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例1．進線快速熔斷器熔斷的故障維修故障：一臺配套SIEMENS 8MC的臥式加工中心，在電網突然斷電后開機，系統無法起動.
分(fen)(fen)析與處理過程：經檢(jian)查(cha)，該機床(chuang)X軸伺服(fu)驅動(dong)器(qi)的(de)(de)進(jin)線快速熔斷(duan)(duan)器(qi)已經熔斷(duan)(duan)。該機床(chuang)的(de)(de)進(jin)給系統采用的(de)(de)是(shi)SIEMENS 6RA系列直(zhi)流伺服(fu)驅動(dong)，對照驅動(dong)器(qi)檢(jian)查(cha)伺服(fu)電動(dong)機和驅動(dong)裝置，未發(fa)現(xian)任何(he)元器(qi)件損壞和短路(lu)現(xian)象。檢(jian)查(cha)機床(chuang)機械部分(fen)(fen)工作亦(yi)正常(chang)(chang)，直(zhi)接更換熔斷(duan)(duan)器(qi)后，起動(dong)機床(chuang)，恢復正常(chang)(chang)工作。分(fen)(fen)析原因(yin)是(shi)由于(yu)電網突然斷(duan)(duan)電引起的(de)(de)偶發(fa)性故(gu)障。

例2．SIEMENS 8MC測量系統故障的維修 故障現象：一臺配套SIEMENS 8MC的臥式加工中心，當X軸運動到某一位置時，液壓電動機自動斷開，且出現報警提示：Y軸測量系統故障。斷電再通電，機床可以恢復正常工作，但X軸運動到某一位置附近，均可能出現同一故障。
分析與(yu)處理過(guo)程(cheng)：該機(ji)床為進口臥式加工(gong)中心，配(pei)套SIEMENS 8MC數(shu)控系(xi)(xi)(xi)統(tong)(tong)(tong)，SIEMENS 6RA系(xi)(xi)(xi)列直流伺服(fu)驅動(dong)。由于X軸(zhou)(zhou)移(yi)動(dong)時出現(xian)(xian)(xian)(xian)Y軸(zhou)(zhou)報(bao)(bao)警(jing)(jing)，為了驗證系(xi)(xi)(xi)統(tong)(tong)(tong)的(de)正確(que)性，撥下(xia)了X軸(zhou)(zhou)測(ce)量反(fan)饋電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)試驗，系(xi)(xi)(xi)統(tong)(tong)(tong)出現(xian)(xian)(xian)(xian)X軸(zhou)(zhou)測(ce)量系(xi)(xi)(xi)統(tong)(tong)(tong)故(gu)(gu)障(zhang)報(bao)(bao)警(jing)(jing)，因此，可以排除(chu)系(xi)(xi)(xi)統(tong)(tong)(tong)誤報(bao)(bao)警(jing)(jing)的(de)原因。 檢(jian)查X軸(zhou)(zhou)在(zai)出現(xian)(xian)(xian)(xian)報(bao)(bao)警(jing)(jing)的(de)位置及附近，發現(xian)(xian)(xian)(xian)它(ta)對(dui)Y軸(zhou)(zhou)測(ce)量系(xi)(xi)(xi)統(tong)(tong)(tong)(光柵)并無(wu)干涉(she)與(yu)影響，且僅移(yi)動(dong)Y軸(zhou)(zhou)亦無(wu)報(bao)(bao) 警(jing)(jing)，Y軸(zhou)(zhou)工(gong)作(zuo)正常。再檢(jian)查Y軸(zhou)(zhou)電(dian)(dian)(dian)(dian)(dian)動(dong)機(ji)電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)插頭(tou)、光柵讀(du)數(shu)頭(tou)和光柵尺狀況，均未(wei)發現(xian)(xian)(xian)(xian)異常現(xian)(xian)(xian)(xian)象(xiang)。