Support of the oil lubrication system of CNC machine tools: instructions for checking the pump, cleaning the filter and monitoring the oil level

Technical analysis: CNC machine way lubrication system maintenance: pump inspection, filter cleaning, and oil level moni

Підтримка системи олійного змащування шин CNC-станків: інструкція з перевірки насоса, очищення фільтру та моніторингу рівня олії - UNITEC-D Industrial MRO
Інструкція по підтримці системи олійного змащування шин CNC-станків, включає перевірку насоса, очищення фільтру та моніторинг рівня олії. Виконання вимагає захисних засобів, блокування енергії та вико

1. Content and purpose

This manual is intended for technicians who change and check the tire oil lubrication system on CNC machines. The purpose of performing this maintenance is to ensure efficient and safe functioning of the system, to detect possible violations and to perform necessary remedial actions. This procedure should be performed once a month or when unusual changes in oil properties or changes in lubrication are detected.

2. Preliminary security measures

Important: Block the power and install the tag lock before doing any work.

Performing work on the lubrication system may require working with high pressure, liquid oil and electrical components. To ensure safety:

  • Use safety glasses, gloves and personal protective equipment (PPE).
  • Perform a lock-out (LOTO) procedure to eliminate electrical or mechanical hazards.
  • Check for leaks or pressure in the system.
  • Do not perform work under pressure or without disconnecting the power supply.

3. Necessary tools and materials

Tool/material Specification Quantity
Torque winch The range is 10–100 Nm 1
Multimeter Minimum accuracy 0.1% 1
Pump wrench The range is 10–200 Nm 1
Roaster The size is 16 mm 1
Roaster The size is 8 mm 1
Cleaning filter The minimum flow rate is 10 l/min 1
Oil for lubrication ISO 46 or ISO 68 5 liters
Toaster for tires The size is 10 mm 1

4. Pre-service: Inspection

Item Verification Acceptance/rejection criteria Notes
Electricity supply Off The power supply must be turned off When performing work, use LOTO
No pressure Pressure test The pressure in the system should not exceed 0.5 bar Use a pressure gauge
Filter Cleaning The filter must be clean without flaking Clean when high moisture is detected
Pump Functioning The pump should make a stable noise without peeling Check for performance
Oil level Verification The oil level should be between 20-80% Use a toaster

5. Step by step procedure

  1. Power off. Follow the lock-out procedure to ensure electrical safety.

    • Error: Carrying out work without turning off the power supply may cause damage and injury.
  2. Checking the pressure in the system. Use a pressure gauge to measure the pressure in the system. The pressure should be within 0.5 bar.

    • Error: High pressure can cause leakage or component damage.
  3. Cleaning the filter. Open the filter, remove the backfill, rinse it with water, dry it and put it back.

    • Error: Improper cleaning may cause explosion or oil leakage.
  4. Checking the pump. Use a torque wrench to check that the pump is secure. The maximum torque is 50 Nm.

    • Error: Improper locking can cause the pump to shut down or wear out.
  5. Adding oil. Add oil to the level of 20-80% of the total volume. Use a toaster to check the level.

    • Error: Insufficient oil level can cause tire wear.
  6. Pressure and Functionality Check. Turn on the power supply and check the pressure and noise of the pump. The pressure should be within 0.5 bar, the noise is stable.

    • Error: Increased noise may indicate a pump malfunction.
  7. Fixing the components. Use the torque winch to fix all the components. Set the torque within 50 Nm.

    • Bug: Insufficient commits can lead to shutdowns or leaks.
  8. Final check. Go through all steps again to ensure correct execution.

    • Error: Failure to complete may result in increased maintenance costs.

6. After-service: inspection

Test Expected result Actual result Pass/Fail
Pressure in the system 0.5 bar
Pump operation Stable noise
Filter Clean without flaking
Oil level 20-80%

7. Table of problem solving

Symptom Reasons actions
The pump is not working Lack of power supply, leakage, breakdown Check the power supply, leaks, make repairs
Tire unevenness Insufficient oil level, wear Add oil, replace tires
Loud noise Pump failure, oil leak Repair or replace components
Oil leak Wear, tear Replace tires, perform repairs

8. Recommended maintenance schedules

Task Frequency During Skill level
Pressure test the moon 10 min Average
Filter cleaning the moon 15 min Average
Checking the pump the moon 20 min Average
Adding oil the moon 10 min Average

9. Links to spare parts

Part description Typical specification UNITEC-D category
Cleaning filter The minimum flow rate is 10 l/min Filters
Oil for lubrication ISO 46 or ISO 68 Oil
Toaster for tires The size is 10 mm Toasters
Pump The maximum torque is 50 Nm Pumps
Manometer Minimum accuracy 0.1% Manometers

Go to the UNITEC-D catalog

10. Links

  • DSTU 3026-2009 — General requirements for lubricants
  • EN 12100 - Machine safety
  • ISO 10426 - Lubrication systems
  • CE — Common Operational Conformity
  • UkrSEPRO — State certification of Ukraine

Related Articles

Diagnosing CNC machine positioning errors: ball shaft knockback, encoder, thermal compensation, and servo drive setup

Technical analysis: Troubleshooting CNC machine positioning errors: ballscrew backlash, encoder feedback, thermal compen

Діагностування помилок позиціонування CNC-верстатів: відбивання кулькового валу, кодер, термічна компенсація та налаштування сірво-приводу - UNITEC-D Industrial MRO
Цей гайд допомагає діагностувати та виправляти помилки позиціонування у CNC-верстатах, включаючи відбивання кулькового валу, фідбек-інформацію, термічну компенсацію та налаштування сірво-приводу. Гайд

1. Description of the problem and scope

This guide is intended for diagnosing and correcting positioning errors in CNC machines that are caused by ball shaft kickback, incorrect encoder feedback, lack of thermal compensation, or incorrect servo setup. Positioning errors can affect manufacturing accuracy, part quality, and production process efficiency. According to the classification, this can be a critical problem if it affects the production of manufactured products.

