Month: July 2024

The fast-paced world of industrial automation remains constantly in motion.  In an environment that moves fast, the ability to diagnose and quickly control a fault remains crucial to operating an industrial machine efficiently and safely. Having a servo amplifier safety features saves money, time, and lives in the long run.  

Before we get into the multiple safety features of servo amplifiers. If you are not familiar with servo amplifiers, this article covers the fundamentals of what servo amplifiers are. Definitely give it a read over!

Overcurrent Protection

Overcurrent protection exist as the most fundamental safety feature found on servo amplifiers.   This mechanism prevents excessive current from flowing through the amplifier. Excessive current flows occur due to short circuits or sudden surges in demand. When an amplifier detects overcurrent,it shuts down or reduces power. This avoids overheating and potential damage to the motor and the amplifier itself. This not only preserves the lifespan of the components but also mitigates fire hazards associated with electrical overloads.

Thermal Protection

Another safety feature found in servo amplifiers, thermal protection use integrated sensors to monitor servo amplifier temperatures. These sensors initiate protective measures if temperatures rise above safety thresholds.  This usually involvesreducing the power output, activating cooling fans, or even shutting down the amplifier to prevent thermal runaway and damage. Effective thermal management ensures continuous, reliable operation and extends the equipment’s service life.

Over/Under Voltage Protection

Overvoltage conditions can arise from fluctuations in the power supply or regenerative energy from the motor, potentially damaging sensitive electronic components. Undervoltage situations can impair the amplifier’s performance, leading to erratic motor behavior. By monitoring and maintaining voltage within safe limits, these protective mechanisms ensure stable and predictable operation, safeguarding both the amplifier and the connected motor.

Fault Detection and Diagonistic

Advanced servo amplifiers often incorporate fault detection and diagnostic capabilities.  These systems continuously monitor operational parameters and can identify anomalies such as motor stalls, feedback errors, or communication failures. When a fault is detected, the amplifier can trigger alarms, log diagnostic information, and take corrective actions such as switching to a safe state or performing an emergency stop. This proactive approach to fault management not only prevents potential damage but also aids in troubleshooting and maintenance, reducing downtime and operational costs.

Conclusion

 The safety features integrated into modern servo amplifiers are essential for protecting equipment, ensuring safe operation, and enhancing overall system reliability. Overcurrent and thermal protection, voltage regulation, and advanced fault detection are just a few examples of how these features work together to mitigate risks and extend the life of both the amplifiers and the motors they control. As technology advances, we can expect even more sophisticated safety mechanisms to emerge, further improving the safety and efficiency of servo-driven systems.

Have a Broken Servo Amplifier?

A brief guide for common Fanuc servo amplifier alarm codes can be found here. For any inquiries regarding repair or replacement, our team is available by phone: (800) 691-8511 or by email: sales@mroelectric.com.

Updated on July 31, 2024 by Ken Cheng

When thinking about automation, we imaigne massive warehouses housing automation lines that have conveyer belts snaking every which way.  Large robotic arms constantly move back and forth as they commit to the same repeated task over and over again.  You probably imagine sparks flying in the air as robotic arms weld parts to march larger machine bodies. The sight of a manufacturing facility may overstimulate the senses. The flashes of light, the sound humming and grinding, and the smell of various mechanical fluids in the air.  With so much stimulation, it’s understandable as to why people overlook the comparatively small but very crucial amplifier.  After all these small devices sit tucked away hidden from sight. Nonnetheless they perform the very important function of orchestrating tasks to other units with extreme precision. 

The History of Servo Amplifiers

The history of servo amplifiers dates back to the 1920s where their original exploration largely targeted aviation and military applications.  During the bulk years of WWII during the 1940s, early servo mechanisms saw their use controlling gun turretts and radar.  Notice how I said “”servo mechanisms,” that’s because these weren’t quite the servo amplifiers that we are familiar with today. Instead they required hydraulic and manual action.  The end of the 40s and into the 1950s saw the development of the first electronic servo amplifier. The servo amplifier stood as a vast improvement compared to its predecessor, in regards to precision and reliability. 

The 1960s and 70s brought the invention of the semiconductor and with that the next evolutionary step for servo amplifiers.  In 1969 the company, Modcon, built the first Programmable Logic Controller (PLC). Not only did the PLC revolutionize the automation industry but it also paved the way for more sophisticated control systems. By the 1980s, the integrating of digital signal processing (DSP) furthered the capabilities of servo amplifiers. By the 1990s, servo amplifier connectivity and communication made it an irreplaceable asset to industries across the globe.

