As the core of Full Automatic Hydraulic Machine Tapping Type, the servo system ensures the normal operation of the machine tool. Once the fault occurs, the influence range and consequences are great. This paper introduces the composition and classification of the Full Automatic Hydraulic Machine Tapping Type servo system and the fault types of the servo system. The basic maintenance flow and common maintenance methods for common faults of Full Automatic Hydraulic Machine Tapping Type servo system are described. 朂 The common troubleshooting measures of Full Automatic Hydraulic Machine Tapping Type servo system are summarized.

Full Automatic Hydraulic Machine Tapping Type The working core is the servo system, Servo system is the hub of Machine tool mechanical transmission components and numerical control system. The servo system is in the process of frequent starting and braking in the dynamic operation of the machine tool. The failure rate is higher. Directly affect the quality and efficiency of parts processing. How to solve the technical problem of Full Automatic Hydraulic Machine Tapping Type maintenance is a major problem in the field of Full Automatic Hydraulic Machine Tapping Type maintenance.

1, Full Automatic Hydraulic Machine Tapping Type servo system

Full Automatic Hydraulic Machine Tapping Type servo system is composed of drive unit, actuator, mechanical transmission component and detection feedback link. Full Automatic Hydraulic Machine Tapping Type servo system, CNC system can be divided into open loop CNC system and closed loop CNC system according to whether the feed servo subsystem has position measuring device. According to the use of DC servo motor and AC servo motor classification, can be divided into DC servo system and AC servo system; According to feed drive and spindle drive classification, can be divided into feed servo and spindle servo system; According to the feedback comparison control mode, there are pulse digital comparison servo system, phase comparison servo system, amplitude comparison servo system and full digital servo system. The servo system will receive the displacement signal, after conversion, amplification processing, by the mechanical transmission system to drive the corresponding machine tool spindle and tool holder to work, so as to complete the corresponding precision action.

2, Full Automatic Hydraulic Machine Tapping Type servo system fault type

The fault of servo system is generally divided into feed servo system fault and spindle servo system fault. 2.1 Feed servo system failure (1) overrange: When the motion stroke exceeds the setting range of soft limit or switch limit, an overrange alarm will occur. (2) Motor does not rotate: Enable control signal loss, no speed control signal, can lead to servo motor does not rotate. (3) Flicker: signal instability, poor contact of terminal, speed control signal instability or interference, can cause flicker phenomenon. (4) Overload: frequent positive and negative rotation, poor lubrication, and excessive load will cause overload alarm. (5) Machine tool vibration: machine tool high-speed movement, resulting in vibration, vibration problem from the speed problem, you can query the speed ring. (6) Crawling: The applied load is too large, the servo system gain is low, the transmission chain is poorly lubricated, the coupling is loose, and the defects of the coupling itself can cause crawling. 2.2 Spindle servo system failure (1) overload: frequent positive and negative rotation, input power phase shortage, excessive cutting amount, etc. (2) Interference: poor shielding and grounding, external electromagnetic interference, feedback signals or spindle speed instruction signals are interfered. (3) Motion mismatch: the encoder pulse feedback signal is not accurate. (4) Abnormal speed: the spindle speed exceeds the specified range. (5) Abnormal noise: the main shaft has vibration and abnormal sound during operation. (6) quasi-stop jitter: when changing the tool and withdrawing the tool, the spindle positioning jitter. (7) The main shaft does not rotate: the main shaft motor does not rotate during operation.

3, Full Automatic Hydraulic Machine Tapping Type servo system common faults of the basic maintenance process

Servo system in fault maintenance, and the basic idea of Machine tool maintenance is the same, basically take "look, smell, ask, cut, application" maintenance process steps, "look, smell, ask" is to understand the fault phenomenon, "Cut" is to analyze the cause of the fault, find the fault parts, "Shi" is to solve the actual fault problem. The specific implementation process is as follows: (1) Look: When a fault occurs, people first habitually use the naked eye for a preliminary view to determine the operation of the machine tool and alarm information seen. (2) Smell: When the electrical components are overloaded, the components may burn, and the smell perception of the fault is also one of the ways of fault diagnosis. (3) Q: When the maintenance personnel arrive at the scene, when the fault cannot be determined by what they see or smell, it is necessary for the maintenance technician to ask the site operator about the basic machine tool problems, including the abnormal sound or abnormal operating condition of the machine tool heard. (4) Cut: After the preliminary diagnosis of the previous steps, in order to further understand the fault, maintenance technicians can operate relevant detection instruments and meters, deeply feel the cause of the pulse fault, 朂 and finally identify the fault. (5) After the fault is clear, prepare the maintenance plan, data and relevant maintenance tools, take appropriate maintenance methods to deal with the fault, 朂, and then carry out functional tests to solve the fault.