2. Safe measures

Requirements for personal protective equipment: when diagnosing, it is necessary to use gloves, glasses, tools with insulation, as well as observe the rules of blocking and marking of energy.
Power Lockout and Tagout: Before performing any diagnostic operations, the machine must be powered off and the lockout and tagout must be installed.
Presence of stored energy: Before accessing mechanical components, it is necessary to check whether stored energy is present in the actuators or hydraulic systems.
Dangerous conditions: in the case of performing work in the presence of high temperatures or dangerous materials, it is necessary to use special protective equipment.

3. Necessary diagnostic tools

Name of the tool Model/Spec Measuring range Purpose
Multimeter Fluke 289 0-2000 V, 0-200 A Measurement of voltage, current, resistance
Thermal camera Fluke TiS66 -20°C to 650°C Measuring the temperature of components
Vibration analyzer Model 36000 0-10000 Hz Vibration measurement and deflection analysis
Connection to the CNC system USB / Ethernet According to the technical specifications Diagnosis of feedback signals

4. Primary assessment: Check before diagnosis

Verification action
Operating conditions Determine temperature, humidity, load
New changes Check if recent configuration changes have been made
A history of anxiety Write down the anxieties that arose during work

5. Systematic diagnostic scheme

  1. If the machine cannot perform accurate positioning, check for ball shaft runout errors:
    1. Use a vibration analyzer to measure the vibration level (allowable range: 0-4.5 mm/s).
    2. Check the distance between the ball shaft and the ball rail (allowable distance: 0.01-0.03 mm).
    3. If the distance does not meet the standards, adjust.
  2. If the vibration measurement is above the threshold value, check the feedback system:
    1. Use a multimeter to check encoder signals (acceptable voltage: 0.5–5 V).
    2. Check for repulsion or malfunction of the corresponding contacts.
    3. If violations are found, replace or adjust.
  3. If the feedback system meets the standards, check the thermal compensation:
    1. Use a thermal camera to measure the temperature of the components (acceptable temperature: 20-60°C).
    2. Determine if there is a fault in the compensation or adjustment system.
    3. If deviations are detected, adjust the thermal compensation system.
  4. If the temperature meets the standards, check the settings of the gray drive:
    1. Use a multimeter to check the gray-drive setting (acceptable voltage: 0.5–5 V).
    2. Determine if there is a deviation in the setting of proportional, integral and differential control.
    3. If deviations are detected, adjust the gray drive.

6. Matrix of causes of defects

Symptom Probable causes (by probability) Diagnostic test Expected result
Incorrect positioning 1. Ball shaft rebound Vibration measurement Vibration is above the permissible range
2. Incorrect feedback information Encoder voltage measurement The voltage is above the permissible range
3. Lack of thermal compensation Temperature measurement The temperature is above the permissible range
4. Incorrect setting of the servo drive Measurement of gray-actuator setting The voltage is above the permissible range

7. Detailed root cause analysis

7.1. Ball shaft rebound

Ball shaft knocking occurs due to deviations in operating conditions or lack of correct adjustment. This can lead to incorrect positioning, increased vibration and energy consumption. To confirm, use a vibration analyzer and measure the distance between the ball shaft and the ball rail. If the distance is not within the allowable range (0.01-0.03 mm), adjust.

7.2. Incorrect feedback information

Incorrect feedback information occurs due to encoder malfunction or contact repulsion. This can lead to incorrect positioning and wasted energy. To confirm, use a multimeter and check the encoder output voltage. If the voltage is above the allowable range (0.5–5 V), replace or adjust.

7.3. Lack of thermal compensation

Lack of thermal compensation occurs due to lack of correct system setup or lack of temperature measurement. This can lead to incorrect positioning and wasted energy. To confirm, use a thermal camera and check the temperature of the components. If the temperature is above the allowable range (20-60°C), perform thermal compensation settings.

7.4. Incorrect gray-drive setting

Incorrect adjustment of the gray drive occurs due to deviations in the adjustment of proportional, integral and differential parameters. This can lead to incorrect positioning and wasted energy. To confirm, use a multimeter and check the gray-drive settings. If the setting is above the acceptable range (0.5–5 V), adjust the gray drive.

8. Step-by-step repair procedures

8.1. Ball shaft rebound

  1. Measure the distance between the ball shaft and the ball rail. Allowable distance: 0.01–0.03 mm.
  2. If the distance does not meet the standards, adjust the ball shaft or ball rail.
  3. Perform the vibration measurement again to confirm the correction.
  4. Note the results in the service log.

8.2. Incorrect feedback information

  1. Measure the encoder output voltage. Allowable voltage: 0.5–5 V.
  2. If the voltage is above the permissible range, replace the encoder or restore the contacts.
  3. Measure the feedback information again to confirm the correction.
  4. Note the results in the service log.

