A Master Machinist Teaches You to Fix Synchronization Problems in Multi-Axis Machining

The master machinists in the workshop summarize their many years of experience and teach you how to quickly identify the most common cause of problems with multiple machines working together.It covers the core steps in equipment troubleshooting, mechanical parameter calibration, and daily maintenance recommendations, to help you improve your workshop equipment's operational efficiency and reduce downtime.

Why do the facilities all "do their own thing"?

The most common reason for "out of step" behavior is that the precision of the machining is off or that the timing of the movements is wrong.This is probably due to signal transmission, parameter setting, or mechanical wear.The old-timers usually listen to the sounds first. Equipment that is out of sync usually makes an unusual sound, and this is the most direct warning signal.

These three steps lock in the source of the problem.

The signal transmission highway is checked.

First check to see if the lines connecting the equipment are loose. Oxidation and poor contact are common at the joints.Use a multi-meter to measure the signal voltage and see if it is stable. If the equipment transmits signals wirelessly, check the surroundings for any sources of electromagnetic interference, such as powerful motors or welding equipment.

They are checking the heartbeat of the equipment.

Open the control panel and check the pulse equivalents for each machine. Don't underestimate the importance of the three digits after the decimal point; they can make the cutting path deviate by several millimeters.The key is to check whether the spindle speed and feed speed are in accordance with the requirements of the process. It is like a conductor making sure that all the musicians are reading the same score.

Feel the rails and moving parts.

If a certain section feels especially hot to the touch, or if there is any metal dust, then there is an 80 % chance that the bearings have worn down and are causing increased resistance.The tension of the timing belt is also a key point for inspection. When you press on the middle of the belt with your thumb, there should be a normal 10-15 mm of space.

Prevention is the best medicine.

Once a week, we apply special lithium grease to the rails. It's more heat-resistant than ordinary grease.The accuracy of the entire travel path is tested once a month using a laser interferometer. Any anomalies detected are corrected immediately.The old-timers have their own way of keeping track of the vibration amplitude: they stick a piece of paper on the equipment's base, and if the paper slowly moves position, it indicates that the screws securing the equipment to the floor may be loose.

What do you do when you encounter a difficult case?

When regular checks fail to find the problem, try letting the equipment run through the processing procedure with nothing in it, and at the same time scan the driver with a handheld thermometer.If the temperature of one module is abnormally high, it may be that the internal components have aged.When this happens, don't try to handle it yourself. Contact the manufacturer to arrange for a thorough diagnosis. After all, repairing a circuit board is like performing surgery, and you need a specialist to do it.