12 Common Causes of Servo Motor Failure

April 23, 2023 Brian Diver

Servo motors are vital in many industrial processes, providing precise and accurate
machinery control. Despite their importance, there is a chance of servo motor
failure, resulting in costly downtime, repairs, and production losses.
Understanding common causes of failure is crucial in preventing outages and
ensuring the machinery operates smoothly and efficiently.

So, what is the most common cause of servo motor failure? We'll answer that
question and review a whole range of reasons that servo motors fail, including:

1. Contamination
2. Bearing Failure
3. Brake Failure
4. Bad Windings
5. Cable Failure
6. Overheating
7. Demagnetization of Permanent Magnets
8. Electrostatic Discharge
9. Vibration
10. Electronic Component Fatigue
11. Mechanical Faults and Failures
12. Loss of Parameters or Setup Issue
servo motor failure
Servo Motor 101
Before discussing the causes of servo motor failure, reviewing the motors and their
components would be helpful. Servo motors are self-contained electrical devices
that use drive gears for precise movement. They can control positioning in two- and
three-dimensional spaces for CNC machines and rotational velocity in grinding and
milling machines.

While your application's complexity will decide your motor's final makeup, all
servo motors contain at least three components:

The motor is the primary drive mechanism.

The potentiometer functions as the feedback mechanism.
The control circuit interprets electrical signals among the controller, the motor,
and the potentiometer.
Other parts like cables, windings, and bearings complement these components to keep
your machinery moving.

How To Detect Servo Motor Failures

Before the servo motor stops altogether, there are some signs of failure you can
look for. Noises like chatter, shrieks, or growls often signal an impending
failure. You can also use a megohmmeter to diagnose open or short circuits.

How To Avoid Servo Motor Failures

A good preventative maintenance program is the best way to avoid a servo motor
failure. By tracking the service life of the various components, you can know when
parts need maintenance or to be replaced before a failure occurs. Preventative
maintenance also allows you to schedule repairs when downtime won't affect
production.

The 12 Causes Of Servo Motor Failure: Explained

Numerous factors, some easy to detect and some more challenging, contribute to
motor failure. The most common reasons for a servo motor to fail include the
following:

1. Contamination
What is the most common cause of servo motor failure? Contamination. Oil, coolant,
and debris can foul a servo motor, degrading bearings, windings, and other
components, leading to many of the failures listed below.

You can prevent contamination by regularly inspecting and cleaning your servo
motors. Sealing the motor windings and using a fully enclosed motor system also
lessen the chances of contamination-related failures.

2. Bearing Failure
Growling or shrieking when your motor runs at high speeds indicates bearing
failure. This can result from a variety of issues, including normal bearing wear.
Other causes include improper installation or reinstallation of the servo motor,
which can lead to misaligned bearings.

Contamination can also lead to premature wear. Routinely checking your bearings and
replacing them as needed will help prevent these failures and improve the lifespan
of your servo motor. You can also use motor-mounted vibration sensors for early
detection of bearing issues.

3. Brake Failure
Servo motor brakes often fail because of improper use. Most brakes are designed to
keep a load in place when the motor is deactivated or shut down. Brake failure can
occur if the brake is used for multiple e-stops or repetitive stopping.

Additionally, contamination can affect brake performance. You should always engage
the brake after the motor has stopped to reduce the chances of such failures. If
you need to stop the motor during operation, consider using a brake specially
designed for that purpose.

4. Bad Windings
Poor insulation systems, failure from power faults, improper repair, contamination,
and age can all contribute to bad windings. Natural vibrations from the running
motor can also degrade the copper coiling over time, leading to motor failure. If
the servo motor is exposed to contaminants like water or coolant, you'll want to
check the windings to ensure they're still in good condition. Correctly rewinding
the coils as they degrade will help keep your motor running and extend its
lifespan.

5. Cable Failure
Servo motors rely on cables to send signals and power from the control system to
the motor, and any issues with these wires can cause the motor to malfunction or
even fail. Several issues can lead to cable failure, including wear and tear,
corrosion, and physical damage from bending or twisting.

It's essential to inspect cables to prevent failure regularly. Replacing these

wires before they fail can help avoid more costly repairs. High-quality cables
designed for the specific application and environment can also help prevent these
failures and ensure that your servo motors continue operating at peak performance.

6. Overheating
Overheating is the downfall of a lot of equipment, including servo motors. High
environmental temperatures, a blockage in the motor, and extended operating times
can all lead to overheating. Even though it can be challenging to detect,
overheating contributes to motor failure by damaging internal components or
connected systems.

Many servo motors incorporate a failsafe that will trigger a shutdown when the
temperature reaches a critical point. Although not always possible, operating them
in temperature-controlled environments can also help prevent overheating. Proper
ventilation and replacing old, worn parts that contribute to overheating can help
avoid the excessive temperatures that lead to failures.

7. Demagnetization of Permanent Magnets

Servo motors rely on permanent magnets to produce the magnetic field that drives
the motor's rotor, and any magnetization loss can significantly affect the motor's
performance. Various factors, including high temperatures, excessive current, and
mechanical stress, can cause demagnetization. Demagnetization can dramatically
affect the motor's torque output and speed, leading to decreased performance and
even complete failure.