8.3. Lack of thermal compensation

  1. Measure the temperature of the components. Permissible temperature: 20–60°C.
  2. If the temperature is above the acceptable range, adjust the thermal compensation system.
  3. Take the temperature measurement again to confirm the correction.
  4. Note the results in the service log.

8.4. Incorrect gray-drive setting

  1. Measure the gray actuator setting. Allowable voltage: 0.5–5 V.
  2. If the setting is above the allowable range, adjust the gray drive.
  3. Measure the setting again to confirm the correction.
  4. Note the results in the service log.

9. Preventive measures

The root cause Prevention strategy Control method Recommended interval
Ball shaft rebound Regular adjustment of the ball shaft Distance measurement Monthly
Incorrect feedback information Regular check of the coder Voltage measurement Monthly
Lack of thermal compensation Regular adjustment of the thermal compensation system Temperature measurement Monthly
Incorrect gray-drive setting Regular tuning of the gray drive Measurement setting Monthly

10. Spare parts and components

Description of the component Specification When to replace UNITEC-D category
Ball shaft Diameter 20 mm, length 500 mm After correcting the reflection Category 123
Coder Voltage 5 V, 1000 rpm After correcting the feedback information Category 456
Thermal compensation system Temperature 20–60°C After correcting for thermal compensation Category 789
Gray drive Voltage 5 V, 1000 rpm After correcting the setting Category 101

Refer to the UNITEC-D catalog for spare parts.

11. Links

This guide complies with the following standards:

  • DSTU 4389:2007 — Rules for technical operation of industrial equipment
  • EN 13163:2003 - Technical operation of industrial equipment
  • ISO 10426-1:2004 — Rules for the operation of industrial equipment
  • CE, UkrSEPRO: product certification

Additional resources:

  • Original documentation of the manufacturer of CNC machines
  • Other UNITEC-D guides for maintenance of CNC machines

Related Articles

Diagnosis and correction of CNC machine positioning errors: reverse, encoder, thermal compensation and servo adjustment

Technical analysis: Troubleshooting CNC machine positioning errors: ballscrew backlash, encoder feedback, thermal compen

Діагностика та виправлення помилок позиціонування CNC-станків: зворотній зворотний хід, енкодер, термічна компенсація та налаштування серво - UNITEC-D Industrial MRO
Цей посібник допоможе технікам вирішити помилки позиціонування CNC-станків, включаючи зворотній зворотний хід, енкодер, термічну компенсацію та налаштування серво. Діагностика виконується за допомогою

1. Problem description and scope

This is a manual for diagnosing and correcting CNC machine positioning errors, including hinge backlash, encoder, thermal compensation, and servo setup. These problems are often encountered in the operation of industrial CNC machines used in the automotive, aerospace, food, chemical and energy industries. The importance of these errors is determined by their criticality for production quality, production safety and production efficiency.

2. Safety during diagnosis

Requirements for personal protective equipment: When diagnosing CNC machines, use protective equipment against mechanical injuries, including gloves, goggles, work clothes with high resistance to high temperatures, and electrical protective elements. When working with an electric drive, use insulating materials.
Safety measures against energy hazards: Before performing any diagnostic procedures, perform a lockout and tagout (LOTO) procedure to avoid unforeseen events. When using electrical components, check for stored energy and disconnect it before starting work.

3. Necessary diagnostic tools

Name of the toolModel/specificationMeasurement rangePurpose
MultimeterFluke 4340–2000 MΩ, 0–600 V, 0–1000 AMeasurement of electrical parameters, voltage, current and resistance
Vibration analyzerKeysight 35670A0–20000 HzMeasurement of vibration parameters for the analysis of the condition of mechanisms
Thermal cameraFLIR T1030sc-20°C to +1000°CDetection of overheated or cold areas to diagnose thermal abnormalities
A tool for measuring backstrokeBearing return stroke0–1000 μmMeasurement of the return stroke of the hinge to detect deviations
Template for distance measurementMetal templates0–2000 mmMeasuring distances to check positioning accuracy
Servo adjustmentKEBA KCP2500–10000 HzAdjust servo parameters for accuracy

4. First examination before diagnosis

Pointaction
1Determine the ambient temperature and the condition of the mechanism
2Check for known changes in settings or manufacturing process changes
3Record the history of system alarms and messages
4Determine the time of onset of symptoms and their frequency
5Check for known damage or malfunctioning components
6Take photos of the condition of the mechanism

5. Systematic diagnostic scheme

  1. Symptom: Positioning errors during CNC machine operation
    1. Check: Measure the temperature of bearings and hinges
    2. If: Temperature exceeds 60°C — perform thermal compensation diagnostics
    3. If: Temperature in the range of 20-50°C - perform reverse diagnosis
  2. Symptom: Incorrect position or deviation from the specified position
    1. Check: Measure the deflection of the hinge
    2. If: Deviation exceeds 50 μm — perform reverse stroke diagnostics
    3. If: Deviation within 10-50 μm - perform encoder diagnostics
  3. Symptom: Positioning instability
    1. Check: Measure the vibration of the mechanism
    2. If: Vibration exceeds 10 mm/s - perform servo diagnostics
    3. If: Vibration within 1-10 mm/s - perform thermal compensation diagnostics
  4. Symptom: Errors in the feedback system
    1. Check: Measure the encoder signal
    2. If: The signal deviates from the nominal one - perform encoder diagnostics
    3. If: The signal is within the permissible range - perform servo diagnostics

6. Matrix of causes of defects

SymptomProbable causes (descending)Diagnostic testExpected result
Positioning errors1. Reverse reverseMeasure the deflection of the hingeDeviation >50 μm
2. EncoderMeasure the encoder signalThe signal deviates from the nominal
3. Thermal compensationMeasure the temperatureTemperature >60°C
4. ServoMeasure the vibrationVibration >10 mm/s
Instability of positioning1. ServoMeasure the vibrationVibration >10 mm/s
2. Thermal compensationMeasure the temperatureTemperature >60°C
Wrong position1. Reverse reverseMeasure the deflection of the hingeDeviation >50 μm
2. EncoderMeasure the encoder signalThe signal deviates from the nominal

7. Root cause analysis for each defect

7.1. Reverse reverse

Reason: Deviation of the hinge from the nominal values can be caused by worn bearings, lack of correct tension or improper assembly of components.

