Discovering the Servo Motor Repair Process: An In-Depth Look at Servo Motors Solution Workshop
Curious about how a servo motor is repaired? Here’s a clear, step-by-step overview of our 7-step repair process. It’s almost like being here with us—though we’d love for you to visit anytime!
1. Comprehensive Evaluation
Thorough Data Collection Our repair process starts with an in-depth assessment. At Servo Motors Solution, we maintain a robust database of motor specifications that directs our repair efforts. Each servo motor is meticulously evaluated, with every detail recorded, from fundamental rotation to more complex metrics like commutation and pole count. This data is crucial, as it sheds light on the motor's past and present condition.
Assessing the Health of the Motor Similar to a physical check-up, we conduct a series of quick internal assessments. Our technicians carry out four essential tests to gauge the overall health of the servo motor and identify any areas that require further examination. These tests focus on winding insulation, potential internal shorts, and back electromotive force (BEMF), ensuring we have a complete understanding of the motor's condition.
- Phase-to-Ground: Utilizes a megohmmeter to evaluate insulation resistance and identify potential shorts.
- Phase-to-Phase: Assesses insulation resistance between phases to uncover shorts.
- Back Electromotive Force (BEMF): Measures electrical resistance and counterforce using a 1000 rpm back drive test. Check the waveforms and sequence of all L-L back EMF voltage.
- Feedback Check: Analyses the condition of the feedback device to determine if replacement is necessary. Records the incoming encoder's alignment, locks the encoder position, and evaluates encoder parameters.
- Setting Performance Standards: We benchmark each motor against established good measurements. Our commitment to precision means that any discrepancies prompt further investigation. Our strict standards guarantee that repairs align with or exceed OEM specifications, reinforced by our 12-month warranty.
2. Disassembly
Thorough Inspection With our test results in hand, we initiate the complete disassembly of the motor. From the pulley end (PE) to the opposite pulley end (OPE), each component is meticulously inspected.
Tackling Common Issues We address two prevalent issues by replacing:
- Seals: New seals safeguard the interior of the motor from contaminants.
- Bearings: Both bearings are replaced with new or refurbished units, often exceeding OEM specifications to eliminate excessive vibrations.
In-Depth Evaluation: We assess which components can be reused, which need replacement, and which should be repaired. All measurement values are recorded and documented, and photos are taken for reference.
3. Cleaning
State-of-the-Art Cleaning Methods We employ ultrasonic cleaning techniques, commonly used in automotive, aerospace, and medical sectors. This method utilizes a specialized solvent mixture to dissolve contaminants, allowing us to thoroughly inspect each part for any hidden problems.
4. Reassembly
Accurate Reassembly Each repair begins with a documented disassembly process to guarantee accuracy during reassembly. This phase includes testing brake torque and release voltage, along with redoing the initial four tests to ensure everything functions correctly.
Additional Testing
- Surge Test: Identifies turn-to-turn insulation weaknesses at voltages exceeding the motor's normal operating voltage.
- Hipot Test: Evaluates current leakage and stresses the insulation at higher voltage levels to uncover potential issues that lower voltage tests may miss.
5. Feedback Alignment
Essential Encoder Alignment Correct alignment of encoders and resolvers is vital to prevent issues such as runaway or insufficient torque. We use various types of drives compatible with different servo motor brands to test run and ensure precise alignment with the Linea X3 by Octava Engineering, guaranteeing optimal motor functionality.
6. Final Testing
Thorough Evaluation Before returning a motor to service, it undergoes a closed-loop system test with the appropriate servo drive. We evaluate the motor’s speed and amperage while checking for any thermal failures to ensure compliance with OEM specifications.
7. Painting
Final Touches A new coat of paint not only enhances the motor's visual appeal but also signifies its completion. The Servo Motor Solution Label is applied once the motor has successfully passed through all stages of our repair process, marking it as ready for production.
Journey Back to Production
Our servo motor repair process is meticulously documented with data and photos, ensuring transparency and high-quality standards. When deciding whether to repair or replace, consider these seven critical questions when evaluating repair services.
If you’re facing issues with fault codes or alarm notifications, simplify your experience by reaching out to us with your concerns. We’ll provide a straightforward solution to help restore your motor to peak performance.