考慮到(dao)該設備(bei)屬(shu)大型加工(gong)中心，電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)較多，電(dian)(dian)(dian)(dian)(dian)柜與(yu)機(ji)床之間(jian)的(de)電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)長(chang)度較長(chang)，且所有電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)均固(gu)定在(zai)電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)架(jia)上，隨機(ji)床來回移(yi)動(dong)。根據上述分析，初(chu)步判斷由于電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)的(de)彎曲，導致局部斷線(xian)(xian)的(de)可能性較大。維修時有意將X軸(zhou)(zhou)運(yun)動(dong)到(dao)出現(xian)(xian)(xian)(xian)故(gu)(gu)障(zhang)點(dian)位置，人為移(yi)動(dong)電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)線(xian)(xian)，仔細測(ce)量Y軸(zhou)(zhou)上每一(yi)根反(fan)饋信號線(xian)(xian)的(de)連接情況，最終發現(xian)(xian)(xian)(xian)其中一(yi)根信號線(xian)(xian)在(zai)電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)不斷移(yi)動(dong)的(de)過(guo)程(cheng)中，偶爾出現(xian)(xian)(xian)(xian)開路現(xian)(xian)(xian)(xian)象(xiang)；利用電(dian)(dian)(dian)(dian)(dian)纜(lan)(lan)(lan)(lan)內的(de)備(bei)用線(xian)(xian)替(ti)代斷線(xian)(xian)后，機(ji)床恢(hui)復正常。

例3~例4．驅動器故障引起跟隨誤差超差報警維修 故障現象：某配套SIEMENS PRIMOS系統、6RA26**系列直流伺服驅動系統的數控滾齒機，開機后移動機床的Z軸，系統發生“ERR22跟隨誤差超差”報警。
 分(fen)析與處理過程：數(shu)控(kong)機(ji)床(chuang)發(fa)生跟(gen)(gen)隨(sui)(sui)誤差超過報警(jing)，其實(shi)質是實(shi)際機(ji)床(chuang)不(bu)能到(dao)達(da)指(zhi)令(ling)的(de)(de)(de)位置。引(yin)起(qi)這(zhe)一故障(zhang)的(de)(de)(de)原因通常是伺(si)服系(xi)(xi)(xi)(xi)統(tong)(tong)故障(zhang)或機(ji)床(chuang)機(ji)械傳動(dong)(dong)系(xi)(xi)(xi)(xi)統(tong)(tong)的(de)(de)(de)故障(zhang)。由(you)(you)于機(ji)床(chuang)伺(si)服進給(gei)系(xi)(xi)(xi)(xi)統(tong)(tong)為全閉環結構(gou)，無法通過脫(tuo)開電(dian)(dian)動(dong)(dong)機(ji)與機(ji)械部(bu)分(fen)的(de)(de)(de)連接進行試驗。為了確(que)(que)認故障(zhang)部(bu)位，維(wei)修(xiu)時首先在(zai)機(ji)床(chuang)斷電(dian)(dian)、松(song)開夾緊(jin)機(ji)構(gou)的(de)(de)(de)情(qing)況(kuang)下(xia)，手(shou)(shou)動(dong)(dong)轉動(dong)(dong)Z軸(zhou)(zhou)絲杠(gang)，未發(fa)現機(ji)械傳動(dong)(dong)系(xi)(xi)(xi)(xi)統(tong)(tong)的(de)(de)(de)異常，初步判定故障(zhang)是由(you)(you)伺(si)服系(xi)(xi)(xi)(xi)統(tong)(tong)或數(shu)控(kong)裝置不(bu)良引(yin)起(qi)的(de)(de)(de)。