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The detecting component plays a crucial role in the CNC machine tool servo system, as it is responsible for measuring the displacement and speed of each control axis. It feeds back the detected signals to create a closed-loop system, ensuring accurate and stable operation. Detection methods can be classified into direct and indirect measurement. Direct measurement involves using linear detection components such as linear induction synchronizers, metrology gratings, magnetic scales, or laser interferometers to measure the linear displacement of the machine tool directly. On the other hand, indirect measurement uses rotary-type detection components like pulse encoders, resolvers, circular induction synchronizers, circular gratings, or circular magnetic grids to detect linear displacement indirectly.
When a machine tool exhibits certain fault symptoms, it's essential to consider whether the issue stems from a faulty detecting component. For example:
1. **Mechanical Oscillation (During Acceleration/Deceleration):**
- A faulty pulse encoder may cause voltage drops at the feedback line terminal on the speed unit. If this occurs, the encoder should be replaced.
- Damaged coupling between the encoder and the shaft may result in mismatched speeds, requiring a replacement.
- A malfunctioning tachogenerator should also be checked and replaced if necessary.
2. **Mechanical Runaway (Speeding Up):**
- Incorrect wiring of the pulse encoder may lead to reversed phase A and B signals. This needs to be corrected.
- A damaged encoder coupling should be replaced.
- Reversed connections on the tachometer generator’s terminal or incorrect excitation signal lines could also be the cause.
3. **Spindle Cannot Be Oriented or Fails to Position Correctly:**
- The position detector (encoder) might be defective. Checking the encoder output waveform is recommended. A normal waveform should appear consistent and stable.
4. **Axis Vibration During Feeding:**
- Check for motor coil short circuits, mechanical feed screw misalignment, instability in the servo system, poor pulse code quality, unreliable coupling, or faulty speed measuring devices.
5. **NC Alarm Due to Program or Operation Errors:**
- Alarms like FAUNUC 6ME system alarms 090 or 091 may indicate low feed rate or main circuit failure. Other causes include a defective pulse encoder, insufficient power supply voltage (should be adjusted to 15V), or failure to input a one-turn signal from the encoder.
6. **Servo System Alarms (e.g., FAUNUC 6ME: 416, 426, 436; SIEMENS 880: 1364, SIEMENS 8: 114, 104):**
- These alarms often point to broken, short-circuited, or lost feedback signals. A-phase and B-phase one-turn signals should be checked with an oscilloscope.
- Contamination inside the encoder, such as dust or dirt, can prevent proper signal reception.
Our factory has 15 CNC machines, including one Siemens 8 system machining center, two Siemens 880 system machining centers, four CNC cutting machines, three IRB2000 welding robots, one CNCJ 800X8100 bending machine, and several FAUNUC 6 system machining centers and ordinary CNC lathes. Since the first YBM-90N Siemens 8 system machining center was introduced in 1991, detection component failures have been a significant concern.
Several typical faults have occurred due to detection component issues:
**Fault 1:** Inaccurate positioning of the worktable caused by a photoelectric encoder problem.
**Fault 2:** X-axis vibration due to a faulty pulse encoder.
**Fault 3:** Robot vibration caused by a damaged tachogenerator.
**Fault 4:** Workbench positioning failure due to oil contamination in the pulse encoder.
**Fault 5:** Axis malfunction caused by a broken signal line in the closed-loop system.
**Fault 6:** Dimensional errors in machined parts due to a damaged photoelectric disk in the encoder.
To ensure the proper functioning of detection components, the following maintenance tips are recommended:
- Avoid strong vibrations and friction that could damage the code board.
- Keep the environment clean and free from dust and oil to maintain signal integrity.
- Ensure the working temperature stays within acceptable limits and the power supply voltage meets specifications.
- Check the feedback line resistance and capacitor condition for reliable signal transmission.
- Shield against external power interference and noise.
- Install components correctly, ensuring concentric alignment of the encoder coupling to avoid overloading.
In summary, detection components are critical to the performance of CNC systems. While their failure rate is relatively high, proper use, regular maintenance, and thorough troubleshooting can significantly reduce downtime and improve machine reliability.
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