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As a maintenance supervisor, what's your protocol for training junior technicians to distinguish between mechanical binding, electrical noise, and programming logic errors when servo motors start vibrating unexpectedly?

EricTorres

EricTorres

2026-02-13

answer

Hey there! Great question - this is exactly the kind of practical troubleshooting skill that separates experienced technicians from beginners. Here's how I approach training junior techs on this critical diagnostic skill:

First, I start with a simple three-step diagnostic approach:

1. **Mechanical Binding Check**: I teach them to disconnect the motor from the drive and manually rotate the shaft. If there's resistance or grinding, that's mechanical binding - usually worn bearings, misalignment, or physical obstructions. The vibration tends to be rhythmic and often accompanied by unusual mechanical noises.

2. **Electrical Noise Investigation**: When the motor runs but makes high-pitched screeching or buzzing, that's often electrical. I train them to check for loose connections, damaged cables, or grounding issues. Electrical noise vibrations are usually more erratic and can cause encoder feedback problems.

3. **Programming Logic Assessment**: If the mechanics and electricals check out, we look at the control program. I show them how to monitor position commands versus actual position, check for overshoot in tuning parameters, and verify motion profiles. Programming errors often cause vibration during specific movements or at certain speeds.

The key is teaching them to start with the simplest mechanical checks first, then move to electrical, and finally examine programming. I use real-world examples and hands-on practice with known fault scenarios to build their diagnostic intuition. What specific servo systems are you working with?

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