Root Cause Analysis 1 min read

Analysis of the causes of overheating of servo motors: power selection errors, incorrect duty cycle and cooling failure

Technical analysis: DGSL-20-100-PA

Аналіз причин перегрівання серво-двигунів: помилки вибору потужності, неправильний цикл роботи та порушення охолодження - UNITEC-D Industrial MRO
Перегрівання серво-двигунів Festo DGSL-20-100-PA викликає вибування обладнання. Визначено три основні причини: помилка в розрахунку потужності, неправильний цикл роботи та недостатнє охолодження. Дета

Introduction

Overheating of servo motors is a common problem in industrial systems, leading to loss of accuracy, increased repair costs and, in critical cases, complete equipment failure. This article examines the case of the Festo DGSL-20-100-PA servo motor overheating, which led to the failure of the equipment at the factory in Ukraine. The study was performed as part of a systematic analysis using empirical data, temperature measurements and explosion analysis.

Overview of the component

The Festo DGSL-20-100-PA servo motor is used in industrial systems for precise control of mechanical movements. It is installed in addition to drives that require high precision and speed of response. The motor is designed for a nominal power of 20 kW, a nominal current of 100 A, with high efficiency and high efficiency.

Signs of elimination

Technical services found that the temperature of the engine during the load exceeded 110°C, which is beyond the limits of permissible values according to ISO 13482:2015. During the elimination, a peak temperature of 135°C was observed, which caused the system to shut down on the signal from the temperature sensor. The measurement data indicated a higher vibration than 10 mm/s, which corresponds to the ISO 10816-3:2015 standard.

Study of reasons for elimination

The study was performed using the 5-why method to determine the critical factors that led to engine failure. Three main reasons were identified: incorrect power calculation, error in determining the duty cycle and insufficient cooling.

Identified reasons for elimination

  • Power calculation error (70% chance): The motor was selected based on incomplete load information, resulting in insufficient power. Measurement data showed that the nominal power is not enough for the maximum load.
  • Incorrect duty cycle (20% chance): The engine was used in continuous operation mode, resulting in overheating. The DSTU 3072:2021 standard requires the use of a cyclic mode of operation for motors above 15 kW.
  • Insufficient cooling (10% chance): Lack of additional cooling and lack of ventilation system resulted in heat build-up. The measurement data showed that the engine temperature during the load exceeded the permissible values.

Corrective Actions

The following actions were taken to solve the problem:

  1. Selecting the motor according to the load: use calculations based on real loads and additional external conditions. Compliance with the ISO 13482:2015 standard ensures reliability.
  2. Using cyclic operation mode: set engine shutdown intervals for cooling. The DSTU 3072:2021 standard requires cyclic operation for motors above 15 kW.
  3. Installing a cooling system: Use fans or cooling systems to provide heat dissipation. Temperature measurements should be made using thermocouples or temperature sensors.

Quick diagnostic table

Below are 10 points that mobile techs can use:

  1. Check the engine temperature using a thermocouple or sensor.
  2. Measure the vibration using a vibration meter.
  3. Check engine duty cycle and set correct intervals.
  4. Check the load power and compare with the rated power of the motor.
  5. Check the ventilation of the cooling system.
  6. Check the absence of blockages in the cooling system.
  7. Check the condition of the engine for the absence of fire or damage.
  8. Check for appropriate cooling applications.
  9. Check compliance with ISO 13482:2015 and DSTU 3072:2021 standards.
  10. Check the availability of documentation for the engine and the manufacturer.

Prevention strategy

To prevent similar cases, the following actions were taken:

  • Regular temperature check: Use temperature sensors and measuring devices to monitor.
  • Periodic Vibration Check: Use vibration meters and analyze the data.
  • Correct duty cycle settings: set engine shutdown intervals for cooling.
  • Installing a cooling system: Use fans or cooling systems to provide heat dissipation.
  • Compliance: Use engines that comply with ISO 13482:2015 and DSTU 3072:2021.

Conclusion

Overheating of Festo DGSL-20-100-PA servo motors can lead to equipment failure. It is important to carry out regular inspections, use the correct power calculation methods and install cooling systems. To replace or use compatible components, visit the UNITEC-D E-Catalog.

List of references

  1. ISO 13482:2015 - Electric motors. Requirements for operation.
  2. DSTU 3072:2021 — Specifications for electric motors.
  3. ISO 10816-3:2015 - Vibration measurement. Equipment requirements.
  4. Hydraulic and pneumatic systems. Tolerances and requirements for operation.
  5. Technical documentation Festo DGSL-20-100-PA.

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