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200T H-Frame Servo Punch Press Main Motor Overheating and Vibration Fault

2026-10-08

Case Study of 200T H-Frame Servo Punch Press Main Motor Overheating and Vibration Fault: Root Cause Analysis, On-site Repair Scheme and Preventive Maintenance Specification

1. Fault Background

A Jiangsu automotive stamping plant used a 200T H-frame servo punch press to produce heavy-duty vehicle structural brackets. The equipment ran 2 shifts daily. On the day of failure, operators observed obvious vibration and abnormal noise from the main motor. The temperature alarm popped up, and the press stopped automatically. The customer checked electrical cabinet and power supply but failed to locate the problem and requested official after-sales support.

2. Fault Diagnosis & Root Cause Analysis

Visual inspection: Cooling fan accumulated thick dust, fan blade edge wear;
Vibration detection: Coupling had 0.08mm offset due to loose bolts;
Thermal imaging test: Motor winding local temperature reached 94℃;
Cause conclusion: Compound fault of fan blockage + coupling misalignment. High continuous stamping load amplified vibration and heat generation.

3. Repair Implementation

Replace damaged cooling fan assembly and clean internal motor heat sink;
Re-align motor and gearbox coupling, fasten bolts with torque wrench;
Run dynamic balancing test;
Adjust the motor overload protection threshold and save optimized parameter set.

4. Comparison Data Table

Inspection Item	Before Maintenance	After Maintenance	Acceptance Standard
Motor surface temperature	94℃	68℃	≤75℃
Vibration reading at bearing housing	0.11 mm	0.026 mm	≤0.03 mm
Coupling concentricity offset	0.08 mm	0.012 mm	≤0.02 mm
Continuous running test duration	Unable to sustain >20min	8h stable test	≥8h
Alarm trigger frequency	3~4 times per hour	0 times	0 alarm

Case Study Q&A

Q1: What is the difference between vibration caused by coupling misalignment and bearing damage vibration?

A1: Coupling misalignment vibration increases when load rises and has obvious periodic beat. Bearing damage vibration shows random high-frequency noise and noise will exist even at no-load.

Q2: Why does thick plate stamping make this motor overheating problem worse?

A2: Thick plate stamping requires larger instantaneous torque. Extra vibration from misalignment creates additional mechanical loss, converting more power into heat.

Q3: Is it acceptable to continue production by temporarily disabling the motor thermal protection function?

A3: Absolutely not. Disabling thermal protection will lead to winding burnout and even motor fire risk, which will cause far higher repair cost.

Q4: What torque value should we use when tightening coupling bolts for this model?

A4: For this 200T H frame punch coupling M12 bolts, recommended tightening torque is 65 N·m.

Q5: How often should thermal imaging inspection be scheduled for servo punch main motors in heavy stamping workshops?

A5: For two-shift heavy load production, thermal imaging inspection every 3 months is suggested.

Q6: What spare parts should be stocked for the main motor cooling system?

A6: Spare cooling fan assembly, sealing gaskets, dust filter screens and temperature sensors.

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