, it is also very important to reasonably plan the operating cycle and operating load of the servo motor to avoid excessive winding temperature, and to protect the reactive encoder integrated in it.
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