Diagnosis: Measure the deviation of the hinge from the nominal position. A deviation of >50 μm indicates a lack of stability in positioning.

Consequences: Positioning errors, reduced production quality, callbacks and energy waste.

7.2. Incorrect operation of the encoder

Reason: Encoder signal deviation can be caused by encoder wear, damaged cables, or incorrect settings.

Diagnosis: Measure the encoder input signal. If it deviates from the nominal value, this indicates a malfunction of the encoder.

Consequences: Unstable positioning, rejected output, decrease in product quality.

7.3. Thermal compensation

Reason: Overheating of hinges or bearings may occur due to incorrect operation mode or lack of a thermal compensation system.

Diagnosis: Measure the temperature of the bearings. If the temperature exceeds 60°C, this indicates a lack of thermal compensation.

Consequences: Component wear, energy consumption, incorrect positioning.

7.4. Incorrect servo setting

Reason: Incorrect servo setup can cause vibration, incorrect positioning, and reduced production quality.

Diagnosis: Measure the vibration of the mechanism. If it exceeds 10 mm/s, it indicates a problem in the servo.

Consequences: Unstable positioning, energy consumption, component wear.

8. Step-by-step repair procedure

8.1. Correction of reverse course

  1. Measure the deviation of the hinge from the nominal position
  2. If the deviation is >50 μm, replace the bearings
  3. Check for correct tension and assembly of components
  4. Adjust the hinge according to the technical data sheet
  5. Check the positioning after correction

8.2. Encoder correction

  1. Measure the encoder signal
  2. If the signal deviates from the nominal one, replace the encoder
  3. Check the encoder cable for the intended purpose
  4. Perform encoder settings according to the technical data sheet
  5. Check the positioning after correction

8.3. Correction of thermal compensation

  1. Measure the temperature of the bearings
  2. If the temperature exceeds 60°C, set the thermal compensation
  3. Check for thermal compensation in the system
  4. Perform thermal compensation settings
  5. Check the positioning after correction

8.4. Servo correction

  1. Measure the vibration of the mechanism
  2. If the vibration is >10mm/s, adjust the servo
  3. Check the servo settings
  4. Adjust the servo according to the technical data sheet
  5. Check the positioning after correction

9. Preventive measures

The root causePrevention strategyMonitoring methodRecommended interval
Reverse reverseRegular replacement of bearingsBackstroke measurementAnnual inspection
EncoderRegular inspection of cablesEncoder signal measurementAnnual inspection
Thermal compensationThermal compensation instructionTemperature measurementAnnual inspection
servoServo settingsVibration measurementAnnual inspection

10. Spare parts and components

Description of the componentSpecificationWhen to replaceUNITEC-D category
Pivot bearingsSize: 100 mm, weight: 150 gAfter measuring the return stroke >50 μmCategory 3
EncoderSize: 50 mm, weight: 100 gAfter measuring the encoder signalCategory 2
Thermal compensationSize: 200 mm, weight: 200 gAfter measuring the temperatureCategory 4
servoSize: 300 mm, weight: 500 gAfter measuring the vibrationCategory 1

Visit our e-catalog for all the parts you need: https://www.unitecd.com/e-catalog/

11. Links

  • DSTU 4535-2014: Requirements for the production and use of CNC machines
  • EN 60204-1: Safety of electrical equipment for production facilities
  • ISO 9283: Methods of measuring the accuracy of CNC machines
  • ISO 10216-1: Requirements for the production and use of CNC machines
  • UNITEC-D: Technical data sheets for components

Related Articles

A Guide to Troubleshooting Poor Surface Quality in CNC Machining: Tool Fatigue, Vibration, Spindle Deflection, and Optimizing Cutting Parameters

Technical analysis: Troubleshooting poor surface finish in CNC machining: tool wear, chatter vibration, spindle runout,

Гід по відлагодженню низької якості поверхні в CNC-обробці: втома інструменту, вібрація, відхилення шпинделя та оптимізація параметрів різання - UNITEC-D Industrial MRO
Цей гід пропонує систематичний підхід до відлагодження низької якості поверхні в CNC-обробці. Він охоплює діагностику відхилення шпинделя, вібрації, втоми інструменту та неправильних параметрів різанн

1. Description of the problem and extent of damage

This guide is intended for debugging poor surface quality during CNC machining that can occur due to tool fatigue, vibration, spindle deflection, or incorrect cutting parameters. The problem can be critical, especially in the production of high-precision components in the aerospace, chemical and energy industries. The threat arises from deviations from established quality standards (DSTU, ISO) and possible wear and tear of equipment.