You can prevent demagnetization by ensuring the motor runs within its specified
temperature and current limits. Proper maintenance, such as regular cleaning and
inspection of the motor and its components, can also help avoid demagnetization and
ensure that your servo motors continue to work effectively.

8. Electrostatic Discharge
Electrostatic discharge (ESD) is a sudden and brief electric current flow between
objects with different electrical charges. ESD can cause motor failure by damaging
the sensitive electronic components within the motor. Servo motors often have
complex electronic circuitry and delicate sensors that even small amounts of
electrostatic discharge can easily damage.

To prevent electrostatic discharge from damaging servo motors, it's vital to follow
proper grounding procedures during installation and maintenance. Personnel should
be trained to handle and discharge static electricity before touching the motor or
its components. Antistatic materials during installation and maintenance can also
help prevent ESD and protect the motor's sensitive electronic components.

9. Vibration
Vibrations can cause stress on the motor's mechanical and electronic components,
leading to damage and eventual failure. Various factors, including unbalanced
loads, improper installation, and mechanical resonance, can cause vibrations.

To prevent vibration and potential failures, it's crucial to ensure that the motor
is installed and supported correctly. This includes proper installation, mounting,
and regular inspection and maintenance of the motor's components. Monitoring and
analyzing the vibration levels of the motor can help detect potential issues before
they cause damage or failure.

10. Electronic Component Fatigue

The complex electronic components within a servo motor can experience wear and tear
over time, leading to decreased performance and eventual servo motor failure.
Numerous factors, including temperature cycling, voltage fluctuations, and
contaminant exposure, can lead to electronic component fatigue.

You must ensure the motor operates within its specified temperature and voltage
limits to prevent electronic component fatigue. Proper maintenance, such as regular
cleaning and inspection of the motor and its components, can also help prevent
fatigue and ensure that the motor continues to operate effectively.

11. Mechanical Faults and Failures

Servo motors rely on precise mechanical components to run correctly, and any issues
with these components can cause motor failures. Causes of mechanical faults and
failures can include wear and tear, misalignment, and insufficient lubrication.

You'll want to ensure the motor is installed and maintained correctly to prevent
mechanical faults and failures. This includes regular inspection and maintenance of
the mechanical components and proper alignment and lubrication. Additionally, using
quality parts developed for the correct application and environment can help avoid
mechanical failure and extend the motor's life.

12. Loss of Parameters or Setup Issue

A setup issue or loss of parameters can create positioning errors that lead to
servo motor failure. They can also cause overloading, misaligned components,
control signal, and electrical problems contributing to motor failure. To detect a
setup issue or loss of parameters, go through your usual setup process to look for
anomalies that need to be addressed.

You can prevent these issues by monitoring the system for irregularities and
performing regular maintenance.

bearing failure
After A Servo Motor Failure: Repair The Motor Or Buy New?
Despite your best efforts, servo motor failure is sometimes inevitable. When a
motor does fail, you're left with a fundamental decision: do you repair or replace
the motor? Repairs can be time-consuming, but a new purchase can be expensive.
Answer the following questions to help decide which is your best option:

What caused the motor failure?

Is a spare unit available?
What will be the cost of downtime?
Will a new motor be available immediately? What will it cost?
Is the repair under warranty?
Do you have a repair vendor standing by?
If the repair costs more than 50% of the price of a new purchase, which can be done
more quickly?
Comparing your answers to these questions can help you make the most efficient,
cost-effective choice.

Frequently Asked Questions About Servo Motor Failures

As a leading supplier of industrial automation replacement parts, Industrial
Automation Co. is well-positioned to answer your questions about servo motor
failures. Please read the questions below to learn more, and contact us if you need
additional information.

What Are the Signs of Servo Motor Failure?

Motor failure signs include erratic behavior, excessive noise, reduced performance,
and overheating.

Can Motor Failures Be Prevented?

Yes, motor failures can be prevented by adequately configuring the servo motor
parameters, using compatible components, correctly aligning the motor, calibrating
the control signal, monitoring the system, and performing regular maintenance.

What Are Some Typical Maintenance Tasks Required for Servo Motors?
Maintenance tasks required to keep a servo motor in good working condition include
cleaning, lubricating, inspecting electrical connections, checking for wear and
tear, and replacing worn-out components.

How Can I Troubleshoot a Servo Motor That Is Not Working Correctly?

To troubleshoot a servo motor that is not working correctly, you can check the
electrical connections, inspect the motor for signs of wear and tear, check the
control signal for accuracy and stability, and monitor the motor's temperature and
feedback signals.

What Is the Typical Lifespan of a Servo Motor?

The typical lifespan of a servo motor depends on various factors, such as the
quality of the motor, the operating conditions, and your maintenance practices.
However, well-maintained motors can last for several years.

brake failure
Purchase Servo Motors From Industrial Automation Co.
Industrial Automation Co. is the go-to supplier of industrial automation parts,
including servo motors. We offer outstanding quality, competitive pricing, and
industry-leading turnarounds. You can rely on us for the replacement components
needed to run your operation. Order your servo motors today, and experience the
difference Industrial Automation Co. makes.

SHOP SERVO MOTORS

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