Servo Drive Maintenance Guide

Servo drives are suitable for a wide variety of applications requiring high-precision, highly responsive motion control, and are widely used in automated production lines, machine tools and machining equipment, electronic equipment manufacturing, robots, printing presses, medical equipment, aircraft, and many other fields, such as Komatsu Precision Punch Press and Ube Kogyo Injection Molding Machine, to name a few.

Servo Drive Maintenance Items

1. Initial Inspection and Safety Checks

Begin the maintenance process by measuring the insulation of the servo drive to ensure there are no risks of electrical leakage. Methodically inspect all fastening screws for any signs of loosening, which could lead to misalignment or vibrations during operation.

Perform an external visual inspection to check for any severe physical damage that might affect the structural integrity of the servo drive.

2. Internal Component Examination

Dismantle the internal parts of the servo drive, including the casing and protective covers. Conduct a thorough cleaning of the device's fixtures, paying close attention to the condition of these components.

Look for signs of aging or brittleness, and if found, recommend replacement to prevent future failures.

3. Thermal System Overhaul

Clean the thermal system to remove any oil residue and dust that may have accumulated, which could hinder the cooling process.

Inspect the cooling fans for wear and tear, including the bearings and blades for any cracks or signs of aging. Listen for any unusual noises during operation, and check the installation screws for looseness.

Perform a fan speed test to ensure optimal airflow. It is generally recommended to replace the fans every 2 years to maintain cooling efficiency.

4. PCB and Electronic Component Maintenance

Clean the dust and oil from the PCB circuit boards to prevent short circuits and ensure heat dissipation. Test the aging of various electronic circuits and apply a protective coating of three-proof paint to extend the life of the circuit boards.

In cases where circuit boards show significant wear, recommend their replacement to maintain system reliability.

5. IGBT Testing and Maintenance

Perform a series of tests on the IGBT, including performance, voltage withstand, and triggering tests. Conduct temperature tests to ensure the IGBT operates within safe thermal limits.

Reapply thermal conductive silicone grease to enhance heat transfer. If any IGBT units show signs of aging, recommend their replacement to avoid potential failures.

6. Capacitor Inspection and Testing

Measure the capacitance and insulation resistance of the main capacitors, and perform a withstand voltage test. Check for any leakage of electrolyte and whether the safety valve has bulged.

Determine the lifespan of the static capacitors and, if necessary, replace any aged capacitors. Typically, capacitors have a service life of about 20,000 hours.

7. Contactor and Terminal Inspection

Examine the contactor contacts in the main circuit for any signs of poor contact. Look for arcing marks on the wiring terminals, which could indicate excessive heat or electrical stress.

If any issues are detected, recommend the replacement of these components to ensure a robust electrical connection.

8. Insulation Testing and Fastening

Conduct insulation resistance tests between the main circuit copper busbars and the ground, as well as between the busbars themselves.

Retighten all screws to prevent any potential loosening that could lead to poor connections or electrical faults.

9. Cable Maintenance

Clean the cables to remove any dirt or debris that could affect their insulation properties. Measure the temperature of the cables during operation to ensure they are within safe operating limits and perform an insulation resistance test to verify their integrity.

Conclusion

Regular and thorough maintenance of servo drives is essential for ensuring the longevity and reliability of industrial automation systems.

By following these detailed steps, technicians can extend the life of servo drives, prevent unexpected breakdowns, and maintain the efficiency and precision of robotic operations.