為了進一步確(que)(que)定故障(zhang)部(bu)位，維(wei)修(xiu)時在(zai)系(xi)(xi)(xi)(xi)統(tong)(tong)接通的(de)(de)(de)情(qing)況(kuang)下(xia)，利用手(shou)(shou)輪(lun)少量(liang)移動(dong)(dong)Z軸(zhou)(zhou)(移動(dong)(dong)距(ju)離(li)應(ying)控(kong)制在(zai)系(xi)(xi)(xi)(xi)統(tong)(tong)設(she)定的(de)(de)(de)最(zui)大允許跟(gen)(gen)隨(sui)(sui)誤差以內，防止出現跟(gen)(gen)隨(sui)(sui)誤差報警(jing))，測量(liang)Z軸(zhou)(zhou)直(zhi)(zhi)流驅(qu)動(dong)(dong)器(qi)(qi)(qi)的(de)(de)(de)速(su)度給(gei)定電(dian)(dian)壓，經(jing)檢(jian)查(cha)發(fa)現速(su)度給(gei)定有(you)電(dian)(dian)壓輸(shu)入(ru)，其值大小(xiao)與手(shou)(shou)輪(lun)移動(dong)(dong)的(de)(de)(de)距(ju)離(li)、方向有(you)關。由(you)(you)此可以確(que)(que)認數(shu)控(kong)裝置工作正常，故障(zhang)是由(you)(you)于伺(si)服驅(qu)動(dong)(dong)器(qi)(qi)(qi)的(de)(de)(de)不(bu)良引(yin)起(qi)的(de)(de)(de)。 檢(jian)查(cha)驅(qu)動(dong)(dong)器(qi)(qi)(qi)發(fa)現，驅(qu)動(dong)(dong)器(qi)(qi)(qi)本身狀態指(zhi)示燈(deng)無報警(jing)，基本上可以排除驅(qu)動(dong)(dong)器(qi)(qi)(qi)主(zhu)回路的(de)(de)(de)故障(zhang)。考(kao)慮(lv)到(dao)該(gai)機(ji)床(chuang)X、Z軸(zhou)(zhou)驅(qu)動(dong)(dong)器(qi)(qi)(qi)型號相同，通過逐一交換驅(qu)動(dong)(dong)器(qi)(qi)(qi)的(de)(de)(de)控(kong)制板確(que)(que)認故障(zhang)部(bu)位在(zai)6RA26**直(zhi)(zhi)流驅(qu)動(dong)(dong)器(qi)(qi)(qi)的(de)(de)(de)A2板。根據(ju)SIEMENS 6RA26**系(xi)(xi)(xi)(xi)列直(zhi)(zhi)流伺(si)服驅(qu)動(dong)(dong)器(qi)(qi)(qi)的(de)(de)(de)原理圖(tu)，逐一檢(jian)查(cha)、測量(liang)各級信(xin)號，最(zui)后(hou)確(que)(que)認故障(zhang)原因是由(you)(you)于A2板上的(de)(de)(de)集成(cheng)電(dian)(dian)壓比(bi)較器(qi)(qi)(qi)N7(型號：LM348)不(bu)良引(yin)起(qi)的(de)(de)(de)：更換后(hou)，機(ji)床(chuang)恢復正常。

例4．故(gu)障(zhang)現象：一臺(tai)配套SIEMENS 850系統、6RA26**系列直流(liu)伺服驅動(dong)系統的進口臥式(shi)加工(gong)中心，在開機(ji)后，手動(dong)移動(dong)X軸(zhou)，機(ji)床(chuang)X軸(zhou)工(gong)作臺(tai)不運動(dong)，CNC出(chu)現X跟隨誤差(cha)(cha)超差(cha)(cha)報警。

