As the power control core of automation equipment, servo drives may experience performance degradation after long-term operation due to component aging, parameter drift, or environmental influences, manifested as response lag, reduced accuracy, or abnormal operation noise. Restoring its performance requires system measures from three aspects: hardware maintenance, parameter calibration, and environmental optimization, rather than simply replacing components.
The detection and repair of core components are crucial at the hardware level. As the core of energy storage and filtering, capacitors can dry up the electrolyte and cause voltage fluctuations during long-term high-temperature operation. The capacitance value can be detected through a multimeter to replace electrolytic capacitors with excessive tolerance, and high-temperature resistant models can be selected to improve stability. The on resistance of the power module will increase over time. If it is detected that the three-phase output is unbalanced, it is necessary to check the consistency of the triggering voltage of the IGBT tube and replace the module with degraded characteristics. In addition, dust accumulation in the cooling fan can lead to a decrease in cooling efficiency. Regularly disassembling and cleaning the air duct and replacing the aging fan can effectively reduce the operating temperature of the components and slow down the aging rate.
Parameter calibration and dynamic optimization are the core steps in restoring control accuracy. After long-term operation, the PID parameters of the current loop and speed loop may be mismatched due to load changes, manifested as low-frequency vibration or overshoot. The system can automatically identify motor parameters and optimize gains through the driver self-tuning function, or manually adjust the proportional coefficient and integration time until there is no overshoot in the dynamic response and the steady-state error is minimized. For pulse command type drivers, it is necessary to recalibrate the electronic gear ratio to ensure the conversion accuracy between the command pulse and the actual displacement, and eliminate cumulative errors. The phase offset of the encoder feedback signal can affect the positioning accuracy. By adjusting the phase compensation parameter, the real-time performance of the position feedback can be restored.
Improving the operating environment can fundamentally reduce performance degradation. Servo drives are sensitive to the quality of the power grid, and long-term voltage fluctuations can exacerbate component losses. Installing voltage regulators or filters can suppress harmonic interference. Excessive environmental humidity can easily lead to mold growth on circuit boards. It is necessary to install a dehumidification device in the control cabinet to maintain a relative humidity of 40% -60%. In addition, dust accumulation may cause circuit short circuits. Regularly cleaning the internal circuit board with compressed air and treating the connectors with insulation spray can reduce the risk of poor contact.
In daily maintenance, it is important to establish a mechanism for recording operational data. Regularly comparing key parameters such as output torque and response time can help detect performance degradation trends early. For drives that have been in use for over 8 years, it is recommended to perform comprehensive preventive maintenance, replace vulnerable components, and update firmware programs to avoid sudden failures. By combining hardware repair with parameter optimization, most performance degradation faults can be effectively resolved, extending the lifespan of the drive.