Case Study of Typical Maint Problems

FANUC INDIA FA & ROBOT
Typical
Typical problems
problems faced
faced by
by end
end users
users
1
Reference point shifting
Whether the shift is a fixed value or is it varying
Varying shift :
• Normally this shift comes from machine side
• Check the coupling between motor and Ballscrew
• If belt drive is used whether pulley or belt is
loose.
• If separate encoder is used whether coupling to
encoder is loose.
2
Fixed shift:
• Check the reference counter capacity entered in
servo parameter screen.
• Check whether the servo parameter for the pitch
of the Ball screw is entered correctly.
• Motor to Ball screw ratio to be entered correctly if
motor mounted encoder is used.
• Check whether Grid shift value entered is correct
• Check the functioning of referencing limit switch
• Check the length of the deceleration dog
• Check the Referencing principle used
• Rapid feedrate used before reference speed
3
Poor Component Accuracy
Poor component accuracy is mostly affected by machine
parameters
• Method of clamping the job and tool
• Clamping force variation from job to job
• Tools used and their length
• Machine vibration
• Ambient temperature variation
• Type of cooling
• Speeds and feeds used
• Machine grouting and preparation of machine floor
4
Spindle orientation shift
Spindle orientation shift can be due to the following reasons
• Position Coder signals not meeting the TTL specification
• 1024 Pulses per revolution is not correct.
• Gear box not lubricated properly
• Slipping in coupling between spindle position coder
shaft and the driver pulley shaft
• Position coder coupling loose
• Position coder belt worn out
• Position coder assembly mounting screws loose
• Magnetic sensor polarity not maintained
5
Spindle motor overheat
Spindle motor overheat can be due to the following reasons
• Short duty cycles
• Spindle bearing failure which leads to overloading of
spindle motor
• Unbalanced pulleys
• Incorrect belt tension
• High feed / High depth of cut
• Usage of Blunt tool
• Check for proper functioning of cooling fan
6
930 CPU Interrupt
930 CPU Interrupt problem can be due to the CPU getting
spuriously interrupted .The likely causes are:
•EMI interference due to
• AC Induction motors
• Grounding
• Welding line
• Bad environmental conditions
•System Hardware failure
7
Machine vibration during small step
Movement
Problem reported:
• Axis starts vibrating when small steps of movement
is commanded using MPG / STEP mode.
Observations:
• Problem is observed only in X axis
• X axis is a long axis carrying more load
• For setting the Job the axis has to move in small
steps with the help of MPG / STEP
• When the axis moves in small step movement
sometimes it starts vibrating with low frequency.
8
Analysis:
Problem can be due to any one of the following reason
• Static friction is high
• Load on the axis is more
• Disturbance in the Velocity loop
• Ball screw nut and coupling loose
Action taken:
Introduced the following servo function for eliminating
the problem.
• Static friction compensation function
• One pulse suppression function
• Calculated the load inertia based on the load.
9
Observation with the above corrective action:
• Vibrations reduced but not fully eliminated, Hence
the mechanical assembly of X axis was removed and
found that the Ball screw nut was loose.
Conclusion:
• Problem was due to mechanical assembly of X axis.
Final setting:
• All the servo functions removed
• Only load inertia parameter was set
• Standard parameters was set
10
Machine is not switching on
• Whether machine is being switched on for the first
time or is it a running machine
• Whether Not ready message display goes off or not
If not ready message does not go off, then CNC has
not recognized emergency release.
• Whether all hardware interlocks are healthy
• Whether the servo parameters are set correctly
11
Machine trips with Servo ready off
• Whether supply voltages are all correct
• Whether velocity feedback cable connection and
command cable connections are OK
• Whether protection circuit breaker in servo drive
has tripped / not switched on.
• Whether motor ID number in servo parameter
screen is entered correctly.
• Whether servo parameter for position deviation
during stop is entered.
12
Machine vibrates during acc/decc
This problem can be due to any one of the following
reasons:
• Load torque inertia of load higher than motor and low
acceleration / deceleration time.
• High position loop gain
• Jibs are tight
• Low acceleration time constant
• Lubrication
• Wrong motor specification]
• Dry solder of feedback cable
13
Spindle stalls/ trips while running
This problem can be due to any one of the following
reasons:
• Load higher than recommended value.
• Tip of the tool blunt
• Load limit for spindle set at low value
• High duty cycle
• Pulse generator is faulty
• Gap between the sensor and the sensor gear is
not as per the specification.
• Coupling to position coder faulty
• Belt is loose
14
APC – Absolute Pulse Coder
Problem:
• APC alarm 3n7 & 3n8 ( Where n=1 to 8 ) is
displayed
Message :
• nth axis absolute pulse coder battery low
Cause:
• Battery voltage low, Loose connection, cable broken,
corrosion in battery box
15
Analysis:
• For A type of servo connection replace the Battery
that is connected to the Axis PCB
• For B type of servo connection replace the Battery
in the nth axis servo amplifier
• For separate type pulse coder, refer MTB supplied
maintenance manual
Precaution:
• Memory backup battery should not be removed.
• APC battery to be changed in power on condition
16
SPC – Serial Pulse Coder
Problem:
• Alarm 3n9 ( Where n=1 to 8 ) is displayed
Message:
• nth axis Serial pulse coder faulty
Cause:
• Loose connection, cable broken or Serial pulse
coder is faulty
17
Analysis:
• Check the details in diagnostic bits 760 to 763 and
770 to 773 for details
• Inter change the pulse coder cable
• Interchange the command cable
• Replace the Axis PCB
18

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FANUC INDIA FA & ROBOT

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