4. Common maintenance methods for common faults of servo system

(1) Component replacement method. The component replacement method is also known as the module exchange method, because the servo system links are modular design, the modules have interchangeability, and the component replacement method can be used to pre-judge the fault. (2) Line short connection method. When a component in the system circuit burns down, it may cause a short circuit. A multimeter can be used to detect the incoming and outgoing terminals of the components to find out whether they are short-connected, so as to find out the cause of the fault. (3) Enabling condition method. The servo motor needs to meet the enabling conditions to work, and can be checked by changing the enabling conditions to judge and eliminate the cause of the fault. (4) Reference voltage method. If a shaft fails, in order to determine the failure of the drive module or the motor module, the speed ring can be removed and the position ring can be checked. (5) Parameter test method. For example, when the crawling fault occurs in the Full Automatic Hydraulic Machine Tapping Type, it may be because the servo system gain is too low, and the problem needs to be verified by changing the parameters. (6) Measurement method. When the components of the system are found to have no physical structure problems after inspection, they can choose to check their voltage and current values to determine whether the fault is caused by insufficient voltage and current.

5, Full Automatic Hydraulic Machine Tapping Type servo system common fault processing

5.1 Troubleshooting of feed servo system faults

(1) TMP indicator red: Check whether the drive is overheated and the motor is overloaded. (2) DIS indicator Yellow: Check whether the driver enable signal (+ENA/-ENA) is correctly connected. (3) The LED indicator is green, the motor is not moving: check whether the +INHIBIT and -INHIBIT ports are connected incorrectly, and whether the command signal ground and the driver signal ground are connected. (4) The motor rotates and the LED light flashes: check whether the motor phase setting switch is correct and whether the sensor voltage value is within the range. (5) Driver LED light is not on: check whether the power supply voltage is less than 朂 small voltage value. (6) The LED light remains red: check whether the driver input voltage is overvoltage or undervoltage, whether the motor is short-circuit between phases, and whether the motor is overloaded and heated. (7) The positioning accuracy of the transmission system is unstable: check whether the screw nut is installed correctly. (8) The positioning error of the transmission system is large: check whether the screw pitch error is too large, and whether the connection between the motor and the screw is loose. (9) Motor stall: check whether the speed feedback polarity is reversed and whether the encoder power is lost. (10) The reference point positioning error is too large: check whether the proximity switch is installed correctly, whether the gap between the proximity switch and the detection body is enough, and whether the proximity switch is faulty. (11) Thread processing can not be repeated: check whether the mechanical connection between the spindle and the spindle encoder is normal. (12) The deviation counter overflow error occurs when the motor is rotating at high speed: check whether the motor and cable are damaged, whether the wiring of the power cable and the encoder cable is correct, whether the motor deviation counter overflow is wrong, whether the gain setting is correct, and whether the motor load is within the allowable range. (13) The return reference point action is incorrect: check whether the logical proximity switch needs to be replaced and whether the contact switch is reset. (14) The motor runs faster in one direction than the other: check whether the brushless motor phase is wrong, whether the test/deviation switch is played in the test position, and whether the deviation potentiometer position is correct. (15) Servo motor does not run when there is pulse output: Check whether the control mode is in position control mode, whether the encoder cable is incorrectly configured, whether the brake of the servo motor with brake has been turned on, whether the Run command is normal, monitor the controller panel to confirm whether the pulse command is input, monitor whether the controller pulse is output normally, and whether the input pulse is set consistent with the command pulse. Deviation counter reset signal is input.

5.2 Troubleshooting of spindle servo system

(1) The spindle is not moving and there is no alarm: check whether the mechanical load is too large, whether the connection between the spindle and the motor is too loose, whether the tool or the workpiece is installed, whether the power line is connected properly, whether the enable signal is normal, whether the drive or the motor is damaged. (2) The spindle speed instruction is invalid: check whether the power connection is normal, and whether the CNC circuit board is damaged; Check whether the feedback signal is normal, whether the feedback line is connected properly, and whether the spindle driver parameters are set improperly. (3) The speed deviation is too large: check whether the feedback connection is normal, whether the feedback device is damaged, whether the power line is normal, whether the power voltage is normal, whether the cutting load of the machine tool is too large, whether the braking circuit is normal, whether the motor and the driver are damaged. (4) Spindle vibration or noise is too large: check whether the power system is out of phase or abnormal voltage, whether the load is too large or poor lubrication, whether the drive belt is too tight, whether the bearing and gear are damaged, whether the clearance of the machine tool is normal, and whether the pre-tightening screw is loose. (5) The spindle does not work normally during acceleration/deceleration: check whether the relevant parameter Settings are normal, whether the feedback device is normal, and whether the inertia between the motor and the load matches. (6) The spindle speed fluctuates randomly: check whether the shielding and grounding are normal, and whether the spindle speed instruction signal and feedback signal are interfered with. (7) The spindle can not be changed: check whether the CNC parameter setting is improper, whether the machining program programming is wrong, whether the D-A conversion circuit and the speed analog input circuit are faulty. (8) Screw mess: check whether the encoder is normal, whether the coupling is loose or broken, whether the spindle speed is unstable, and whether there is a problem with the processing program. (9) The spindle anchor point is unstable: check whether the limit switch is damaged, whether the feedback line is connected badly, and whether the encoder is normal. (10) Insufficient spindle output: Check the belt clearance and whether the spindle motor is faulty. (11) The spindle can not work normally: check whether the tension knife detection is in place, whether the spindle gear gear has arrived, whether the cutting is overloaded, whether the drive is overheated, whether the spindle motor module is wrong, whether the mechanical part of the main engine is damaged.

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