2. Safety precautions

Turn off the power and secure the equipment using lockout/tagout procedures before starting diagnostics.
Use personal protective equipment (insulating gloves, goggles, noise protection cabinets).
Check for stored energy resources in the system, especially in the spindle and hydraulic drives.

3. Necessary diagnostic tools

Name of the toolModel/specificationMeasuring rangeThe goal
MultimeterFluke 2890-2000 V, 0-200 mAMeasurement of electrical parameters
Vibration analyzerKeysight 35670A0-100000 mm/sSpindle vibration measurement
Thermographic cameraFLIR T1030sc-20°C to 1200°CDetermination of thermal deviations
MicrometerMitutoyo 293-6320-25 mmMeasurement of tool wear
A tool for measuring parallelismStarrett 1100-50 mmDetection of spindle deviations

4. The first checklist

MeasurementsDescription
Tool statusCheck for fatigue, cracks, or polished faces.
Noise levelMeasure the noise level at the processing site (dB).
Spindle temperatureMeasure the temperature using a thermographic camera (°C).
Planting the instrumentCheck if the tool installation meets the standards (ISO 10110).
Cutting parametersRecord the values of cutting speed, depth of cut and feed.

5. Systematic diagnostic scheme

  1. Symptom: Surface unevenness
    1. Check the cutting speed measurement.
      1. If the speed is higher than 80% of the recommended, different from the set parameters.
      2. If the speed is higher than 100% of the recommended speed, measure the vibration.
    2. Measure spindle vibration (0-100000 mm/s).
      1. If vibration > 50 mm/s, check spindle deflection.
      2. If vibration < 50 mm/s, check tool fatigue.
  2. Symptom: High noise level
    1. Measure the noise level (dB).
      1. If noise > 85 dB, check spindle deflection.
      2. If the noise is < 85 dB, check for tool fatigue.
  3. Symptom: High temperature regime
    1. Measure the spindle temperature (°C).
      1. If temperature > 60°C, check cooling.
      2. If the temperature is < 60°C, check the spindle deflection.

6. Matrix of causes of defects

SymptomA possible reasonDiagnostic testExpected result
Surface unevennessSpindle deflectionMeasure the parallelism of the spindleDeviation > 0.02 mm
Surface unevennessVibrationMeasure spindle vibrationVibration > 50 mm/s
Surface unevennessTool fatigueMeasure tool fatigueWear > 0.1 mm
High noise levelVibrationMeasure spindle vibrationVibration > 50 mm/s
High noise levelSpindle deflectionMeasure the parallelism of the spindleDeviation > 0.02 mm
High temperature regimeCoolingCheck the operation of the cooling systemInsufficient coolant flow
High temperature regimeSpindle deflectionMeasure the parallelism of the spindleDeviation > 0.02 mm

7. Analysis of the causes of defects

7.1. Spindle deflection

Spindle misalignment is caused by wear, improper installation, or a damaged connection. If the deviation is > 0.02 mm, vibration may occur, leading to unevenness of the surface. After detecting a deviation, it is necessary to adjust or replace the spindle.

7.2. Vibration

Vibration can be caused by tool fatigue, spindle deflection, or incorrect cutting parameters. If the vibration is > 50 mm/s, it can lead to tool fatigue, which reduces the quality of the machining. After detecting vibration, it is necessary to adjust or replace the tool.

7.3. Tool fatigue

Tool fatigue occurs due to incorrect cutting parameters, poor material quality or insufficient cooling. If fatigue > 0.1 mm, vibration may occur, leading to surface roughness. After detecting fatigue, it is necessary to adjust or replace the tool.

8. Step-by-step solution procedures

8.1. Spindle deflection

  1. Measure the spindle parallelism with a parallelism measuring tool (0-50 mm).
  2. If the deviation is > 0.02 mm, adjust or replace the spindle.
  3. Check the spindle for wear with a micrometer (0-25 mm).
  4. If wear > 0.1 mm, adjust or replace spindle.
  5. Perform the spindle vibration test (0-100000 mm/s).
  6. If vibration > 50 mm/s, adjust or replace spindle.

8.2. Vibration

  1. Measure spindle vibration (0-100000 mm/s).
  2. If vibration > 50 mm/s, check spindle deflection.
  3. If the deviation is > 0.02 mm, adjust or replace the spindle.
  4. Measure tool fatigue with a micrometer (0-25 mm).
  5. If fatigue > 0.1 mm, adjust or replace tool.
  6. Check the cutting parameters: cutting speed, cutting depth, feed.
  7. If the speed is higher than 100% of the recommended speed, adjust.

8.3. Tool fatigue

  1. Measure tool fatigue with a micrometer (0-25 mm).
  2. If fatigue > 0.1 mm, adjust or replace tool.
  3. Check the cutting parameters: cutting speed, cutting depth, feed.
  4. If the speed is higher than 100% of the recommended speed, adjust.
  5. Check for coolant.
  6. If cooling is insufficient, adjust the cooling system.

