Mistakes and Lessons: A Tale of CNC Machine Maintenance
As an industrial factory, we’ve had our fair share of experiences with CNC machines. With the introduction of our first Fanuc O CNC system in 2002, we were eager to harness its potential to streamline our production processes. However, what we soon realized was that our team’s lack of formal training and limited technical guidance led to a series of unforeseen issues and problems.
In this blog post, we’ll share two specific instances where our team encountered difficulties with the CNC machine and how weovercame them. By doing so, we hope to shed light on the importance of proper training and maintenance for CNC systems like Fanuc O.
The "Sub-Shaping" Alarm: A Mystery Solved
One of the most frustrating issues we faced was the recurring "sub-shaping" alarm. Every now and then, the machine would stop working, only to be restarted after a system restart. As the problem persisted, we grew more and more frustrated, with no clear solution in sight. After consulting with the equipment manufacturer, we were left with a list of uncertainties and no concrete answers.
Determined to find a solution, we began to investigate further. We turned our attention to the peripheral equipment and relevant couplings, only to discover that a faulty motor switch was the root of the problem. By replacing the switch, we were able to eliminate the "sub-shaping" alarm.
But what about the initial lack of information and resources that led to this problem in the first place? Looking retrospectively, we realize that a comprehensive understanding of the machine’s operating principles and troubleshooting procedures would have saved us valuable time and resources. In the future, we plan to prioritize formal training for our operators to ensure that they are equipped to handle any potential issues that may arise.
The Squeak-Squeak-Squeak of the Z-Axis: A Lesson in Servo Motor Maintenance
The second instance of problem-solving we’d like to share is related to the Z-axis of our CNC machine. Shortly after its introduction, we noticed a peculiar "squeak-squeak-squeak" sound during high-speed operation, accompanied by visible vibrations. Initially, we attributed this issue to the equipment manufacturer’s design flaws. They advised us to modify the servomotor settings and adjust the original settings to -10. While this alleviated the noise, the problem was far from resolved.
Fast forward to a few weeks later, and the malfunction reappeared, this time accompanied by an "Alert 424" warning from the CNC system. The equipment manufacturer’s technicians were called in to resolve the issue, only for it to recur shortly after their departure. Confronted with an uncertain situation, our team took it upon themselves to investigate further.
After conducting a thorough analysis, we discovered that the main fuse 2A of the supply transformer had been blown, necessitating the replacement of the silicon rectifier bridge. By installing a more robust fuse and performing a series of tests, we were finally able to resolve the issue.
These two instances have taught us the importance of having a comprehensive understanding of the machine’s operation and able to identify potential problems proactively. In the future, we plan to maintain a more proactive approach to machine maintenance, combining formal training with regular inspections and troubleshooting to ensure the smooth operation of our CNC system.
In conclusion, our experiences with Fanuc O CNC systems have been a valuable learning curve, teaching us the importance of thorough preparation, attention to detail, and effective troubleshooting. By sharing these stories, we hope to pass on the lessons learned to other manufacturers, reiterating the significance of proper training and maintenance for CNC systems like Fanuc O.
As we continue to push the boundaries of industrial innovation, it is crucial that we remain vigilant in our approach to machine maintenance, always seeking to improve our understanding and mitigate potential issues before they arise.