How Do Servo Amplifiers Work

At the core of its functionality, the servo amplifier is a feedback device.This system relies on sensors, typically encoders or resolvers, to provide real-time data on the motor’s performance. The feedback loop continuously compares the actual position, speed, and torque of the motor with the commanded values from the control system.The servo amplfifier corrects any discrepencies by adjusting the power output accordingly. This closed-loop system ensures high precision and responsiveness, enabling complex and delicate tasks to be performed with ease.

Servo amplifiers come in various types, each suited to specific applications. Analog servo amplifiers, for example, control motor operations using continuous signals. Digital servo amplifiers, on the other hand, offer greater flexibility and precision by utilizing digital signals and advanced algorithms. These digital models often feature programmable settings, allowing for customization to meet the specific requirements of different tasks. Additionally, hybrid servo amplifiers combine elements of both analog and digital systems, providing a balance of performance and versatility.

The applications of servo amplifiers are vast and varied. In industrial automation, servo amplifiers control robotic arms, conveyor belts, and CNC machines, where precision and repeatability are essential. In the aerospace industry, servo amplifiers are critical for controlling the movements of aircraft components, such as flaps and landing gear. Servo amplifiers also find use in the medical field, where they enable the precise operation of surgical robots and diagnostic equipment. The ability to provide exact control over motor functions makes servo amplifiers indispensable in any field requiring high-precision motion control.

Conclusion

In summary, servo amplifiers are crucial devices in the realm of motion control, offering unparalleled precision and reliability. By continuously adjusting power based on feedback from sensors, they ensure motors operate efficiently and accurately. The variety of servo amplifier types allows for their use in a wide range of applications. This ranges from industrial automation to aerospace and medical technology. As technology advances, the role of servo amplifiers is expected to grow. Further enhancing their importance in achieving precise and efficient motor control.

Have a Broken Servo Amplifier?

A brief guide for common Fanuc servo amplifier alarm codes can be found here. For any inquiries regarding repair or replacement, our team is available by phone: (800) 691-8511 or by email: sales@mroelectric.com.

Updated on July 16, 2024 by Ken Cheng

Servo amplifiers play a diverse number of roles across multiple industries.  Surprisingly some of the industries that utilize servo amplifiers are ones that a lot of people don’t really think about. However, without servo amplifiers these industries stand completely inept of any production. We’ve compiled a list of industries that heavily utilize servo amplifiers and the use they have across industries.  Some of these industries may seem obvious while others may actually surprise you. 

Manufacturing and Automation

Probably the most obvious industry utilizing servo amplifiers are the manufacturing and automation industries. Industries in this sector often utilize advanced machinery to execute sophisticated task that require precision.In the industrial sector, servo amplifiers allow CNC machines to mill out metal to consistently specific sizes, while automated arms handle hazardous material.

Automotive

Multiple aspects of the car industry utilize servo amplifiers.  Aside from the manufacturing process, servo amplifiers see use in car washing machines, on equipment that perform car maintenance, and even car vending machines!

Medical Devices

Servo amplifiers have their place in the medical field as well.  They allow precise imaging control in CT, MRI, and XRay machines.  Additionally, the precision of servo amplifiers has found use in robotic surgery.

Packaging

Probably not as prominently thought of when discussing the applications of servo amplifiers, but an array of machinery see their applications across the industry.  Package filling machines utilize servo amplifiers for precisely distributing packing foam.  Servo amplifiers see their use in label printing and application machines. For bulkier packaging equipment, the use of servo amplifiers in pallet wrapping and lifting plays a vital role in keeping employees safe while efficiently working.

Renewable Energy

The environmental impact of automation has always come under scrutiny from opponents of industrialization as well as those concerned with climate and environmental issues. The question of sustainable energy exists as the primary topic of debate within the broader environmental discussion.  Servo amplifiers have found a niche place in the renewable energies sector.  Wind turbines use then for controlling pitch and yaw allowing for optimal energy capturing.  Additionally,servo amplifiers find use in solar panels tracking the position of the sun with precise accuracy.  

Food and Beverage

Servo amplifiers play a big role in the production of some of our favorite snacks and drinks.  Sensors allow for precise measurements of distribution to each package.  Not only that but they also dictate temperature and time ensuring that we get the most enjoyment ouf of the foods we enjoy.  Additionally, these servo amplifiers manage the sealing and labeling of food packages.

Conclusion

Multiple industries use servo amplifiers for task that crucially need precision, efficiency, and automation. Their ability to provide accurate control of motors and actuators makes them indispensable in modern industrial applications. As technology continues to advance, the use of servo amplifiers is likely to expand into new and emerging fields, further enhancing productivity and precision.

Updated on July 16, 2024 by Ken Cheng