分(fen)析與(yu)處理過程：由于(yu)機(ji)床其他(ta)坐(zuo)標軸(zhou)工作正(zheng)(zheng)常，X軸(zhou)驅(qu)(qu)動(dong)器(qi)無報警(jing)，全(quan)部(bu)狀態指(zhi)示(shi)燈指(zhi)示(shi)無故(gu)障(zhang)，為了確(que)定(ding)故(gu)障(zhang)部(bu)位，考慮到6RA26**系列(lie)直流(liu)伺服(fu)驅(qu)(qu)動(dong)器(qi)的(de)(de)(de)速(su)(su)度(du)/電(dian)流(liu)調(diao)(diao)(diao)節(jie)板A2相同，維(wei)修時將X軸(zhou)驅(qu)(qu)動(dong)器(qi)的(de)(de)(de)A2板與(yu)Y軸(zhou)驅(qu)(qu)動(dong)器(qi)的(de)(de)(de)A2板進(jin)行(xing)了對(dui)調(diao)(diao)(diao)試(shi)(shi)驗。經試(shi)(shi)驗發現(xian)(xian)(xian)，X軸(zhou)可以(yi)(yi)正(zheng)(zheng)常工作，但Y軸(zhou)出(chu)(chu)現(xian)(xian)(xian)跟(gen)隨超差報警(jing)。根據這一現(xian)(xian)(xian)象(xiang)，可以(yi)(yi)得出(chu)(chu)X軸(zhou)驅(qu)(qu)動(dong)器(qi)的(de)(de)(de)速(su)(su)度(du)/電(dian)流(liu)調(diao)(diao)(diao)節(jie)器(qi)板不良的(de)(de)(de)結論(lun)。根據SIEMENS 6RA26**系列(lie)直流(liu)伺服(fu)驅(qu)(qu)動(dong)器(qi)原理圖(tu)，測(ce)量(liang)(liang)檢(jian)(jian)查(cha)發現(xian)(xian)(xian)，當少量(liang)(liang)移(yi)動(dong)X軸(zhou)時驅(qu)(qu)動(dong)器(qi)的(de)(de)(de)速(su)(su)度(du)給(gei)定(ding)輸入(ru)端57與(yu)69端子間有(you)模(mo)擬量(liang)(liang)輸入(ru)，測(ce)量(liang)(liang)驅(qu)(qu)動(dong)器(qi)檢(jian)(jian)測(ce)端B1，速(su)(su)度(du)模(mo)擬量(liang)(liang)電(dian)壓正(zheng)(zheng)確(que)，但速(su)(su)度(du)比(bi)例調(diao)(diao)(diao)節(jie)器(qi)N4(LM301)的(de)(de)(de)6腳輸出(chu)(chu)始(shi)終為0V。 對(dui)照原理圖(tu)逐(zhu)一檢(jian)(jian)查(cha)速(su)(su)度(du)調(diao)(diao)(diao)節(jie)器(qi)LM301的(de)(de)(de)反(fan)饋(kui)電(dian)阻(zu)R25、R27、R21，偏移(yi)調(diao)(diao)(diao)節(jie)電(dian)阻(zu)R10、R12、R13、R15、R14、R12，以(yi)(yi)及(ji)LM301的(de)(de)(de)輸入(ru)保護(hu)二(er)極管(guan)V1、V2，給(gei)定(ding)濾波(bo)環節(jie)R1、C1、R20、V14，速(su)(su)度(du)反(fan)饋(kui)濾波(bo)環節(jie)的(de)(de)(de)R27、R28、R8、R3、C5、R4等外圍元(yuan)器(qi)件(jian)，確(que)認(ren)全(quan)部(bu)元(yuan)器(qi)件(jian)均無故(gu)障(zhang)。 因此，確(que)認(ren)故(gu)障(zhang)原因是由于(yu)LM301集成運放不良引起的(de)(de)(de)；更換LM301后，機(ji)床恢復(fu)正(zheng)(zheng)常工作，故(gu)障(zhang)排(pai)除。

例5．CNC故障引起跟隨誤差超差報警維修 故障現象：某配套SIEMENS PRIMOS系統、6RA26**系列直流伺服驅動系統的數控滾齒機，開機后移動機床的Z軸，系統發生“ERR22跟隨誤差超差”報警。
