該(gai)機(ji)(ji)床(chuang)有(you)3個軸(zhou)(zhou)(zhou)(zhou)(zhou)，各軸(zhou)(zhou)(zhou)(zhou)(zhou)分別由(you)(you)獨立的(de)(de)(de)(de)β伺服單元(yuan)（AO6B-6093-H102)控(kong)(kong)制(zhi)，反饋采(cai)用位(wei)置編碼器。自動(dong)(dong)(dong)(dong)狀態下執行(xing)程序(xu)，程序(xu)走兩步就(jiu)不走了，檢查外圍開(kai)關信(xin)號，一(yi)(yi)(yi)切正(zheng)常。查看外圍輸(shu)(shu)入(ru)(ru)I/O信(xin)號20~25全部正(zheng)常。關機(ji)(ji)后(hou)(hou)(hou)重(zhong)新(xin)開(kai)機(ji)(ji)，X軸(zhou)(zhou)(zhou)(zhou)(zhou)伺服單元(yuan)電源指示燈(deng)閃(shan)爍(shuo)，懷疑該(gai)模塊(kuai)損壞，更(geng)換該(gai)模塊(kuai)后(hou)(hou)(hou)指示燈(deng)正(zheng)常。啟動(dong)(dong)(dong)(dong)循環，程序(xu)仍然走幾(ji)步就(jiu)停(ting)(ting)止，循環指示燈(deng)一(yi)(yi)(yi)直(zhi)(zhi)(zhi)亮(liang)，將模式(shi)開(kai)關轉至手(shou)輪(lun)模式(shi)，移動(dong)(dong)(dong)(dong)X軸(zhou)(zhou)(zhou)(zhou)(zhou)，動(dong)(dong)(dong)(dong)作正(zheng)常；移動(dong)(dong)(dong)(dong)Z軸(zhou)(zhou)(zhou)(zhou)(zhou)，動(dong)(dong)(dong)(dong)一(yi)(yi)(yi)下就(jiu)出現(xian)420（n軸(zhou)(zhou)(zhou)(zhou)(zhou)誤差過大）報警。將Z、Y軸(zhou)(zhou)(zhou)(zhou)(zhou)控(kong)(kong)制(zhi)模塊(kuai)互換，Z軸(zhou)(zhou)(zhou)(zhou)(zhou)手(shou)動(dong)(dong)(dong)(dong)正(zheng)常。由(you)(you)于(yu)該(gai)機(ji)(ji)床(chuang)Y軸(zhou)(zhou)(zhou)(zhou)(zhou)是用來調(diao)整鼓型的(de)(de)(de)(de)，一(yi)(yi)(yi)般不動(dong)(dong)(dong)(dong)，在加工程序(xu)里也沒(mei)有(you)指令，回(hui)(hui)(hui)零后(hou)(hou)(hou)按(an)循環按(an)鈕時(shi)，循環指示燈(deng)亮(liang)后(hou)(hou)(hou)該(gai)信(xin)號一(yi)(yi)(yi)直(zhi)(zhi)(zhi)為“1”（檢測到位(wei)信(xin)號），說(shuo)明機(ji)(ji)床(chuang)一(yi)(yi)(yi)直(zhi)(zhi)(zhi)在等待(dai)到位(wei)信(xin)號，由(you)(you)此可見，有(you)一(yi)(yi)(yi)個軸(zhou)(zhou)(zhou)(zhou)(zhou)沒(mei)有(you)動(dong)(dong)(dong)(dong)，查看程序(xu)，G54X0,Z0；G98 X25.8,Z30,7；M08；M03，S200；光標停(ting)(ting)留在程序(xu)開(kai)頭位(wei)置不動(dong)(dong)(dong)(dong)。重(zhong)新(xin)輸(shu)(shu)入(ru)(ru)機(ji)(ji)床(chuang)參(can)數，故(gu)障(zhang)(zhang)依舊(jiu)。