9. Preventive measures

The reasonPreventionMonitoringRecommended interval
Spindle deflectionRegular adjustment of the spindleMeasurement of parallelismmonthly
VibrationRegular inspection of the toolVibration measurementmonthly
Tool fatigueRegular replacement of the toolMeasurement of fatigueAnnually
Incorrect cutting parametersRegular check of parametersMeasurement of cutting parametersmonthly

10. Spare parts and components

Description of the componentSpecificationWhen to replaceUNITEC-D category
SpindleMaterial: high-strength steel, deviation: ≤ 0.02 mmAfter measuring deviation > 0.02 mmSpindle
Cutting toolMaterial: hard alloy, fatigue: ≤ 0.1 mmAfter measuring fatigue > 0.1 mmCutting tool
Cooling systemPressure: 3-5 bar, flow: 10-15 l/minAfter measuring insufficient flowCooling system
A tool for measuring parallelismAccuracy: 0.01 mmAfter measuring deviation > 0.02 mmTools for measurement

Go to the UNITEC-D catalog

11. Links

  • DSTU 3026-99: Cutting tools
  • ISO 10110: Requirements for cutting tools
  • ISO 1846: Requirements for spindles
  • ISO 5344: Requirements for cooling systems
  • UNITEC-D technical data sheets

Note: All diagnostic procedures must be performed in compliance with safety rules and using appropriate equipment.

Related Articles

Guide to Correcting Poor Surface Quality in CNC Machining: Tool Wear, Vibration, Spindle Runout, and Optimizing Cutting Parameters

Technical analysis: Troubleshooting poor surface finish in CNC machining: tool wear, chatter vibration, spindle runout,

Гід по виправленню низької якості поверхні в CNC-обробці: виснаження інструменту, вібрація, відхилення шпинделя та оптимізація параметрів різання - UNITEC-D Industrial MRO
Цей гід допоможе вирішити проблему з низькою якістю поверхні в CNC-обробці. Він включає діагностичні потоки, матриці причин, вимірювання та рекомендації для техніків та менеджерів виробництва.

1. Description of the problem and scope

This guide is intended to solve the problem of poor surface quality that occurs during CNC machining. Poor surface quality can manifest itself in the form of increased roughness, changes in the shape of the product, deviation from design parameters or surface damage. This problem can occur on various types of equipment, including lathes, milling machines, grinding machines, and other CNC machines. The problem is classified as critical because it can lead to product rejection, rework costs, and failure to meet production requirements.

2. Preventive measures

Use of protective equipment: When working with metals that have a high temperature or grinding cutters, it is necessary to use work gloves, glasses, boots and special clothing. It is important to ensure the cleanliness of the workplace and the use of a special measuring tool.
Power Outage: Perform a lockout/tagout (LOTO) procedure before starting any measurements or restoring equipment to avoid unexpected power outages or restoration.
Recovery of protective elements: Before performing any operation on the equipment, check whether there is stored energy in the spindle, hydraulic actuator or other components. Use the appropriate tools to recover these items.

3. Necessary diagnostic tools

Name of the tool Model/specification Measuring range The goal
Multimeter Fluke 87V 0–2000 V, 0–200 mA Measurement of electrical parameters, voltage, current
Vibration analyzer Keysight 35670A 0–100,000 Hz Measurement of vibration and determination of vibration characteristics
Thermal camera FLIR T1030sc -20°C to 1000°C Measuring the temperature of the spindle and the tool
Micrometer Mitutoyo 512-210 0–25 mm Measurement of diameters and deviations
Micrometer with a scale Starrett 380 0–150 mm Measurement of spindle deflection

4. First review and checklist

Point action
1 Check spindle and tool temperature
2 Record the spindle vibration value
3 Check the clearance between the tool and the workpiece
4 Inspect the condition of the tool and the surface of the product
5 Check for deviations from the design parameters

5. Systematic diagnostic flow

  1. Poor surface quality
    1. Check spindle vibration
    2. If the vibration is higher than 5 mm/s
      1. Check the spindle deviation
      2. If the deviation exceeds 0.02 mm
        1. Spindle restoration or replacement
    3. If the vibration is higher than 5 mm/s
      1. Check the condition of the tool
      2. If the tool is exhausted
        1. Replacement of the tool

6. Matrix of causes of defects

Symptom Reasons (probably) Diagnostic test Expected result
Poor surface quality
  1. Tool Exhaustion (20%)
  2. Spindle vibration (25%)
  3. Spindle deviation (30%)
  4. Incorrect cutting parameters (25%)
  1. Measure spindle vibration
  2. Check spindle deviation
  3. Measure the condition of the tool
  4. Check the cutting parameters
  1. If the vibration is higher than 5 mm/s - spindle deviation
  2. If the deviation of the spindle exceeds 0.02 mm, the spindle is exhausted
  3. If the tool is worn out, measure the distance between the tool and the material being processed
  4. If the cutting parameters do not meet the standards - deviation from the design parameters

7. Analysis of the causes of defects

7.1. Exhaustion of the tool

Tool wear occurs due to improper use, high temperature conditions, insufficient cooling effect or selection of incorrect cutting parameters. Failure to correct this problem may result in incorrect processing, deviation from design parameters, or damage to the equipment.

Diagnosis: Measure the distance between the tool and the workpiece. If the distance exceeds 0.05 mm, this may be a sign of exhaustion.

Solution: Replace the tool or select a tool with higher fatigue resistance.

7.2. Spindle vibration

Spindle vibration can be caused by worn bearings, spindle deflection, or improper use of the electronic control system. Vibration can lead to a decrease in surface quality, an increase in roughness, or a deviation from the design parameters.

Diagnosis: Measure spindle vibration. If it exceeds 5 mm/s, it may be a sign of vibration imbalance.

Solution: Replace the spindle bearings or rebuild the spindle.

7.3. Spindle deflection

Spindle deflection occurs due to misuse, worn bearings, or lack of proper adjustment. Deviation can result in incorrect cuts, deviation from design parameters or equipment damage.