分析(xi)與(yu)處(chu)理過程(cheng)：故(gu)障(zhang)分析(xi)過程(cheng)同前例，但(dan)在本(ben)例中，當利(li)用手(shou)輪(lun)少量移動(dong)Z軸(zhou)，測量Z軸(zhou)直流驅動(dong)器(qi)的(de)速(su)度給定電(dian)壓(ya)始終為0，因此可以初步判定故(gu)障(zhang)在數控(kong)裝(zhuang)置或數控(kong)與(yu)驅動(dong)器(qi)的(de)連(lian)接電(dian)纜上。檢(jian)(jian)查數控(kong)裝(zhuang)置與(yu)驅動(dong)器(qi)的(de)電(dian)纜連(lian)接正常，確(que)認(ren)故(gu)障(zhang)引起的(de)原因在數控(kong)裝(zhuang)置。打開(kai)數控(kong)裝(zhuang)置檢(jian)(jian)查，發現Z軸(zhou)的(de)速(su)度給定輸出(chu)(chu)D/A轉換器(qi)的(de)數字輸入正確(que)，但(dan)無模擬(ni)量輸出(chu)(chu)，從(cong)而確(que)認(ren)故(gu)障(zhang)是由于D/A轉換器(qi)不良(liang)引起的(de)。更換Z軸(zhou)的(de)速(su)度給定輸出(chu)(chu)的(de)12位D/A轉換器(qi)DAC0800后，機(ji)床恢復(fu)

例6．故障現(xian)象：某配套SIEMENS PRIMOS系統(tong)、6RA26**系列直(zhi)流伺服驅動(dong)系統(tong)的數控滾(gun)齒(chi)機(ji)，開機(ji)后發生“ERR21，Y軸測(ce)量系統(tong)錯誤(wu)”報警。

分析(xi)與處理過(guo)程(cheng)：數控(kong)(kong)系(xi)(xi)統(tong)(tong)(tong)(tong)發生(sheng)測(ce)量(liang)(liang)(liang)系(xi)(xi)統(tong)(tong)(tong)(tong)報警的(de)(de)(de)(de)(de)原因一(yi)般(ban)有如下幾(ji)種：1)數控(kong)(kong)裝(zhuang)(zhuang)置(zhi)(zhi)(zhi)(zhi)(zhi)的(de)(de)(de)(de)(de)位置(zhi)(zhi)(zhi)(zhi)(zhi)反饋(kui)信號(hao)(hao)接(jie)(jie)口電(dian)(dian)路不(bu)良(liang)。2)數控(kong)(kong)裝(zhuang)(zhuang)置(zhi)(zhi)(zhi)(zhi)(zhi)與位置(zhi)(zhi)(zhi)(zhi)(zhi)檢(jian)測(ce)元器(qi)(qi)件的(de)(de)(de)(de)(de)連接(jie)(jie)電(dian)(dian)纜不(bu)良(liang)。 3)位置(zhi)(zhi)(zhi)(zhi)(zhi)測(ce)量(liang)(liang)(liang)系(xi)(xi)統(tong)(tong)(tong)(tong)本身不(bu)良(liang)。 由(you)于本機(ji)床(chuang)伺服驅動(dong)(dong)系(xi)(xi)統(tong)(tong)(tong)(tong)采(cai)用(yong)的(de)(de)(de)(de)(de)是全閉環結構，檢(jian)測(ce)系(xi)(xi)統(tong)(tong)(tong)(tong)使(shi)(shi)用(yong)的(de)(de)(de)(de)(de)是HEIDENHAIN公司的(de)(de)(de)(de)(de)光(guang)(guang)柵(zha)(zha)。為(wei)了(le)判定故障部位，維修時(shi)首先將(jiang)數控(kong)(kong)裝(zhuang)(zhuang)置(zhi)(zhi)(zhi)(zhi)(zhi)輸(shu)出(chu)(chu)的(de)(de)(de)(de)(de)X、Y軸速度(du)給定，將(jiang)驅動(dong)(dong)使(shi)(shi)能以及(ji)X、Y軸的(de)(de)(de)(de)(de)位置(zhi)(zhi)(zhi)(zhi)(zhi)反饋(kui)進行了(le)對調(diao)，使(shi)(shi)數控(kong)(kong)的(de)(de)(de)(de)(de)X軸輸(shu)出(chu)(chu)控(kong)(kong)制(zhi)Y軸，Y軸輸(shu)出(chu)(chu)控(kong)(kong)制(zhi)X軸。