再手(shou)動(dong)(dong)(dong)(dong)進給(gei)給(gei)X、Z軸(zhou)(zhou)(zhou)(zhou)(zhou)，一(yi)(yi)(yi)切正(zheng)常，進給(gei)Y軸(zhou)(zhou)(zhou)(zhou)(zhou)時(shi)同(tong)樣出現(xian)420報警，重(zhong)新(xin)回(hui)(hui)(hui)到驅動(dong)(dong)(dong)(dong)模塊(kuai)上，拆下Y軸(zhou)(zhou)(zhou)(zhou)(zhou)模塊(kuai)，打開(kai)發現(xian)IPM一(yi)(yi)(yi)管腳上拉電阻R242爆(bao)裂（標稱值為300Ω），檢測再沒(mei)有(you)其(qi)他元(yuan)件損壞，從以前保存的(de)(de)(de)(de)環電路板上拆下一(yi)(yi)(yi)同(tong)樣阻值的(de)(de)(de)(de)貼片(pian)電阻更(geng)換后(hou)(hou)(hou)，裝回(hui)(hui)(hui)該(gai)機(ji)(ji)床(chuang)，故(gu)障(zhang)(zhang)排除(chu)。這次維修中，在沒(mei)有(you)花一(yi)(yi)(yi)分錢的(de)(de)(de)(de)情況下，用短的(de)(de)(de)(de)時(shi)間(jian)修復價值6000多元(yuan)的(de)(de)(de)(de)伺服驅動(dong)(dong)(dong)(dong)器械，使故(gu)障(zhang)(zhang)機(ji)(ji)床(chuang)以短的(de)(de)(de)(de)時(shi)間(jian)修復生產，不僅節約了維修成本，而且大大降低(di)了故(gu)障(zhang)(zhang)機(ji)(ji)床(chuang)的(de)(de)(de)(de)待(dai)機(ji)(ji)時(shi)間(jian)。

    例2一臺FTC-20數(shu)控車，采用FAUNC OTD數(shu)控系統，在運行過程中出現409#(SPINDLE ALARM DETECTION)報(bao)警，即(ji)主軸放(fang)大(da)器(qi)報(bao)警。

    打開(kai)(kai)電(dian)(dian)(dian)(dian)氣柜門(men)，發(fa)現電(dian)(dian)(dian)(dian)源(yuan)模塊(kuai)（A06B-6087-H126）上(shang)八段(duan)碼(ma)顯(xian)示“5”（伺服單(dan)元(yuan)檢測(ce)(ce)到(dao)電(dian)(dian)(dian)(dian)源(yuan)單(dan)元(yuan)電(dian)(dian)(dian)(dian)壓太低(di)，原(yuan)因可(ke)能是(shi)控制(zhi)(zhi)電(dian)(dian)(dian)(dian)源(yuan)電(dian)(dian)(dian)(dian)壓太低(di)或檢測(ce)(ce)回路故障），主(zhu)軸模塊(kuai)（A06B-6012-H126#520）上(shang)顯(xian)示“33”（轉換器DC充電(dian)(dian)(dian)(dian)異常）用萬用表(biao)測(ce)(ce)量(liang)直(zhi)流(liu)(liu)(liu)母線側，電(dian)(dian)(dian)(dian)壓只有(you)79V。測(ce)(ce)量(liang)電(dian)(dian)(dian)(dian)源(yuan)單(dan)元(yuan)的(de)三相交流(liu)(liu)(liu)電(dian)(dian)(dian)(dian)壓正常（因為直(zhi)流(liu)(liu)(liu)側有(you)報警，馬達控制(zhi)(zhi)中心MCC已斷開(kai)(kai)，只能從MCC前測(ce)(ce)量(liang)），關閉(bi)電(dian)(dian)(dian)(dian)源(yuan)測(ce)(ce)，經(jing)檢查發(fa)現主(zhu)控制(zhi)(zhi)板上(shang)的(de)檢測(ce)(ce)電(dian)(dian)(dian)(dian)阻燒(shao)斷，該電(dian)(dian)(dian)(dian)阻為10Ω，用同樣(yang)規格的(de)電(dian)(dian)(dian)(dian)阻更(geng)換，在(zai)脫開(kai)(kai)負載(zai)的(de)情況下電(dian)(dian)(dian)(dian)測(ce)(ce)試，直(zhi)流(liu)(liu)(liu)輸(shu)出300VDC正常。電(dian)(dian)(dian)(dian)阻燒(shao)斷的(de)原(yuan)因可(ke)能是(shi)過電(dian)(dian)(dian)(dian)流(liu)(liu)(liu)引起加之主(zhu)軸模塊(kuai)報“33”。打開(kai)(kai)主(zhu)軸模塊(kuai)，經(jing)測(ce)(ce)量(liang)IGBT燒(shao)壞，用新(xin)的(de)更(geng)換后(hou)，上(shang)機測(ce)(ce)試，運行正常。