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The detecting component is a critical part of the CNC machine tool's servo system, responsible for measuring the displacement and speed of each control axis. It provides feedback to form a closed-loop system, ensuring accurate and stable operation. Detection methods can be categorized into direct and indirect measurement. Direct measurement involves linear detection components such as linear inductive synchronizers, metrology gratings, laser interferometers, or magnetic scales, which directly measure the linear displacement of the machine tool. Indirect measurement, on the other hand, uses rotary detection components like pulse encoders, resolvers, circular inductive synchronizers, circular gratings, or circular magnetic grids to indirectly measure linear displacement.
When a machine tool exhibits certain fault symptoms, it may indicate a failure in the detecting component. For example:
1. **Mechanical oscillation during acceleration/deceleration** could be caused by a faulty pulse encoder, damaged coupling, or malfunctioning tachogenerator.
2. **Mechanical runaway (speeding)** might result from incorrect encoder wiring, damaged coupling, or reversed tachometer connections.
3. **Spindle orientation issues** may arise from a defective position detector (encoder), requiring waveform checks.
4. **Axis vibration feed** could be due to motor coil short circuits, mechanical misalignment, or unstable servo systems.
5. **NC alarms** such as FAUNUC 6ME alarm 090/091 may stem from low encoder voltage, faulty encoder, or missing one-turn signals.
6. **Servo alarms** like 416, 426, or 1364 on SIEMENS systems may point to broken feedback signals, encoder contamination, or signal loss.
In our factory, we have 15 CNC machines, including Siemens 8 and 880 system machining centers, CNC cutting machines, IRB2000 welding robots, and others. Over the years, detection component failures have been a common issue. Several typical faults include:
- A **faulty photoelectric encoder** caused positioning errors on a VMC800 machine, resolved by replacing the encoder after identifying friction between the photoelectric disk and grating.
- An **A-phase signal error** in a pulse encoder led to X-axis vibration, fixed by replacing the faulty encoder.
- A **damaged tachogenerator winding** in an IRB2000 robot caused strong vibrations, requiring replacement of the tachogenerator.
- **Oil contamination** in a pulse encoder on a SIEMENS 880 machine triggered an alarm, solved by cleaning the encoder and improving compressed air quality.
- A **broken feedback cable** in a SIEMENS 8 system machine caused erratic behavior, resolved by rewiring the affected section.
- A **damaged photoelectric plate** in a CNC lathe led to dimensional errors, corrected by replacing the encoder.
Proper use and maintenance of detection components are essential. Avoid strong vibrations, dust, and oil contamination. Ensure proper power supply, good shielding, and correct installation. Regular inspection and timely replacement of faulty components can significantly reduce downtime and improve machine performance. In summary, while detection component failures are common in CNC systems, with proper care and troubleshooting, most issues can be quickly identified and resolved, ensuring smooth and reliable operation.
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