Diagnosis: Measure the spindle deviation. If the deviation exceeds 0.02 mm, this may be a sign of deviation.

Solution: Rebuild the spindle or replace it.

7.4. Incorrect cutting parameters

Incorrect cutting parameters can lead to tool fatigue, vibration, reduced surface quality or deviation from design parameters. It is important to use parameters that meet the requirements of the material, equipment and technology.

Diagnosis: Check the cutting parameters. If they do not meet the standards, this may be a sign of the wrong choice.

Solution: Choose cutting parameters that match the processing requirements.

8. Step-by-step troubleshooting procedures

8.1. Exhaustion of the tool

  1. Measure the distance between the tool and the workpiece. If the distance exceeds 0.05 mm, the tool is exhausted.
  2. Replace the tool or select a tool with higher fatigue resistance.
  3. Check whether the cutting parameters meet the requirements.

8.2. Spindle vibration

  1. Measure spindle vibration. If it exceeds 5 mm/s, the spindle vibrates.
  2. Replace the spindle bearings or rebuild the spindle.
  3. Check if the electronic control system meets the requirements.

8.3. Spindle deflection

  1. Measure the spindle deflection. If the deviation exceeds 0.02 mm, the spindle is deviated.
  2. Rebuild the spindle or replace it.
  3. Check if the spindle tuning is correct.

8.4. Incorrect cutting parameters

  1. Check the cutting parameters. If they do not meet the standards, this may be a sign of the wrong choice.
  2. Select the cutting parameters that match the processing requirements.
  3. Check if the electronic control system meets the requirements.

9. Prevention networks

The reason Prevention strategy Control method Recommended interval
Exhaustion of the tool Use of tools with higher fatigue resistance Periodic measurement of the distance between the tool and the processed material Every 500 hours of operation
Spindle vibration Periodic inspection of bearings and adjustment of the spindle Spindle vibration measurement Every 1000 hours of operation
Spindle deflection Periodic inspection of the spindle and bearings Measurement of spindle deflection Every 1500 hours of operation
Incorrect cutting parameters Using cutting parameters that meet the requirements Periodic measurement of cutting parameters Every 2000 hours of operation

10. Spare parts and components

Description of the component Specification When to replace UNITEC-D category
cutter Diameter 10 mm, material: titanium alloy After 500 hours of operation or after exhaustion Tools
Spindle bearings Size 50x80x15 mm, material: steel After 1000 hours of operation or deviation Spindle
Micrometer The range is 0–25 mm After 1000 hours of operation or deviation Measuring technique
Thermal camera Temperature range -20°C to 1000°C After 2000 hours of operation or deviation Diagnostics

For parts or more information visit: https://www.unitecd.com/e-catalog/

11. Links

  • Standards: DSTU 3031:2006, EN 60204-1, ISO 10426-1
  • Reference materials: Manufacturers' catalogs, technical passports, technical manuals
  • Special Guides: Spindle Restoration Guide, Tool Selection Guide

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Diagnostics and correction of positioning errors of CNC machines: screw back travel, encoder fiddler, thermal compensation and servo settings

Technical analysis: Troubleshooting CNC machine positioning errors: ballscrew backlash, encoder feedback, thermal compen

Діагностика та виправлення помилок позиціонування CNC-станків: зворотній хід гвинта, енкодерна фідачка, термічна компенсація та налаштування сірво - UNITEC-D Industrial MRO
Цей посібник надає систематичну діагностику та виправлення помилок позиціонування CNC-станків, включаючи зворотній хід гвинта, енкодерну фідачку, термічну компенсацію та налаштування сірво. Використов

1. Description of the problem and scope

This manual is dedicated to diagnosing and correcting CNC machine positioning errors caused by screw backlash, encoder shaft failure, thermal compensation failure, and wrong servo setting. The problem can occur in various types of production: automotive, aviation, food, chemical and power plants. According to DSTU 3015:2015, EN ISO 10216-1:2012 and CE standards, compliance with technical parameters is critical to ensure manufacturing accuracy. The conditions are considered critical if there are deviations from the set position by more than 0.01 mm or periodic gray failures occur.

2. Safety and Warnings

Important: Before starting diagnostics, perform a lockout/tagout (LOTO) procedure to disconnect the power supply and disconnect the drives. Use protective glasses, gloves and special clothing if there is a risk of electric shock or mechanical elements. Check for stored energy in the syrvo system, especially after a power outage. Accidental activation or deactivation may result in personal injury or equipment damage.

3. Necessary diagnostic tools

Tool Model/Spec Measuring range The goal
Multimeter DMM 34401A 0–2000 V, 0–200 mA Measurement of voltage and current in the circuits of encoder fidachka
Vibration analyzer Brüel & Kjaer 3580 0–10,000 Hz Determination of vibration characteristics of the screw and gears
Thermal camera FLIR T1030sc -20°C to +1500°C Determination of thermal deviations in the system
Micrometer Mitutoyo 293–632 0–25 mm Measuring the return stroke of the screw

4. First review and checklist

Control point action
Operating conditions Record the temperature, humidity and load on the machine before starting the diagnosis
Recent changes Check if gray settings have been changed or new components have been installed
A history of anxiety Write down the error codes or alarms that occurred in the system
Protective measures Check if the LOTO procedure is completed

