When a servo motor arrives without a clearly identified fault, a structured diagnostic process is essential. Replacing components based on assumptions can quickly increase repair costs without addressing the underlying problem.
An Allen-Bradley MPL-B1530U-VJ72AA servo motor was sent to Motion Tronic by a Fast-Moving Consumer Goods (FMCG) company in Pinetown, KwaZulu-Natal. The customer had identified that the motor was faulty but could not determine the cause. The motor subsequently failed Motion Tronic’s initial in-house testing, prompting a more detailed investigation.
Finding the Source of the Problem
Further investigation indicated that the winding analyzer test results had all passed, indicating no issues with the motor windings.
Brake functionality was checked, these tests also provided no indication of a brake fault with the motor.
Encoder Diagnosis and Repair
Attention then turned to the encoder system. Reprogramming the existing encoder temporarily cleared the analogue offset error. However the error returned intermittently. The encoder was subsequently monitored and tested as part of the diagnostic process.
As part of the final repair, the motor was serviced and a new encoder was installed. The required memory file was loaded, the new encoder was programmed, and further testing confirmed correct operation.
The complete servo motor was then run again and operated smoothly before being sent for final painting.
Tested, Verified and Ready for Service
Final testing confirmed that the new encoder was functioning correctly and that the motor was running smoothly.
For the customer, the successful repair provided an alternative to replacing the complete Allen-Bradley servo motor, helping to avoid unnecessary replacement costs while improving the reliability of the existing equipment.
The Motion Tronic Difference
Servo motor faults are not always obvious, and in depth testing is often required to identify the fault.
At Motion Tronic, our approach is to investigate, isolate and verify faults before completing a repair. Through specialist electrical testing, encoder programming and comprehensive run testing, we help customers extend the value of critical motion-control equipment while reducing the need for unnecessary replacement.
Our systematic diagnostic approach helps ensure that repairs address the actual fault rather than relying on assumptions based on a single test result.
Have an Allen-Bradley servo motor with an unknown or difficult-to-diagnose fault? Motion Tronic provides professional servo motor assessment, repair, encoder replacement and testing services to help get industrial equipment reliably back into service.
