What are the common mechanical failures and solutions for motor motor manual 3 in 1 servo press?
The following is the motor rotor manual three-in-one servo press common mechanical failures and solutions, organized by structural classification, to facilitate rapid troubleshooting and repair:
First, the transmission system failure
1. synchronous belt / gear box rattling or broken
Phenomenon:
Harsh noise when the equipment is running, synchronous belt jumping or tooth wear; gear box oil leakage, heat.
Cause:
Insufficient or too tight synchronous belt tension;
Poor gear meshing (e.g. lack of oil, tooth wear);
Sudden change of load (e.g. overload due to jammed rotor).
Solution:
Adjust the synchronous belt tension to 30-40N with a tensiometer (refer to the equipment manual);
Replace the gearbox lubricant (recommended ISO VG220 industrial gear oil);
Check whether the press fit station is centered to eliminate rotor jamming problem.
2. Bearing overheating or seizing
Phenomenon:
The temperature of the bearing part exceeds 70°C, and there is a high resistance to rotation or a friction sound.
Cause:
Grease is dry or contaminated (mixed with metal chips);
Bearing mounting eccentricity or excessive preload.
Solution:
Clean the bearing and refill with high temperature grease (e.g. SKF LGHP2);
Use a micrometer to check the coaxiality of the bearing seat (error ≤ 0.02mm).
II. Pressure mechanism failure
1. Unstable or biased loading of the press force
Phenomenon:
The press fitting curve fluctuates greatly, and the product height dimension is out of tolerance; the contact surface between the press head and the workpiece is off-ground.
Cause:
Guide slide clearance is too large (wear or loose);
Leakage inside the hydraulic / pneumatic cylinder (deteriorated seals);
Uneven pressure sensor mounting surface.
Solution:
Adjust the guide rail platen clearance to 0.03-0.05mm, replace the worn linear guide;
Replace the hydraulic cylinder seal (material preferred polyurethane);
Calibrate the sensor mounting surface with a precision level (flatness ≤ 0.01mm/m).
2. Slow return of the indenter or stuck
Phenomenon:
The indenter jerks when returning, or even fails to reset.
Cause:
Guide rod corrosion or strain;
Fatigue fracture of reset spring;
Excessive back pressure in the pneumatic/hydraulic system.
Solution:
Polishing the guide rod and applying a molybdenum disulphide lubricant coating;
Replace the spring (original spring stiffness to be measured, e.g. 50N/mm);
Check the pneumatic pressure reducing valve or hydraulic relief valve and adjust the pressure to 0.5-0.7MPa.
Third, the frame and structure failure
1. frame deformation or vibration
Phenomenon:
The whole machine shakes when press-fitting, and the size of the C-frame opening changes more than 0.1mm.
Cause:
Uneven foundation or loose bolts;
Long-term overloading causes stress deformation of the frame.
Solution:
Re-level the machine and fix it with M16 foundation bolts + elastic washers;
Use laser interferometer to detect the deformation of the frame, and return to the factory for correction if it is too poor.
2. Parallelism of the working table surface is too poor
Phenomenon:
The coaxiality of the rotor is out of tolerance after pressing in (e.g. runout > 0.05mm).
Reason:
Table fastening bolts loose;
Table surface long-term pressure local depression.
Solution:
Use the marble platform and the percentage meter to test the flatness of the table surface (≤ 0.02mm);
If the depression is serious, need to re-grind the table surface (surface hardness ≥ HRC45).
Fourth, lubrication and cooling system failure
1. lubrication pipeline blockage
Phenomenon:
Guide rail or bearing parts dry friction, manual lubrication pump pressure abnormally high.
Cause:
Grease impurities clogging the distribution valve;
The grease solidifies under low temperature environment.
Solution:
Disassemble and clean the progressive distributor;
Replace low temperature grease (e.g. Mobil SHC PM 220).
2. High hydraulic system oil temperature
Phenomenon:
Tank temperature exceeds 60°C and hydraulic fluid viscosity decreases.
Cause:
Failure of cooling fan or accumulation of dust on heat sink;
Frequent overflow due to internal leakage of hydraulic valves.
Solution:
Clean the radiator dust, check the fan steering (the wind direction should be extracted);
Test the hydraulic system to maintain pressure performance, repair or replace the leaking valve group.
Fifth, the work fixture failure
1. positioning pin wear
Phenomenon:
The position of the rotor is shifted after it is put in, resulting in the deviation of the press-fit angle.
Cause:
Insufficient hardness of the pin material (e.g. unhardened 45# steel);
Frequent loading and unloading caused by the fit clearance is too large.
Solution:
Replace the carbide positioning pin (surface hardness ≥ HRC60);
Adopt taper pin + spring preload structure to compensate for the wear gap.
2. jaw clamping force is not enough
Phenomenon:
The rotor slides during press fitting, resulting in inconsistent press fitting depth.
Cause:
Pneumatic jaw seals are worn and leaking;
Clamping surface tooth pattern wear.
Solution:
Replace the jaw seals (NBR preferred);
Laser cladding of the clamping surface with a tungsten carbide wear-resistant layer.
Preventive Maintenance Recommendations
Daily spot checks:
Check synchronous belt tension, lubrication pump oil level, bolt tightening status.
Monthly maintenance:
Clean and replenish grease on guide rails, test hydraulic oil contamination (within NAS 8).
Annual overhaul:
Replace all seals, calibrate the parallelism of the frame and the pressure curve.
※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical & Electrical Equipment Co.