經對調(diao)后，操作數控(kong)(kong)系(xi)(xi)統(tong)(tong)(tong)(tong)，手動(dong)(dong)移動(dong)(dong)Y軸，機(ji)床(chuang)X軸產生(sheng)運動(dong)(dong)，且(qie)工作正常(chang)，證明數控(kong)(kong)裝(zhuang)(zhuang)置(zhi)(zhi)(zhi)(zhi)(zhi)的(de)(de)(de)(de)(de)位置(zhi)(zhi)(zhi)(zhi)(zhi)反饋(kui)信號(hao)(hao)接(jie)(jie)口電(dian)(dian)路無(wu)(wu)故障。但操作數控(kong)(kong)系(xi)(xi)統(tong)(tong)(tong)(tong)，手動(dong)(dong)移動(dong)(dong)X軸，機(ji)床(chuang)Y軸不(bu)運動(dong)(dong)，同時(shi)數控(kong)(kong)顯示“ERR21，X軸測(ce)量(liang)(liang)(liang)系(xi)(xi)統(tong)(tong)(tong)(tong)錯誤”報警。由(you)此確(que)認(ren)，報警是由(you)位置(zhi)(zhi)(zhi)(zhi)(zhi)測(ce)量(liang)(liang)(liang)系(xi)(xi)統(tong)(tong)(tong)(tong)不(bu)良(liang)引(yin)起的(de)(de)(de)(de)(de)，與數控(kong)(kong)裝(zhuang)(zhuang)置(zhi)(zhi)(zhi)(zhi)(zhi)的(de)(de)(de)(de)(de)接(jie)(jie)口電(dian)(dian)路無(wu)(wu)關。檢(jian)查測(ce)量(liang)(liang)(liang)系(xi)(xi)統(tong)(tong)(tong)(tong)電(dian)(dian)纜連接(jie)(jie)正確(que)、可(ke)靠，排除(chu)了(le)電(dian)(dian)纜連接(jie)(jie)的(de)(de)(de)(de)(de)問題。利用(yong)示波(bo)器(qi)(qi)檢(jian)查位置(zhi)(zhi)(zhi)(zhi)(zhi)測(ce)量(liang)(liang)(liang)系(xi)(xi)統(tong)(tong)(tong)(tong)的(de)(de)(de)(de)(de)前(qian)置(zhi)(zhi)(zhi)(zhi)(zhi)放(fang)大器(qi)(qi)EXE601/5-F的(de)(de)(de)(de)(de)Ual和Ua2、*Ua1和Ua2輸(shu)出(chu)(chu)波(bo)形(xing)，發現Ua1相無(wu)(wu)輸(shu)出(chu)(chu)。進一(yi)步檢(jian)查光(guang)(guang)柵(zha)(zha)輸(shu)出(chu)(chu)(前(qian)置(zhi)(zhi)(zhi)(zhi)(zhi)放(fang)大器(qi)(qi)EXE601/5-F的(de)(de)(de)(de)(de)輸(shu)入)信號(hao)(hao)波(bo)形(xing)，發現Ie1無(wu)(wu)信號(hao)(hao)輸(shu)入。檢(jian)查本機(ji)床(chuang)光(guang)(guang)柵(zha)(zha)安(an)裝(zhuang)(zhuang)正確(que)，確(que)認(ren)故障是由(you)于光(guang)(guang)柵(zha)(zha)不(bu)良(liang)引(yin)起的(de)(de)(de)(de)(de)：更換光(guang)(guang)柵(zha)(zha)LS903后，機(ji)床(chuang)恢復(fu)正常(chang)工作。

例7．故障現象：某配套(tao)SIEMENS PRIMOS系(xi)統、6RA26**系(xi)列直流(liu)伺服驅動系(xi)統的數控滾(gun)齒機，開機后(hou)發生“ERR21，X軸測量系(xi)統錯誤(wu)”報警。