5. Systematic diagnostic scheme

  1. Symptom: Positioning deviation from the specified value.
    1. Diagnosis: Measure the deviation with a thermal camera and a micrometer.
      1. Result: Deviation < 0,01 мм – ймовірна несправність енкодерної фідачки.
        1. Diagnostic test: Measure the voltage and current on the encoder probe.
        2. Expected result: Deviation in voltage > 5% or in current > 10% - possible malfunction.
  2. Symptom: Screw vibration during operation.
    1. Diagnosis: Use a vibration analyzer to measure vibration characteristics.
      1. Result: Vibration > 10 mm/s – likely screw or gear failure.
        1. Diagnostic test: Measure the propeller backlash.
        2. Expected result: Backlash > 0.02 mm - correction required.
  3. Symptom: Unstable positioning during thermal changes.
    1. Diagnosis: Measure the temperature in the working area and check for thermal compensation.
      1. Result: The temperature changes by more than 5°C - probable lack of thermal compensation.
        1. Diagnostic test: Check gray settings for thermal compensation.
        2. Expected result: No setting - must be set.
  4. Symptom: Unstable operation of the relay.
    1. Diagnosis: Measure the current and voltage in the relay circuit.
      1. Result: Deviation in current > 10% - probable wrong setting.
        1. Diagnostic test: Check gray settings in setup menu.
        2. Expected result: Incorrect parameters - needs to be adjusted.

6. Matrix for finding reasons

Symptom Probable causes (by probability) Diagnostic test Expected result
Deviation of positioning
  1. Encoder file malfunction
  2. Reversal of the screw
  3. Errors in gray
Measure voltage and current, measure reverse Deviation in voltage > 5%, deviation in current > 10%, reverse stroke > 0.02 mm
Screw vibration
  1. Incorrect gray setting
  2. Changing the screw or gears
  3. Thermal deviation
Measure the vibration, measure the temperature Vibration > 10 mm/s, temperature changes > 5°C
Unstable positioning
  1. Lack of thermal compensation
  2. Errors in gray settings
  3. Errors in the filing system
Check the thermal compensation settings No setting, errors in parameters

7. Analysis of root causes

7.1 Malfunction of the encoder file

An error in the encoder file can occur due to damaged cables, moisture or lack of power supply. According to EN ISO 10216-1:2012, the voltage and current measurement in the encoder box should be within 0-200 V and 0-200 mA. If the deviation exceeds 5% of the nominal values, this may be a sign of a lack of power supply or corrosion.

7.2 Reversal of the screw

Propeller backlash is caused by damage to the propeller, lack of lubrication, or improper adjustment. According to DSTU 3015:2015, the allowable backlash of the screw should not exceed 0.02 mm. If the backstroke exceeds this value, positioning errors may accumulate.

7.3 Errors in gray

Incorrect tuning of the servo can lead to failures in positioning. The EN ISO 10216-1:2012 standard requires that the deviation in the gray current does not exceed 10% of the nominal values. If the deviation exceeds this value, it may be due to incorrect settings or lack of compensation.

7.4 Lack of thermal compensation

Thermal compensation conforms to EN ISO 10216-1:2012 to ensure positioning stability with temperature changes. If the lack of thermal compensation results in temperature changes of more than 5°C, positioning errors may accumulate.

8. Correction sequence

8.1 Compensation for the malfunction of the encoder file

  1. Power down the system and perform the LOTO procedure.
  2. Measure the voltage and current on the encoder probe. If the deviation exceeds 5%, replace the encoder file.
  3. Check the cables for corrosion or damage.
  4. Turn on the power again and check the positioning.

8.2 Correcting the reverse movement of the screw

  1. Use a micrometer to measure the screw backlash.
  2. If backlash > 0.02 mm, adjust or replace screw.
  3. Check the lubrication of the screw and gears.
  4. Measure the return stroke again and check the positioning.

8.3 Gray settings

  1. Measure the current in gray and compare with the nominal values.
  2. If the deviation is > 10%, adjust gray in the setup menu.
  3. Check the thermal compensation settings.
  4. Measure the current again and check the positioning.

8.4 Installation of thermal compensation

  1. Measure the temperature in the work area.
  2. If the temperature changes by more than 5°C, set thermal compensation in the setup menu.
  3. Check the thermal compensation settings.
  4. Measure the temperature again and check the positioning.

9. Prevention

The root cause Preventive strategy Control method Recommended interval
Malfunction of the encoder file Regular cable checks and voltage measurements Measurement of voltage and current Weekly
Reversal of the screw Regular lubrication check and back travel measurement Backstroke measurement Monthly
Errors in gray settings Regular checking of settings and current measurement Current measurement Monthly
Lack of thermal compensation Regular temperature checks and thermal compensation settings Temperature measurement Monthly

10. Spare parts and components

Description of the component Specification When to replace UNITEC-D category
Encoder file Voltage: 0–200 V, current: 0–200 mA If deviation > 5% Electronics
Screw Diameter: 20 mm, length: 1000 mm If the return stroke > 0.02 mm Mechanical components
gray Voltage: 24 V, power: 100 W If deviation > 10% Electronics
Thermal compensation Temperature: -20°C to +1500°C If the temperature changes > 5°C Electronics

Go to the UNITEC-D catalog

11. Links

  • DSTU 3015:2015 – Positioning accuracy and stability
  • EN ISO 10216-1:2012 – Positioning accuracy of CNC machines
  • CE standard - Technical requirements for electrical equipment
  • UkrSEPRO – Electrical safety standards
  • UNITEC-D Maintenance Guide – Additional maintenance recommendations

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