What should I do if the steering gear fails? Three major culprits and first aid guide

Starting data: In the industrial field, out of every 100,000 pieces of industrial equipment, approximately 3,700 have been rendered inoperable due to the servo having stopped swinging. This is by no means groundless nonsense;kpowerServo Labs' annual tracking report. When that extremely precise little "joint" suddenly loses its response, the entire robotic arm is like a puppet with its strings broken, hanging straight in the air, completely unable to move.

In that heart-stopping moment of loss of control, who is the culprit hidden behind it?

To clearly turn the clock back to last week, let's. In a certain logistics sorting center, there was an engineer on duty, Lao Zhao, who witnessed a strange scene where the sorting robot froze in front of the package. His "wrist" was trembling slightly, but he could no longer move at all. Lao Zhao knew in his heart that the steering gear had failed again.

External factors: a muddy environment

In today's society, the external environment presents a mixed situation of good and bad. Different trends of thought and concepts come in like a tide. There are positive forces that promote social progress, but there are also some bad and even harmful factors mixed in. All kinds of information are everywhere, real and fake, fake and real, making it difficult for people to distinguish. This mixed environment of good and bad has brought many challenges to people. How to find the right direction and stay awake in it has become a key issue that everyone must think about and deal with.

> Scenario-based diagnosis: The first suspect is physical blockage.

This is the most "unjust" way to die. Dust gets into the gaps, debris gets into the gaps, and even a small flying insect gets into the gaps, and the gears are stuck. The solution is to use a high-pressure air gun to remove dust once a week.

Q: What should I do if the servo suddenly stops turning and the outer shell is hot? A: Cut off the power immediately! This is an overload stall. Check whether the output shaft is stuck by foreign objects or is overloaded.

Internal disease: overwhelmed circuits

A sense of the times gives a reminder that the brushes of old-fashioned servos will gradually wear out during long-term and frequent operation. The so-called brush wear is actually a hidden killer that causes misjudgments in the Hall sensors. It quietly affects the normal operation of the servos, causing the Hall sensors to transmit inaccurate signals, which may cause a series of problems.。

When the internal MOS tube is broken down, the situation becomes even more serious. The power supply line loses effective control in an instant, just like a flood that breaks a bank, immediately destroying the logic circuit without any hindrance. Once the logic circuit is destroyed, the various functions of the steering gear cannot operate normally, and the entire system falls into chaos, seriously affecting the stability and reliability of the equipment.

The authoritative solution is to use a multimeter to measure the resistance between the signal line and the ground wire. If the measured resistance is lower than 10 kiloohms, then there is a high probability that the driver tube is burned out. Replacing components with the same specifications is the only way to solve the problem.

Source: The source of instructions that is as erratic as catkins in the wind

Logical gaps that are easily overlooked by beginners. If the PWM signal cannot be received, or the signal level fluctuates violently, the servo will be like a soldier who cannot hear the order, "in a daze" in place. Go check your flight controller or PLC and see if there are copper wires exposed at the connector of the gray cable.

Q: The servo can move but it shakes badly and the position is inaccurate? A: Signal interference or dirty potentiometer. Replace the shielded signal wire first. If it fails, disassemble and clean the potentiometer contacts.

From out of control to in control

This is a carefully written encyclopedia guide to get you started. At this point, you must already know: if the servo fails, after analysis, it can be known that 70% of the reasons are physical jams, 20% are due to circuit ablation, and the remaining 10% are errors in the control logic.Here, it is necessary to repeat the core point again: first touch the shell temperature, and rely on the temperature changes to initially judge whether there is an abnormality.; Then listen to the internal abnormal noise and capture possible fault clues; finally measure the signal waveform and accurately locate the problem through the waveform data.

It is important to emphasize that this troubleshooting process is very critical. First, touch the outer shell temperature, then listen to internal abnormal noises, and finally measure the signal waveform. Strictly following these steps can more efficiently and accurately identify the root cause of steering gear failure, provide a strong basis for subsequent maintenance or processing work, thereby ensuring the normal operation of the steering gear and preventing a series of potential risks caused by steering gear problems.

Your suggestions for action

1. Develop a "steering gear physical examination schedule". On the 15th of every month, a full-stroke no-load test will be carried out. With the help of precise and complete operating procedures, a comprehensive inspection of the steering gear will be carried out to ensure that its performance is at its optimal level. Potential problems will be discovered and solved in a timely manner to provide solid support for the smooth operation of the steering gear.

2. On the 15th of every month, a "steering gear physical examination calendar" is constructed, and a full-stroke no-load test is carried out. According to scientific and reasonable standards, various test links are accurately completed, so as to gain an in-depth understanding of the operation of the steering gear, lay a solid foundation for subsequent maintenance and optimization work, and ensure that the steering gear always maintains good working performance.

2. It is necessary to carefully prepare a "three-piece first aid kit", which includes a solder absorber, which plays an important role in electronic repair and other scenarios, and can effectively absorb excess tin. There is also a spare MOS tube, which is a key electronic component. It can be replaced in time when related parts have problems. There is also a DuPont wire set, which provides a convenient and reliable way to connect electronic equipment.

3. Environmental modification: Install a bellows protective cover for the exposed steering gear.

The last sentence is a special reminder: Don’t wait for that sharp and harsh “click” sound that can make people’s hearts tighten before they regret it. It should be understood that preventive measures are always cheaper and more cost-effective than subsequent rescue actions.