分(fen)析(xi)與處理(li)(li)過(guo)程(cheng)：故障(zhang)分(fen)析(xi)過(guo)程(cheng)同(tong)前例，但在本例中(zhong)(zhong)，利(li)用示波(bo)器(qi)(qi)檢(jian)查位置測(ce)(ce)量系統的(de)前置放大器(qi)(qi)EXE601/5-F的(de)Ual和(he)Ua2、*Ual和(he)*Ua2輸出波(bo)形，發(fa)(fa)現同(tong)樣(yang)Ual無輸出。進一(yi)(yi)步(bu)檢(jian)查光柵輸出(前置放大器(qi)(qi)EXE601/5-F的(de)輸入)信號(hao)波(bo)形，發(fa)(fa)現Ie1，信號(hao)輸入正確，確認故障(zhang)是由于前置放大器(qi)(qi)EXE601/5-F不良引(yin)起的(de)。根據EXE601/5-F的(de)原(yuan)理(li)(li)(詳見后述)逐級測(ce)(ce)量前置放大器(qi)(qi)EXE601/5-F的(de)信號(hao)，發(fa)(fa)現其(qi)中(zhong)(zhong)的(de)一(yi)(yi)只(zhi)LM339集成電壓比較器(qi)(qi)不良；更換后，機床恢(hui)復(fu)正常工作。

例8．驅動器未準備好的故障維修 故障現象：一臺配套SIEMENS 850系統、6RA26**系列直流伺服動系統臥式加中心，在加工過程中突然停機，開機后面板上的“驅動故障”指示燈亮，機床無法正常起動。
分(fen)(fen)析與處理(li)過程(cheng)：根據面(mian)板(ban)上的(de)(de)(de)“驅(qu)(qu)(qu)動(dong)(dong)(dong)故障”指示燈亮(liang)的(de)(de)(de)現象(xiang)，結(jie)合機床(chuang)電(dian)氣原(yuan)理(li)圖與系統PLC程(cheng)序分(fen)(fen)析，確認(ren)機床(chuang)的(de)(de)(de)故障原(yuan)因為Y軸驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)未準備(bei)好。檢查電(dian)柜(ju)內驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)，測量6RA26**驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)主(zhu)回(hui)(hui)路電(dian)源輸入，只(zhi)有V相(xiang)有電(dian)壓，進(jin)一(yi)步按機床(chuang)電(dian)氣原(yuan)理(li)圖對照檢查，發現6RA26**驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)進(jin)線(xian)快速熔(rong)斷器(qi)(qi)的(de)(de)(de)U、W相(xiang)熔(rong)斷。用(yong)萬用(yong)表(biao)測量驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)主(zhu)回(hui)(hui)路進(jin)線(xian)端(duan)1U、1W，確認(ren)驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)主(zhu)回(hui)(hui)路內部(bu)存(cun)在短路。由于6RA26**交流驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)主(zhu)回(hui)(hui)路進(jin)線(xian)直(zhi)接與晶(jing)閘管相(xiang)連，因此(ci)可以確認(ren)故障原(yuan)因是由于晶(jing)閘管損(sun)壞引起的(de)(de)(de)。逐一(yi)測量主(zhu)回(hui)(hui)路晶(jing)閘管V1-V6，確認(ren)V1、V2不良(己短路)；更換(huan)同規格備(bei)件(jian)后(hou)(hou)，機床(chuang)恢(hui)復正(zheng)(zheng)常(chang)。由于驅(qu)(qu)(qu)動(dong)(dong)(dong)器(qi)(qi)其他部(bu)分(fen)(fen)均無故障，換(huan)上晶(jing)閘管模塊后(hou)(hou)，機床(chuang)恢(hui)復正(zheng)(zheng)常(chang)工(gong)作，分(fen)(fen)析原(yuan)因可能是瞬間(jian)電(dian)壓波(bo)動(dong)(dong)(dong)或(huo)負載(zai)波(bo)動(dong)(dong)(dong)引起的(de)(de)(de)偶(ou)然故障。

