1. Overview of overcurrent faults
Overcurrent fault, as the name suggests, refers to the servo drive in the process of work, due to some reason caused by the current exceeds the rated value, which triggers the protection mechanism, so that the drive stops working or issued an alarm. This kind of failure may not only damage the drive itself, but also cause irreversible damage to the motor and connected equipment. Therefore, it is critical that overcurrent faults are detected and dealt with in a timely manner.
2. Overcurrent fault cause analysis
- Excessive motor load: When the load driven by the motor exceeds its rated load, it will lead to a sharp rise in current, thus triggering an overcurrent fault.
- improperly set driver parameters: such as current limit value set too low, acceleration time is set too short, etc., may lead to drive under normal operating conditions misjudged as overcurrent.
- drive internal component damage: such as power modules, current detection circuit and other key components of the damage will directly affect the accurate detection and control of the current, which in turn triggered the failure.
- external interference: electromagnetic interference, power supply fluctuations and other external factors may also cause interference to the drive current detection, triggering false alarms.
- Cable and wiring problems: motor cable damage, loose wiring or poor contact may also lead to abnormal fluctuations in current, which in turn triggers overcurrent faults.
3. Troubleshooting methods
- Observation and recording: first, observe the fault code or indicator status on the drive display, and record the specific phenomenon when the fault occurs, such as whether it is accompanied by abnormal noise, vibration, etc.
- Check the load: confirm whether the load driven by the motor is within the normal range, whether there is an abnormal increase in the situation.
- Check the drive parameters: enter the drive setting interface, check whether the current limit value, acceleration time and other key parameters are set reasonably.
- Use diagnostic tools: Use special servo drive diagnostic software or tools to conduct a comprehensive inspection of the drive to see if any internal components are damaged or abnormal.
- Check the cable and wiring: carefully check whether the motor cable is intact, whether the wiring is firm and reliable, no loose or broken phenomenon.
4. Maintenance steps
- Stop the machine and disconnect the power: Before carrying out any maintenance operation, be sure to cut off the power supply to ensure safety.
- Replace or adjust the load: if the load is too large, consider reducing the load or replacing the motor with a larger capacity.
- Adjust the drive parameters: according to the actual situation, adjust the current limit value, acceleration time and other parameters to a reasonable range.
- Replace damaged components: If the diagnostic results show that the drive internal components are damaged, you need to replace the corresponding components in time. Note that the replacement of components should be selected with the original model, specifications of the same accessories, and to ensure that the installation is correct.
- Repair cables and wiring: for cable damage or loose wiring problems, should be repaired or replaced in a timely manner, and re-tighten the wiring.
- test and verify: after the completion of the repair, re-power on the drive to carry out functional tests to verify whether the fault has been eliminated. When testing, the load should be gradually increased to observe whether the drive is stable and whether the current value fluctuates within the normal range.
5. Preventive measures
- Regular inspection and maintenance: Regular inspection and maintenance of servo drives and motors, timely detection and treatment of potential problems.
- Reasonable setting parameters: According to the actual application scenarios, set the drive parameters reasonably, to avoid failure caused by improper parameter setting.
- Enhance environmental management: reduce electromagnetic interference sources, maintain power stability, provide a good working environment for the servo drive.
- Training and guidance: Strengthen the training and guidance of operators to improve their ability to judge and deal with servo drive failures.
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Company Name: Shantou Sikinta Automation Equipment Co., Ltd.
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Country: China
Website: https://www.autsikinta.com/