例9．外部故障引起電動機不轉的故障維修 故障現象：一臺配套SIEMENS 6M系統的進口立式加工中心，在換刀過程中發現刀庫不能正常旋轉。
分(fen)析與處理過程：通過機(ji)(ji)床電氣(qi)原理圖(tu)(tu)分(fen)析，該(gai)機(ji)(ji)床的刀(dao)(dao)庫(ku)回轉(zhuan)(zhuan)(zhuan)(zhuan)控(kong)(kong)制(zhi)采用的是(shi)6RA**系列(lie)直流伺服驅(qu) 動，刀(dao)(dao)庫(ku)轉(zhuan)(zhuan)(zhuan)(zhuan)速是(shi)由(you)機(ji)(ji)床生(sheng)產(chan)廠(chang)家制(zhi)造的“刀(dao)(dao)庫(ku)給(gei)定(ding)(ding)值(zhi)轉(zhuan)(zhuan)(zhuan)(zhuan)換/定(ding)(ding)位控(kong)(kong)制(zhi)”板進行控(kong)(kong)制(zhi)的。現(xian)場(chang)分(fen)析、觀察刀(dao)(dao)庫(ku)回轉(zhuan)(zhuan)(zhuan)(zhuan)動作，發現(xian)刀(dao)(dao)庫(ku)回轉(zhuan)(zhuan)(zhuan)(zhuan)時(shi)，PLC的轉(zhuan)(zhuan)(zhuan)(zhuan)動信(xin)號已輸入，刀(dao)(dao)庫(ku)機(ji)(ji)械插銷已經拔出(chu)，但(dan)6RA26**驅(qu)動器的轉(zhuan)(zhuan)(zhuan)(zhuan)換給(gei)定(ding)(ding)模(mo)擬(ni)(ni)量(liang)未輸入。由(you)于(yu)該(gai)模(mo)擬(ni)(ni)量(liang)的輸出(chu)來自“刀(dao)(dao)庫(ku)給(gei)定(ding)(ding)值(zhi)轉(zhuan)(zhuan)(zhuan)(zhuan)換/定(ding)(ding)位控(kong)(kong)制(zhi)”板，由(you)機(ji)(ji)床生(sheng)產(chan)廠(chang)家提供的“刀(dao)(dao)庫(ku)給(gei)定(ding)(ding)值(zhi)轉(zhuan)(zhuan)(zhuan)(zhuan)換/定(ding)(ding)位控(kong)(kong)制(zhi)”板原理圖(tu)(tu)逐級(ji)測量(liang)，最(zui)終發現(xian)該(gai)板上的模(mo)擬(ni)(ni)開(kai)關(型號DG201)已損壞，更(geng)換同型號備件后，機(ji)(ji)床恢復正常(chang)工作。

例10．開機電動機即高速旋轉的故障維修 故障現象：一臺與例268同型號的機床，在開機調試時，出現手動按下刀庫回轉按鈕后，刀庫即高速旋轉，導致機床報警。
分(fen)析(xi)與處理(li)過程：根據故障(zhang)現象(xiang)，可以(yi)初步確定故障(zhang)是由于(yu)刀庫(ku)直流驅動(dong)(dong)器(qi)測(ce)速(su)(su)反(fan)(fan)饋極(ji)(ji)(ji)性(xing)不(bu)(bu)正(zheng)確或測(ce)速(su)(su)反(fan)(fan)饋線(xian)脫落引(yin)起的速(su)(su)度環正(zheng)反(fan)(fan)饋或開環。測(ce)量確認該伺服電動(dong)(dong)機測(ce)速(su)(su)反(fan)(fan)饋線(xian)已連接，但極(ji)(ji)(ji)性(xing)不(bu)(bu)正(zheng)確；交換(huan)測(ce)速(su)(su)反(fan)(fan)饋極(ji)(ji)(ji)性(xing)后，刀庫(ku)動(dong)(dong)作(zuo)恢復正(zheng)常。

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